Ryobi AG401 User Manual
OPERATOR'S MANUAL
4 in. (100 mm) Angle Grinder
Model AG401 /
Double Insulated
4’’ Grinder
SPECIFICATIONS:
Grinding Wheel Capacity 4 in. (100 mm)
Rating 120 V c.a., 60Hz
No Load Speed 11,000 RPM
Amperes 4.4 A
Net Weight 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:
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.
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:
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
FORESIGHT IS BETTER
GLASSES
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.
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 atmo-
spheres, 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 po-
larized 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 insu-
lation 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 condi-
tions. 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 out-
door extension cord marked “W-A” or “W”. These
cords are rated for outdoor use and reduce 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 tool while tired or under the influence of
drugs, alcohol, or medication. A moment
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 be-
fore 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 turn-
ing the tool on. A wrench or a key that is left at-
tached to a rotating part of the tool may result in
personal injury.
Do not overreach. Keep proper footing and bal-
ance at all times. Proper footing and balance en-
ables better control of the tool in unexpected situations.
Use safety equipment. Always wear eye protec-
tion. Dust mask, non-skid safety shoes, hard hat, or
hearing protection must be used for appropriate conditions.
Tool Use and Care
Use clamps or other practical way to secure and
support the workpiece to a stable platform. Hold-
ing 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 be-
fore 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.
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.
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 replace-
ment 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.
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 per-
forming 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.
Before attaching the grinding wheel, inspect it for
visible defects. If cracked, chipped, or warped, do not
install it.
Do not overtighten the clamp nut on the grinding
wheel. Excessive tightening can cause the wheel to
crack during operation
Make sure that the guard is in good condition and
securely installed before operating grinder.
Do not clamp the grinder in a vise or use as a
fixed grinder.
Never turn on the grinder with the grinding wheel
or any rotating parts touching the workpiece.
Use only grinding wheels in compliance with ANSI
standard B7.1 and rated greater than 11,000 RPM.
Do not use the grinder if the disc flange or clamp
nut is missing or if the spindle is bent.
Always hold the grinder securely with two hands
while working and at all times when it is running.
Never cover the air vents in the motor housing
with your hands while operating the grinder.
Hold the tool away from your body while it is
running. Keep your hands away from the abrasive
attachments.
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.
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. Ev-
eryday 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 condi-
tion. 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
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.
extension cord 100 feet or less in
Page 4
RULES FOR SAFE OPERATION
Inspect for and remove all foreign objects from
workpiece before grinding. Following this rule will
reduce the risk of serious personal injury.
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.
Keep hands away from grinding area. 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.
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:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other
masonry products, and
• arsenic and chromium from chemically-treated
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
SAFETY AND INTERNATIONAL SYMBOLS
This operator’s manual describes safety and international symbols and pictographs that may appear on this product.
Read the operator’s manual for complete safety, assembly, operating and maintenance, and repair information.
MEANING
Do not expose to rain or use in damp locations
Page 5
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