Hobart 4-1/2 In. User manual

4-1/2 In. Angle
Grinder
www.HobartWelders.com
Description
OM-254 206A 2011−08
File: Accessory
Accessory

Hobart is registered to
the ISO 9001 Quality
System Standard.
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS - READ BEFORE USING 1.................................
1-1. Symbol Usage 1.......................................................................
1-2. Hazards 1............................................................................
1-3. Additional Symbols For Installation, Operation, And Maintenance 2.............................
1-4. California Proposition 65 Warnings 3......................................................
1-5. Principal Safety Standards 3.............................................................
SECTION 2 −ADDITIONAL SAFETY PRECAUTIONS 4...........................................
SECTION 3 −DEFINITIONS 4..................................................................
3-1. Symbols And Definitions 4...............................................................
SECTION 4 −SPECIFICATIONS 4..............................................................
4-1. Angle Grinder Components 4............................................................
4-2. Specifications 5........................................................................
SECTION 5 −INSTALLATION 5................................................................
5-1. Serial Number And Rating Label Location 5................................................
5-2. Selecting A Location 5..................................................................
5-3. Installing And Positioning Guard 6........................................................
5-4. Installing/Removing Wheel 7.............................................................
5-5. Installing Stabilizer Handle 7.............................................................
SECTION 6 −OPERATION 8...................................................................
6-1. Controls 8............................................................................
6-2. Operating The Grinder 8................................................................
SECTION 7 −MAINTENANCE 9................................................................
7-1. Routine Maintenance 9.................................................................
7-2. Replacing Motor Brushes 9..............................................................
WARRANTY

OM-254 206 Page 1
SECTION 1 −SAFETY PRECAUTIONS - READ BEFORE USING
Pwr. Tools 2011−08
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! −Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE −Indicates statements not related to personal injury.
.Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The input power circuit and machine
internal circuits are live when power is on.
DDo not touch live electrical parts.
DDo not use equipment in damp areas, if movement is confined, or if
there is a danger of falling.
DAdditionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the equipment. And, do not work
alone!
DDisconnect input power before installing or servicing this equip-
ment.
DProperly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
DAlways verify the supply ground −check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
DDo not touch grounded surfaces when using this equipment (metal
pipes, enclosures, structures, etc.).
DWhen making input connections, attach proper grounding conduc-
tor first −double-check connections.
DKeep cords dry, free of oil and grease, and protected from hot metal
and sparks.
DFrequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged −bare wiring can kill.
DTurn off all equipment when not in use. Do not leave equipment
until it has completely stopped.
DUse only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
DKeep all panels and covers securely in place.
HOT PARTS can burn.
DDo not touch hot parts bare handed.
DAllow cooling period before working on equip-
ment.
DTo handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Using this equipment with certain materials may
produce fumes, gases, and particles. Breathing
these fumes, gases,and particles can be hazardous
to your health.
FUMES, GASES, AND PARTICLES can
be hazardous.
DKeep your head out of the fumes, gases, and particles. Do not
breathe the fumes, gases, and particles.
DIf inside, ventilate the area and/or use local forced ventilation to re-
move fumes, gases and particles.
DIf ventilation is poor, wear an approved air-supplied respirator.
DRead and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
DWork in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Fumes, gases, and particles can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
DDo not work in locations near degreasing, cleaning, or spraying
operations.
DDo not work on materials that may contain hazardous substances,
including masonry, treated lumber, and items with lead-based
paint. Do not work on on coated metals, such as galvanized, lead,
or cadmium plated steel, unless the coating is removed from the
work area, the area is well ventilated, and while wearing an air-
supplied respirator. Coatings and any materials containing these
elements can give off toxic fumes, gases, and particles when
worked on.

OM-254 206 Page 2
Sparks can fly off from the equipment. The flying
sparks, hot workpiece, and hot equipment can
cause fires and burns. Accidental contact with metal
objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before doing any work.
SPARKS can cause fire or explosion.
DRemove all flammables within 35 ft (10.7 m) of the equipment. If
this is not possible, tightly cover them with approved covers.
DDo not work where flying sparks can strike flammable material.
DProtect yourself and others from flying sparks and hot metal.
DBe alert that sparks and hot materials can easily go through small
cracks and openings to adjacent areas.
DWatch for fire, and keep a fire extinguisher nearby.
DDo not work where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
DWear oil-free protective garments such as a heavy shirt, cuffless
trousers, high shoes, and a cap.
DRemove any combustibles, such as a butane lighter or matches,
from your person before doing any work.
DAfter completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
DUse only correct fuses or circuit breakers. Do not oversize or by-
pass them.
DFollow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
DWelding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
DWear approved safety glasses with side
shields even under your welding helmet.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
DWear approved ear protection if noise level is
high.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
DDo not install or place unit on, over, or near
combustible surfaces.
DDo not install unit near flammables.
DDo not overload building wiring −be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
DUse equipment of adequate capacity to lift and
support unit.
DKeep equipment (cables and cords) away from
moving vehicles when working from an aerial
location.
DDo not stand on the equipment.
DIf applicable, bolt equipment to a smooth surface large and
strong enough to safely support it.
DFollow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
FLYING SPARKS can injure.
DWear a face shield to protect eyes and face.
DOperate equipment with proper guards, and in
a safe location while wearing proper face, and
body protection.
DSparks can cause fires — keep flammables away.
MOVING PARTS can injure.
DKeep away from moving parts.
DKeep all doors, panels, covers, and guards
closed and securely in place.
DHave only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
DReinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
DDo not wear clothing, gloves, or jewelry, or other items that may
be caught in moving parts. Wear a hat or other covering to con-
tain long hair.
DDo not make adjustments on moving equipment. Remove ad-
justing tools (keys, wrenches) before using equipment.
DVerify the switch is in the Off position before plugging in the
equipment.
DUse the equipment only for the recommended application and at
the specified rate. Do not use the equipment for tasks for which it
is not intended.
DDo not hold workpiece in your hand when using equipment. Use
a vice or clamp to hold workpiece.
READ INSTRUCTIONS.
DRead and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
DUse only genuine replacement parts from the manufacturer.
DPerform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.

OM-254 206 Page 3
1-4. California Proposition 65 Warnings
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], web-
site: www.ansi.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: [phone], website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

OM-254 206 Page 4
SECTION 2 −ADDITIONAL SAFETY PRECAUTIONS
!Do not use this equipment unless
you are sure it is correctly
assembledand working properly.
!Turn off grinder and disconnect
input power before installing,
adjusting, or servicing this
equipment.
!Use GFCI protection when operat-
ing this equipment outdoors or in a
damp location. If GFCI receptacle is
not available, use a GFCI-protected
extension cord.
!Use only wheels and accessories
with a bore equal to the arbor
(spindle) on the grinder. Do not
modify wheels and accessories to fit
the arbor.
!Inspect wheels and accessories for
damage before use. Replace and
dispose of damaged or vibrating
wheels and accessories.
!Test wheels and accessories before
use according to the manufacturer’s
instructions.
!Store wheels and accessories in a
dry location where they are
protected against damage from
impact, chemicals, and extreme
temperatures.
!Do not overtighten the hardware
securing the wheel or accessory.
!Securely attach guard to grinder.
Position guard so the operator is
least exposed to the wheel or ac-
cessory,
!Be sure guard is correctly installed
and adjusted before using grinder.
Do not operate grinder with guard
removed.
!Use only wheels and accessories
suitable for this equipment. Do not
use wheels and accessories rated
lower than 10,500 RPM.
!Do not apply excessive force to
wheels and accessories or they may
break or be damaged.
!Do not position yourself in line with
the rotating wheel or accessory. To
prevent injury from kickbacks and
flying debris, always stand directly
behind the equipment.
!Run grinder at normal operating
speed for one minute before using.
!Do not start the grinder with the
wheel or accessory touching the
workpiece. Allow grinder to reach
full speed before touching work-
piece.
!Use wheel flanges and blotters
(paper discs on sides of grinding
wheels) when mounting wheels.
Use only the wheel flanges supplied
with the grinder.
!Keep power cord away from the
wheel or accessory.
!Do not use the grinder without the
stabilizer handle installed. Always
use two hands to keep a firm grip on
the grinder.
!Do not adjust guards and shields
while the grinder is running.
!Be sure grinder comes to a com-
plete stop before setting it down.
NOTICE −Keep the grinder air vents clean.
NOTICE −Do not apply coolant to a grind-
ing wheel or the wheel may be damaged.
SECTION 3 −DEFINITIONS
3-1. Symbols And Definitions
AAmperage VVoltage WWatt Hz Hertz
Off On AlternatingCurrent
(AC)
SECTION 4 −SPECIFICATIONS
4-1. Angle Grinder Components
1 Power Switch
2 Wheel −4-1/2 (114 mm)
Diameter
3 Guard
4 Quick Release Lever
5 Spindle Lock Button
6 Stabilizer Handle
7 6 ft (1.8 m) 115 Volt Power
Cord
.Some assembly is required.
For additional options and
accessories, contact your
distributor.
2
3
67
1
5
4

OM-254 206 Page 5
4-2. Specifications
Voltage
Rating Amperage Rating No Load Speed Arbor Size Maximum
Wheel
Size Wheel Types Weight w/
Wheel Overall Dimensions
120 Volts
AC,
60 Hz 7.5 Amperes 10,500 RPM
7/8 in. (22.2 mm)
5/8 -11 in.
Threaded Spindle
4-1/2 in.
(114 mm)
Diameter
Grinding Wheels
Cut-Off Wheels
Wire Wheels
Flap Discs
Cup Brushes
5.2 lb
(2.4 kg)
Length: 12-1/4 in.
(31.1 cm)
Width: 9-3/8 in.
(22.9 cm)
Height: 4-1/4 in.
(10.8 cm)
.Grinding wheels and optional accessories must be 4-1/2 in. (114 mm) diameter or less, rated for a minimum of 10,500 RPM, and fit
a 7/8 in. (22 mm) arbor or 5/8-11 threaded spindle. Contact your distributor for available options.
SECTION 5 −INSTALLATION
5-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the bottom. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
5-2. Selecting A Location
!Use GFCI protection when oper-
ating this equipment outdoors
or in a damp location. If GFCI re-
ceptacle is not available, use a
GFCI-protected extension cord.
!Special installation may be
required where gasoline or
volatile liquids are present −see
NEC Article 511 or CEC Section
20.
1 120 Volt, 60 Hz, AC Receptacle
(Customer Supplied)
A 120 volt AC, 60 Hz, 15 ampere
individual branch circuit protected by
time-delay fuses or circuit breaker is
required.
Select extension cord of 18 AWG for up
to 25 ft (8 m) or 16 AWG for up to 50 ft
(15 m).
1
Notes

OM-254 206 Page 6
5-3. Installing And Positioning Guard
!Turn off grinder and
disconnect input power
before installing, adjusting,
or servicing this equipment.
!Securely attach guard to
grinder. Position guard so
the operator is least exposed
to the wheel or accessory
!Be sure guard is correctly in-
stalled and adjusted before
using grinder. Do not operate
grinder with guard removed.
1 Guard
2 Quick Release Lever
3 Pressure Ring And Key
4 Spindle Housing
5 Notch In Collar
6 Groove In Collar
The guard is equipped with a quick
release lever to secure it to the
spindle housing.
Pull the lever to open the pressure
ring. Align the key in the pressure
ring with the notch in the collar of the
spindle housing and slide the guard
over the collar on the spindle hous-
ing just above the spindle.
Rotate the guard to lock the key into
the groove in the collar. Be sure the
guard is completely on the collar,
then push the lever to secure the
pressure ring.
To reposition the guard on the
spindle housing, pull the lever and
rotate the guard to the desired posi-
tion. Push the lever to secure the
pressure ring.
1
Tools Needed:
2
3
54
6

OM-254 206 Page 7
5-4. Installing/Removing Wheel
!Turn off grinder and disconnect
input power before installing,
adjusting, or servicing this
equipment.
!Be sure guard is correctly installed
and adjusted before using grinder.
Do not operate grinder with guard
removed.
!Use only wheels and accessories
suitable for this equipment. Do not
use wheels and accessories rated
lower than 10,500 RPM.
!Use only wheels and accessories
with a bore equal to the arbor
(spindle) on the grinder. Do not
modify wheels and accessories to fit
the arbor.
!Inspect wheels and accessories for
damage before use. Replace and
dispose of damaged or vibrating
wheels and accessories.
!Do not overtighten the hardware
securing the wheel or accessory.
1 Guard
Position the guard (see Section 5-3).
2 Flange
3 Flange Nut
Clean and Inspect flange nut and flange to
remove debris and check parts for any
damage (replace part(s) if necessary).
4 Spindle
5 Flats On Spindle Shaft
6 Slotted Shoulder On Flange
Slotted shoulder is on bottom of flange.
Place flange on spindle so that slotted
shoulder fits over flats on spindle shaft.
7 Grinding Wheel
8 Spanner Wrench
Place wheel on the spindle so that the collar
of the wheel fits onto the flange. Install
flange nut on the spindle so that the raised
shoulder fits into the wheel.
Press the spindle lock button on top of the
spindle housing, and rotate flange nut until
spindle locks. Keep rotating flange nut until
finger tight. Finish tightening flange nut by
using the spanner wrench.
To remove the wheel, reverse the proced-
ure.
1
6
2
3
7
8
4
5
Tools Needed:
5-5. Installing Stabilizer Handle
!Turn off grinder and
disconnectinput power before
installing, adjusting, or
servicing this equipment.
!Do not use the grinder without
the stabilizer handle installed.
Always use two hands to keep
a firm grip on the grinder.
1 Stabilizer Handle
2 Spindle Housing
3 Threaded Holes
The stabilizer handle may be installed
into the top or on either side of the
spindle housing. Select a location
that provides the best protection and
control of the grinder. Thread stabil-
izer handle into desired threaded hole
in spindle housing until hand tight.
3
2
1

OM-254 206 Page 8
SECTION 6 −OPERATION
6-1. Controls
!Do not use this equipment
unless you are sure it is
correctly assembled and
working properly.
1 Power Cord
2 Stabilizer Handle
3 Frame Handle
4 Power Switch
Check that all components are
clean, tight, working properly, and
there is no visible damage before
using the angle grinder.
23
4
1
6-2. Operating The Grinder
!Do not use this equipment unless
you are sure it is correctly
assembledand working properly.
!Turn off grinder and disconnect
input power before installing,
adjusting, or servicing this
equipment.
!Do not adjust guards and shields
while the grinder is running.
!Use only wheels and accessories
with a bore equal to the arbor
(spindle) on the grinder. Do not
modify wheels and accessories to fit
the arbor.
!Inspect wheels and accessories for
damage before use. Replace and
dispose of damaged or vibrating
wheels and accessories.
!Test wheels and accessories before
use according to the manufacturer’s
instructions.
!Do not position yourself in line with
the rotating wheel or accessory. To
prevent injury from kickbacks and
flying debris, always stand directly
behind the equipment.
!Run grinder at normal operating
speed for one minute before using.
!Do not start the grinder with the
wheel or accessory touching the
workpiece. Allow grinder to reach
full speed before touching work-
piece.
!Be sure guard is correctly installed
and adjusted before using grinder.
Do not operate grinder with guard
removed.
!Position guard so the operator is
least exposed to the wheel or ac-
cessory.
!Do not apply excessive force to
wheels and accessories or they may
break or be damaged.
!Keep power cord away from the
wheel or accessory.
!Do not use the grinder without the
stabilizer handle installed. Always
use two hands to keep a firm grip on
the grinder.
!Be sure grinder comes to a complete
stop before setting it down.
!Store wheels and accessories in a
dry location where they are
protected against damage from
impact, chemicals, and extreme
temperatures.
To Operate Grinder
Hold the grinder with both hands. Place one
hand on the frame handle and the other
hand on the stabilizer handle.
Push down on the back of the Power switch
and slide switch forward until the grinder
starts.
Release the switch and the grinder stops.
To lock the switch in the On position, press
down on the back of the switch, slide it
forward, and then press down on the front
of the switch. Press down and release the
switch to stop the grinder.
Start grinder and run at full speed for one
minute. Check for misaligned, loose, or
damagedparts. Correct or replace parts as
necessary before using the grinder.
Allow grinder to reach full speed before
making contact with a workpiece.
Be sure grinder comes to a complete stop
before setting it down.
Clamp workpiece with a vise or other
device to prevent the workpiece from
moving and to allow the use of both hands
on the grinder.
Control the amount of force used to apply
pressure to the grinder on the workpiece.
Using excessive force can result in too
much pressure which may damage the
grinder and/or workpiece.
Tools Needed:
Respirator