Ryobi BGH625, BGH825, BGH615 User Manual

OPERATOR'S MANUAL

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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

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.

Page 2

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.

Page 3

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.

Page 4

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.

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.

Page 5

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.