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OPERATOR'S MANUAL
BENCH GRINDER
MODELS BGH615/BGH625/BGH825
MODEL BGH625
MODEL BGH615
MODEL BGH825
THANK YOU FOR BUYING A RYOBI BENCH GRINDER.
Your new Bench Grinder has been engineered and manufactured to Ryobi's high standards 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 machine.
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 we can be of future service to you.
Thank you again for buying Ryobi tools.
SAVE THIS MANUAL FOR FUTURE REFERENCE
Page 2
TABLE OF CONTENTS
n Table of Contents............................................................................................................................................2
n Product Specifications....................................................................................................................................2
n Rules for Safe Operation ............................................................................................................................ 3-5
n Electrical .........................................................................................................................................................6
n Unpacking.......................................................................................................................................................6
n Loose Parts List ..............................................................................................................................................7
n Tools Needed..................................................................................................................................................7
n Features .................................................................................................................................................... 8-10
n Assembly ................................................................................................................................................ 11-13
n Operation ................................................................................................................................................ 14-15
n Maintenance .................................................................................................................................................16
n Parts Ordering / Service ...............................................................................................................................20
PRODUCT SPECIFICATIONS
BGH615 BGH625 BGH825
Wheels:
- Diameter 6 in. (152 mm) 6 in. (152 mm) 8 in. (203 mm)
- Thickness 3/4 in. (19 mm) 3/4 in. (19 mm) 1 in. (25.4 mm)
- Arbor Hole 1/2 in. (13 mm) 1/2 in. (13 mm) 5/8 in. (16 mm)
No Load Speed 3600 RPM 3600 RPM 3600 RPM
Rating 120 Volts, 60Hz-AC Only 120 Volts, 60Hz-AC Only 120 Volts, 60Hz-AC Only
Input 2.1 Amperes 2.1 Amperes 3.1 Amperes
Tool Weight 25 lbs. (11 kg) 22 lbs. (10 kg) 34 lbs. (15 kg.)
Look for this symbol to point out important safety precautions. It
means attention!!! Your safety is involved.
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RULES FOR SAFE OPERATION
Safe operation of this power tool requires that you read and
understand this operator's manual and all labels affixed to
the tool. Safety is a combination of common sense, staying
alert, and knowing how your bench grinder works.
READ ALL INSTRUCTIONS
n KNOW YOUR POWER TOOL. Read the operator's
manual carefully. Learn the applications and limitations
as well as specific potential hazards related to this tool.
n GUARD AGAINST ELECTRICAL SHOCK by prevent-
ing body contact with grounded surfaces. For example:
pipes, radiators, ranges, refrigerator enclosures.
n KEEP GUARDS IN PLACE and in working order. Never
operate the tool with any guard or cover removed. Make
sure all guards are operating properly before each use.
n REMOVE ADJUSTING KEYS AND WRENCHES. Form
habit of checking to see keys and adjusting wrenches are
removed from tool before turning it on.
n KEEP THE WORK AREA CLEAN. Cluttered work areas
and work benches invite accidents.
n AVOID DANGEROUS ENVIRONMENTS. Do not use
power tools near gasoline or other flammable liquids,
in damp or wet locations or expose them to rain. Keep
work area well lighted.
n KEEP CHILDREN AND VISITORS AWAY. All visitors
should wear safety glasses and be kept a safe distance
from work area.
n MAKE WORKSHOP CHILDPROOF with padlocks,
master switches, or by removing starter keys.
n DON’T FORCE THE TOOL. It will do the job better and
safer at the rate for which it was designed.
n USE THE RIGHT TOOL. Do not force the tool or attach-
ment to do a job for which it was not designed.
n USE THE PROPER EXTENSION CORD. 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. An undersized
cord will cause a drop in line voltage resulting in loss of
power and overheating. A wire gage size (A.W.G.) of at
least 16 is recommended for an extension cord 25 feet
or less in length. If in doubt, use the next heavier gage.
The smaller the gage number, the heavier the cord.
n INSPECT EXTENSION CORDS PERIODICALLY and
replace if damaged.
n WEAR PROPER APPAREL. Do not wear loose clothing,
neckties, or jewelry that can get caught in the tool’s
moving parts and cause personal injury. Nonslip footwear
is recommended when working outdoors. Wear protective
hair covering to contain long hair.
n ALWAYS W EAR SAF ETY GLAS SES WIT H SIDE
SHIELDS. Everyday eyeglasses have only impact-
resistant lenses; they are NOT safety glasses.
n PROTECT YOUR LUNGS. Wear a face or dust mask if
the cutting operation is dusty.
n PROTECT YOUR HEARING. Wear hearing protection
during extended periods of operation.
n DON’T ABUSE CORD. Never carry tool by the cord or
yank it to disconnect from receptacle. Keep cord from
heat, oil, and sharp edges.
n DO NOT OVERREACH. Keep proper footing and balance
at all times.
n MAINTAIN TOOLS WITH CARE. Keep tools sharp and
clean for best and safest performance. Follow instructions
for lubricating and changing accessories.
n NEVER LEAVE TOOL RUNNING UNATTENDED. TURN
POWER OFF. Disconnect all tools when not in use, before
servicing, or when changing attachments, wheels, etc.
n AVOID ACCIDENTAL STARTING. Be sure switch is off
when plugging in.
n USE RECOMMENDED ACCESSORIES. The use of
improper accessories may cause risk of injury.
n USE ONLY GRINDING WHEELS that comply with ANSI
B7.1 and rated greater than 3600 RPM.
n DO NOT use wheels with incorrect size holes. NEVER
use wheel washers or wheel screws that are defective
or incorrect and NEVER touch grinding wheel or other
moving parts.
n NEVER STAND ON TOOL. Serious injury could occur if
the tool is tipped or if the wheel is unintentionally contacted.
n DIRECTION OF FEED. Be aware of wheel rotation direc-
tion; never grind without the workrest being properly set.
NEVER grind more than one workpiece at a time.
WARNING: Wheel coasts after turn off.
n 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 must
be properly repaired or replaced by an authorized service
center to avoid risk of personal injury.
n KEEP TOOL DRY, CLEAN, AND FREE FROM OIL AND
GREASE. Always use a clean cloth when cleaning. Never
use brake fluids, gasoline, petroleum-based products, or
any solvents to clean tool.
n INSPECT TOOL CORDS AND EXTENSION CORDS
PERIODICALLY and, if damaged, have repaired by a
qualified service technician. Stay constantly aware of
cord location and keep it well away from the rotating
wheel.
n NEVER USE IN AN EXPLOSIVE ATMOSPHERE. Normal
sparking of the motor or sparking from grinding metal could
ignite fumes.
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Page 4
RULES FOR SAFE OPERATION
DO N OT EX POS E
TO RAIN OR USE IN
DAMP LOCATIONS
n US E OUTDOOR EXT ENSION CORDS. Use only
extension cords with approved ground connection that
are intended for use outdoors and so marked.
n NEVER reach to pick up a workpiece, a piece of scrap,
or anything else that is in or near the grinding path of the
wheel.
n AVOID AWKWARD OPERATIONS AND HAND POSI-
TIONS where a sudden slip could cause your hand to
move into the wheel. ALWAYS make sure you have good
balance.
n NEVER stand or have any part of your body in line with
the path of the wheel.
n DO NOT USE TOOL IF SWITCH DOES NOT TURN IT
ON AND OFF. Have defective switches replaced by an
authorized service center.
n DO NOT TURN THE MOTOR SWITCH ON AND OFF
RAPIDLY. This could cause the wheel to loosen and could
create a hazard. Should this ever occur, stand clear and
allow the wheel to come to a complete stop. Disconnect
your grinder from the power supply and securely retighten
the wheel nut.
WARNING:
When servicing use only identical Ryobi replacement
parts. Use of any other parts may create a hazard or
cause product damage.
n USE ONLY FLANGES furnished with this bench
grinder.
n IF ANY PART OF THIS GRINDER IS MISSING or should
break, bend, or fail in any way, or should any electrical
component fail to perform properly, shut off the power
switch, remove the machine plug from the power source
and have damaged, missing, or failed parts replaced before resuming operation.
n MAKE SURE THE GRINDER IS SECURELY MOUNTED
as described in the operating instructions before connecting the tool to a power supply.
n DO NOT OVERTIGHTEN THE WHEEL NUT. Excessive
tightening can cause the wheel to crack during operation.
n INSPECT GRINDING WHEEL for visible defects. Check
the wheel for fissures and cracks, and test for normal
operation prior to use.
n ADJUST distance between wheel and work rest to main-
tain 1/16 in. or less separation as the diameter of the
wheel decreases with use. The value of separation used
in the marking is to be the separation recommended by
the manufacturer but shall not be more than 1/8 in.
n ALWAYS EASE THE WORKPIECE AGAINST THE
ABRASIVE WHEEL when starting to grind. A harsh
impact can break the wheel. Use light pressure when
starting to grind; too much pressure on a cold wheel can
cause the wheel to crack.
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n RISK OF INJURY DUE TO ACCIDENTAL STARTING.
Do not use in an area where children may be present.
n NEVER START THE GRINDER when the wheel is in
contact with the workpiece.
n SECURE WORK. Always hold workpiece firmly against
the work rest.
n DO NOT USE THE BENCH GRINDER if the flange nut
or clamp nut is missing or if the spindle shaft is bent.
n FREQUENTLY clean grinding dust from beneath grind-
er.
n DO NOT OPERATE THIS TOOL WHILE UNDE R
THE INFLUENCE OF DRUGS, ALCOHOL, OR ANY
MEDICATION.
n ALWAYS STAY ALERT. Do not allow familiarity (gained
from frequent use of your grinder) to cause a careless
mistake. ALWAYS REMEMBER that a careless fraction
of a second is sufficient to inflict severe injury.
n STAY ALERT AND EXERCISE CONTROL. Watch what
you are doing and use common sense. Do not operate
tool when you are tired. Do not rush.
n SAVE THESE INSTRUCTIONS. Refer to them frequently
and use them to instruct other users. 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.
Page 5
RULES FOR SAFE OPERATION
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
SAFETY ALERT SYMBOL:
Indicates danger, warning, or caution. May be used in conjunction with other symbols or picto-
graphs.
DANGER: Failure to obey a safety warning will result in serious injury to yourself or to others. Always
follow the safety precautions to reduce the risk of fire, electric shock and personal injury.
WARNING: Failure to obey a safety warning can result in serious injury to yourself or to others.
Always follow the safety precautions to reduce the risk of fire, electric shock and personal injury.
CAUTION: Failure to obey a safety warning may result in property damage or personal injury to
yourself or to others. Always follow the safety precautions to reduce the risk of fire, electric shock
and personal injury.
NOTE: Advises you of information or instructions vital to the operation or maintenance of the equip-
ment.
IMPORTANT
Servicing requires extreme care and knowledge 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.
The operation of any 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.
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 this operator's manual
and review frequently for continuing safe operation and
instructing others who may use this tool.
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ELECTRICAL
EXTENSION CORDS
Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool's plug.
When using a power tool at a considerable distance from the
power source, use an extension cord heavy enough to carry
the current that the tool will draw. An undersized extension
cord will cause a drop in line voltage, resulting in a loss of
power and causing the motor to overheat. Use the chart
provided below to determine the minimum wire size required
in an extension cord. Only round jacketed cords listed by
Underwriter's Laboratories (UL) should be used.
Length of Extension Cord Wire Size (A.W.G.)
Up to 25 feet 16
26-50 feet 16
51-100 feet 16
When working with the tool outdoors, use an extension cord
that is designed for outside use. This is indicated by the
letters WA on the cord's jacket.
Before using an extension cord, inspect it for loose or
exposed wires and cut or worn insulation.
GROUNDING
PIN
COVER OF GROUNDED
OUTLET BOX
Fig. 1
ELECTRICAL CONNECTION
Your Ryobi Bench Grinder is powered by a precision built
electric motor. It should be connected to a power supply
that is 120 volts, 60Hz, 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 the machine does not operate when plugged
into an outlet, double check the power supply.
CAUTION:
Keep the cord away from the grinding area and position
the cord so that it will not be caught on material, tools,
or other objects.
GROUNDING INSTRUCTIONS
In the event of a malfunction or breakdown, grounding
provides a path of least resistance for electric current to
reduce the risk of electric shock. This tool is equipped with
an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a
matching outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
Do not modify the plug provided. If it will not fit the outlet,
have the proper outlet installed by a qualified electrician.
Improper connection of the equipment-grounding conductor
can result in electrical shock. The conductor with insulation
having an outer surface that is green with or without yellow
stripes is the equipment-grounding conductor. If repair or
replacement of the electric cord or plug is necessary, do
not connect the equipment-grounding conductor to a live
terminal.
Check with a qualified electrician or service personnel if the
grounding instructions are not completely understood, or if
in doubt as to whether the tool is properly grounded.
Repair or replace a damaged or worn cord immediately.
This tool is intended for use on a circuit that has an outlet
like the one shown in figure 1. It also has a grounding pin
like the one shown.
UNPACKING
n Carefully remove all parts from the shipping carton.
n Lift the bench grinder from the carton and place it on a
level work surface.
n Do not discard the packing materials until you have care-
fully inspected the machine, identified all loose parts, and
satisfactorily operated your bench grinder.
n Examine all parts to make sure no breakage or damage
has occurred during shipping.
n If all parts have been included, proceed to assembly.
Page 6
n If any parts are damaged or missing, do not attempt to
plug in this tool or turn it on until the damaged or missing
parts are obtained and installed correctly.
n Contact your nearest Ryobi dealer or call 1-800-525-2579
in the United States or 1-800-265-6778 in Canada for
assistance if any parts are missing or damaged.
WARNING:
If any parts are missing do not operate this machine until
the missing parts are replaced. Failure to do so could
result in possible serious injury.
Page 7
LOOSE PARTS LIST
LOOSE PARTS LIST – BGH615
The following items are included with your Bench Grinder:
n Shield Rods – one left, one right ................................. 2
n Shield Rod Brackets with Hardware............................ 2
n Safety Shields.............................................................. 2
n Spark Deflectors – one left, one right.......................... 2
n Work Rests – one left, one right .................................. 2
LOOSE PARTS LIST – BGH625
The following items are included with your Bench Grinder:
n Shield Rods – one left, one right ................................. 2
n Shield Rod Brackets with Hardware............................ 2
n Safety Shields ............................................................. 2
n Spark Deflectors.......................................................... 2
n Work Rests – one left, one right .................................. 2
n Lock Washers (5 mm).................................................. 2
n Washers (5 mm)........................................................... 2
n Washers (6 mm)........................................................... 2
n Washers (8 mm)........................................................... 6
n Hex Bolts (6 mm x 6) ................................................... 2
n Hex Bolts (8 mm x 8) ................................................... 4
n Hex Bolts (8 mm x 14) ................................................. 2
n Operator's Manual
n Washers (8 mm)........................................................... 2
n Phillips Screws (5 mm x 8) .......................................... 2
n Hex Bolts (8 mm x 14) ................................................. 2
n Adjustment Knobs....................................................... 2
n Hex Nuts (5 mm).......................................................... 2
n Washers (5 mm)........................................................... 2
n Operator's Manual
LOOSE PARTS LIST – BGH825
The following items are included with your Bench Grinder:
n Shield Rods – one left, one right ................................. 2
n Shield Rod Brackets with Hardware............................ 2
n Safety Shields.............................................................. 2
n Spark Deflectors.......................................................... 2
n Work Rests – one left, one right .................................. 2
n Lock Washers (5 mm).................................................. 2
n Washers (5 mm)........................................................... 2
n Washers (8 mm)........................................................... 2
n Phillips Screws (5 mm x 8) .......................................... 2
n Hex Bolts (8 mm x 14) ................................................. 2
n Hex Bolts (5 mm x 10) ................................................. 2
n Operator's Manual
TOOLS NEEDED
The following tools (not included) are needed for assembly and alignment:
7 MM, 10 MM, AND 12 MM
COMBINATION WRENCH
PHILLIPS SCREWDRIVER
ADJUSTABLE WRENCH
Page 7
Fig. 2
Page 8
FEATURES – BGH615
KNOW YOUR BENCH GRINDER
See Figure 3a.
Before attempting to use your new tool, familiarize yourself with all operating features and safety requirements.
Carefully read this operator’s manual before using your
grinder.
ON/OFF SWITCH
Your BGH615 Bench Grinder features a front access On/
Off switch for convenience and safety.
MOTOR
Powered by a precision-built electric induction motor, your
bench grinder has sufficient power to handle tough grinding jobs.
GRINDING WHEEL
Equipped with course and fine grinding wheels to suit
most applications.
Note: New wheels sometimes require dressing to true up
the face of the wheel.
WORKLIGHT
SWITCH
WORKLIGHT
SAFETY SHIELD AND SPARK DEFLECTOR
The safety shields and spark deflectors are adjustable for
operator convenience. Operating the grinder without these
features attached could result in serious injury. Do not grind
with the safety shield raised; always wear safety glasses for
personal protection.
WORK REST
The work rests are independently adjustable to compensate for wheel wear. Before grinding, make certain
the work rests are adjusted properly. Generally the object
being ground is done slightly above center of the grinding
wheel.
Adjust the distance between the wheel and the work rest
to maintain 1/16 in. or less separation as the diameter of
the wheel decreases with use.
WORKLIGHT
Your BGH615 Bench Grinder comes equipped with a permanently mounted worklight that lights the work area for
safer, more accurate grinding and sharpening. (Requires a
40 watt bulb – not included.)
SPARK
DEFLECTOR
(LEFT)
WHEEL
GUARD
SAFETY
SHIELD(S)
SHIELD RODS
(RIGHT AND LEFT)
SPARK
DEFLECTOR
(RIGHT)
WORK REST
(RIGHT)
OFF
ON
SWITCH
WORK REST
(LEFT)
MODEL BGH615
Fig. 3a
Page 8
Page 9
FEATURES – BGH625
KNOW YOUR BENCH GRINDER
See Figure 3b.
Before attempting to use your new tool, familiarize yourself
with all operating features and safety requirements. Carefully
read this operator’s manual before using your grinder.
ON/OFF SWITCH
Your BGH625 Bench Grinder features a front access On/Off
switch for convenience and safety.
MOTOR
Powered by a precision-built electric induction motor, your
bench grinder has sufficient power to handle tough grinding jobs.
GRINDING WHEEL
Equipped with course and fine grinding wheels to suit most
applications.
Note: New wheels sometimes require dressing to true up
the face of the wheel.
SAFETY SHIELD AND SPARK DEFLECTOR
The safety shields and spark deflectors are adjustable for
operator convenience. Operating the grinder without these
features attached could result in serious injury. Do not grind
with the safety shield raised; always wear safety glasses for
personal protection.
WORK REST
The work rests are independently adjustable to compensate
for wheel wear. Before grinding, make certain the work rests
are adjusted properly. Generally the object being ground is
done slightly above center of the grinding wheel.
Adjust the distance between the wheel and the work rest to
maintain 1/16 in. or less separation as the diameter of the
wheel decreases with use.
WHEEL DRESSING TOOL
A buildup of metals, dirt, rust, etc. will become embedded
in the grinding wheel as it wears. Using the Wheel Dressing
Tool to clean the wheel of these ground-in particles will help
improve the grinder’s performance.
AUTO-ON WORKLIGHT
Your BGH625 Bench Grinder comes equipped with a
permanently mounted worklight that automatically lights
the work area for safer, more accurate grinding and
sharpening.
COOLANT TRAY
When grinding, metal objects become heated quickly. It is
important to keep moving the object back and forth across
the grinding wheel and to cool the object frequently using
the grinder’s Coolant Tray.
SPARK
DEFLECTOR
(LEFT)
SAFETY
SHIELD(S)
WHEEL
GUARD
AUTO-ON
WORKLIGHT
WORK REST
(LEFT)
SHIELD RODS
(RIGHT AND LEFT)
ADJUSTMENT
KNOB(S)
COOLANT
TRAY
SPARK
DEFLECTOR
(RIGHT)
WORK REST
(RIGHT)
ON
OFF
SWITCH
MODEL BGH625
Page 9
Fig. 3b
Page 10
FEATURES – BGH825
KNOW YOUR BENCH GRINDER
See Figure 3c.
Before attempting to use your new tool, familiarize yourself
with all operating features and safety requirements. Carefully
read this operator’s manual before using your grinder.
ON/OFF SWITCH
Your BGH825 Bench Grinder features a front access On/Off
switch for convenience and safety.
MOTOR
Powered by a precision-built electric induction motor, your
bench grinder has sufficient power to handle tough grinding jobs.
GRINDING WHEEL
Equipped with course and fine grinding wheels to suit most
applications.
Note: New wheels sometimes require dressing to true up
the face of the wheel.
SAFETY SHIELD AND SPARK DEFLECTOR
The safety shields and spark deflectors are adjustable for
operator convenience. Operating the grinder without these
features attached could result in serious injury. Do not grind
with the safety shield raised; always wear safety glasses for
personal protection.
WORK REST
The work rests are independently adjustable to compensate
for wheel wear. Before grinding, make certain the work rests
are adjusted properly. Generally the object being ground is
done slightly above center of the grinding wheel.
Adjust the distance between the wheel and the work rest to
maintain 1/16 in. or less separation as the diameter of the
wheel decreases with use.
WHEEL DRESSING TOOL
A buildup of metals, dirt, rust, etc. will become embedded
in the grinding wheel as it wears. Using the Wheel Dressing
Tool to clean the wheel of these ground-in particles will help
improve the grinder’s performance.
AUTO-ON WORKLIGHT
Your BGH825 Bench Grinder comes equipped with a
permanently mounted worklight that automatically lights
the work area for safer, more accurate grinding and
sharpening.
COOLANT TRAY
When grinding, metal objects become heated quickly. It is
important to keep moving the object back and forth across
the grinding wheel and to cool the object frequently using
the grinder’s Coolant Tray.
WHEEL
GUARD
SPARK
DEFLECTOR
(LEFT)
SAFETY
SHIELD(S)
AUTO-ON
WORKLIGHT
WORK REST
(LEFT)
SHIELD RODS
(RIGHT AND LEFT)
COOLANT TRAY
MODEL BGH825
SPARK
DEFLECTOR
(RIGHT)
WORK REST
(RIGHT)
ON
OFF
SWITCH
Fig. 3c
Page 10
Page 11
ASSEMBLY
WARNING:
Always disconnect the bench grinder from the power
source before performing any assembly or adjustment.
Failure to do so could result in accidental starting resulting in possible serious personal injury.
SPARK DEFLECTOR – BGH615
See Figure 4a.
Using two 6 mm hex bolts and washers, attach the spark
deflector to the inside of the wheel guard.
Adjust the spark deflectors to within 1/16 in. of the grinding
wheel. Tighten the hex bolts securely.
SPARK DEFLECTOR – BGH625 AND BGH825
See Figures 4b and 4c.
Using the two phillips head screws, washers, and lock
washers, attach the spark deflector to the top of the wheel
guard.
Adjust the spark deflectors to within 1/16 in. of the grinding
wheel. Tighten the hex bolts securely.
WARNING:
Always spin the wheel by hand before turning on the
grinder to make sure the spark deflector doesn’t hit the
grinding wheel.
HEX BOLT
BGH615
WASHER
SPARK
DEFLECTOR
Fig. 4a
SPARK DEFLECTOR
WASHER
SCREW
LOCK
WASHER
WARNING:
Always make sure your bench grinder is securely mounted
to a workbench or an approved workstand. Failure to do
so could result in an accident resulting in possible serious personal injury.
BGH625
SPARK DEFLECTOR
Fig. 4b
WASHER
SCREW
LOCK
WASHER
Page 11
BGH825
Fig. 4c
Page 12
ASSEMBLY
SHIELD BRACKET ASSEMBLY
See Figure 5.
Note: The hardware used for assembling the safety
shields to the shield brackets has been preassembled and
prepackaged.
Remove the two phillips head screws, washers, and hex
nuts from the shield bracket. Fit the shield bracket to the
top of the safety shield. Reattach the screws, washers, and
hex nuts taking care not to tighten the screws so tight as to
crack the plastic. Repeat for the other shield bracket and
safety shield.
WARNING:
To prevent personal injury, never operate the bench
grinder unless the safety shields and spark deflectors
are properly installed and in place.
MOUNTING SAFETY SHIELDS
See Figures 6a - 6c.
Mount the left and right shield rods to the inside of the wheel
guards using the clamp brackets, hex bolts (8 mm x 14 mm),
and washers (8 mm).
Locate your grinder in figures 6a, 6b, or 6c. Use the illustration as a guide to determine which shield rod is mounted
on the left and which shield rod is mounted on the right of
the grinder.
Once shield rods are firmly in place, slide the shield bracket
onto the shield rod. Tighten the carriage bolt leaving it loose
enough to allow the safety shield to be raised and lowered
easily.
SHIELD ROD
CLAMP BRACKET
WASHER
HEX BOLT
SHIELD ROD
CLAMP BRACKET
WASHER
HEX BOLT
BGH615
Fig. 6a
SHIELD ROD
WASHER
HEX NUT
WASHER
LOCK
WASHER
HEX NUT
CARRIAGE
LOCK
WASHER
SAFETY
SHIELD
BOLT
PHILLIPS SCREW
SHIELD
BRACKET
Fig. 5
Page 12
SHIELD ROD
CLAMP BRACKET
WASHER
HEX BOLT
BGH625
BGH825
Fig. 6b
Fig. 6c
Page 13
ASSEMBLY
WORK REST – BGH615
See Figure 7a.
Mount the work rests to the inside of each wheel guard using two hex bolts (8 mm x 8) and two washers (8 mm) on
each side.
Before tightening the bolts, adjust the gap between the
grinding wheel and the work rest to a maximum of 1/16 in.
Tighten securely.
WORK REST – BGH625
See Figure 7b.
Mount the work rests to the work rest bracket using the
knob, washer, and one hex nut.
Before tightening the bolts, adjust the gap between the
grinding wheel and the work rest to a maximum of 1/16 in.
Tighten securely.
WORK REST – BGH825
See Figure 7c.
Before attempting to mount the work rest, remove the hex
nut and star washer from the phillips screw. See Figure 7c.
Place the work rest over the phillips screw before replacing the
hex nut and star washer. Using the hex bolt (5 mm x 10 mm)
and washer (5 mm), secure the work rest against the inside
of the wheel guard.
Before tightening the bolts, adjust the gap between the
grinding wheel and the work rest to a maximum of 1/16 in.
Tighten securely.
HEX BOLTS
BGH615
WORK
REST
WASHERS
Fig. 7a
HEX
NUT
WASHER
KNOB
BGH625
WORK REST
BRACKET
WORK
REST
Fig. 7b
PHILLIPS
SCREW
WORK
REST
STAR
WASHER
Page 13
HEX BOLT
WASHER
BGH825
HEX NUT
Fig. 7c
Page 14
OPERATION
BASIC OPERATION
WARNING:
Always wear safety goggles or safety glasses with side
shields during power tool operation or when blowing dust.
If operation is dusty, wear a dust mask.
To be efficient and work as designed, your tools should be
kept sharp. Dull tools can and will cause accidents.
Bench Grinders are ideal for sharpening tools such as
chisels, planer blades, scissors, etc., and for removing rust
or corrosion.
WARNING:
Never sharpen or grind anything made of aluminum.
Grinders remove material rapidly so pressure is the key to
efficient grinding.
The proper way to sharpen a tool and avoid overheating
is:
n Keep the object in constant motion, moving it at an even
pace.
n Never force a tool against the grinding wheel.
n Keep the tool cool by using either a cooling tray or a pan
of water.
n The grinding wheel should rotate “into” the object being
sharpened.
Note: Excessive pressure may damage the tool, cause the
motor to overheat, and prematurely wear down the grinding
wheel.
BIT SHARPENING
SCREWDRIVER
V-GROOVE
Fig. 8
LAWN MOWER BLADE
VISE
WARNING:
Excessive pressure on a cold wheel may cause the wheel
to crack.
The following recommendations will help you sharpen
specific tools:
TWIST DRILL BITS
See Figure 8.
Drill bits are best sharpened on a sharpening jig (available
at most hardware stores). Begin on one side of the point
at the existing angle, then twist the bit while maintaining
contact with the grinding surface. Sharpen only the tip.
This technique requires considerable practice, so take your
time and make a few “dry runs” first with the grinder off. Be
sure to maintain the original cutting edge angle as this is
important to the efficiency of your bits. One work rest has
a V-groove (models BGH615 and BGH825 only) angled to
fit most drill bits.
Fig. 9
LAWN MOWER BLADES
See Figure 9.
Lawn mower blades are usually sharpened on only one
edge and dressed up slightly on the other. Perform this
sharpening process on both cutting ends of the blade.
After sharpening, be sure to balance the blade by removing
additional material.
CAUTION:
An unbalanced lawn mower blade may cause excessive
vibration which will damage the lawn mower.
Page 14
Page 15
OPERATION
CHISELS AND SCREWDRIVER BLADES
See Figure 10.
When sharpening chisels and screwdrivers, work rest
should support the chisel at the correct angle against the
wheel.
WARNING:
Always disconnect the bench grinder from the power
source before performing any assembly or adjustment.
Failure to do so could result in accidental starting resulting in possible serious personal injury.
WHEEL REPLACEMENT
See Figure 11.
If you must replace a grinding wheel, be sure to obtain one
with a safe rated speed at least as high as the “no load
speed” RPM marked on the data plate of the grinder and
which is marked to comply with ANSI B7.1.
To replace the grinding wheel, remove the wheel cover by
loosening the screws. Loosen the wheel nut in a clockwise
direction for the left side and a counterclockwise direction
for the right side. Remove the outer flange and grinding
wheel. To install a new grinding wheel, reverse the above
procedure. Be sure the grinding wheel and outer flange are
properly seated on the spindle shaft.
CHISEL SHARPENING
Fig. 10
SCREW(S)
WHEEL
GUARD COVER
OUTER
FLANGE
STAR
WASHER(S)
SPINDLE
WHEEL
NUT
SHAFT
GRINDING
WHEEL
HEX NUT(S)
INNER
FLANGE
Fig. 11
Page 15
Page 16
MAINTENANCE
WARNING:
When servicing, use only identical Ryobi replacement
parts. Use of any other part may create a hazard or cause
product damage.
GENERAL
Keep the bench grinder clean. Remove dust from working
parts and beneath the grinder frequently.
Make sure the bench grinder operates properly. Check
screws, nuts, and bolts for tightness.
EXTENSION CORDS
The use of any extension cord will cause some loss of
power. To keep the loss to a minimum and to prevent tool
overheating, use an extension cord that is heavy enough to
carry the current the tool will draw.
A wire gage size (A.W.G.) of at least 16 is recommended for
an extension cord 25 feet or less in length. When working
outdoors, use an extension cord that is suitable for outdoor
use. The cord's jacket will be marked WA.
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.
10 WATT, 120 VOLT
WORKLIGHT BULB
SLOT
BGH625/BGH825
TO REMOVE BULB
TAB
TO INSTALL BULB
10 WATT, 120 VOLT
WORKLIGHT BULB
Fig. 12
WORKLIGHT BULB REPLACEMENT
For models BGH625 and BGH825, Figure 12.
To remove worklight bulb, gently push the bulb into the
socket and turn counterclockwise. To install the new bulb,
gently push the bulb into the socket and turn clockwise.
For model BGH615, Figure 13.
To remove bulb, turn counterclockwise. To install new bulb,
turn clockwise.
Note: To avoid the risk of fire, never use a bulb with a wattage
higher than 40.
WHEEL DRESSER
For models BGH625 and BGH825 ONLY.
Dressing a wheel is done to renew sharpness or to true up
the face of the wheel.
Set the work rest of the bench grinder at a slight angle and
brace the wheel dresser against it. Do not make contact with
the grinding wheel until after you have turned on the motor
and the wheel is rotating at full speed. Press the dresser
slightly against the rotating wheel until you get a bite, then
move slowly from side to side across the wheel. A small bite
and many passes is better than a big bite and one pass.
Work cautiously, hold the dresser with force on the work rest.
Do not use excessive pressure against the grinding wheel.
Proceed slowly until you master the technique.
40 WATT
WORKLIGHT
BULB
REMOVE BULB
BGH615
TO
INSTALL BULB
TO
Fig. 13
Page 16
Page 17
NOTES
NOTES
Page 17
Page 18
OPERATOR'S MANUAL
Bench Grinder
Models BGH615/BGH625/BGH825
EXTENSION CORD CAUTION
When using a power tool at a considerable distance from a power
source, be sure to use an extension cord that has the capacity to
handle the current the tool will draw. An undersized cord will cause
a drop in line voltage, resulting in overheating and loss of power.
Use the chart to determine the minimum wire size required in an
extension cord. Only round jacketed cords should be used.
When working with a tool outdoors, use an extension cord that
is designed for outside use. This is indicated by the letters "WA"
on the cord's jacket.
Before using any extension cord, inspect it for loose or exposed
wires and cut or worn insulation.
• 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 www.ryobitools.com for
a complete list of Authorized Service Centers.
**Ampere rating
(on tool data plate) 0-2.0 2.1-3.4 3.5-5.0 5.1-7.0 7.1-12.0 12.1-16.0
Cord Length Wire Size (A.W.G.)
25' 16 16 16 16 14 14
50' 16 16 16 14 14 12
100' 16 16 14 12 10 —
CAUTION: Keep the extension cord clear of the working
area. Position the cord so that it will not get caught on workpiece,
tools, or other obstructions while you are working with a power
tool.
**Used on 12 gauge - 20 amp circuit.
• MODEL NO.
The model and serial numbers of your tool will be found on a plate attached to the motor
housing. Please record the serial number in the space provided below.
• MODEL NUMBER BGH615/BGH625/BGH825
• SERIAL NUMBER
972000-880
7-04
RYOBI TECHNOLOGIES INC.
1428 Pearman Dairy Road Anderson, SC 29625
Post Office Box 1207 Anderson SC 29622-1207
Phone 1-800-525-2579
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