HeAvy-dUTy ANgLe gRINdeR
model no. 054-7221-4
IMPORTANT:
Read and understand this instruction manual thoroughly before using the product.
INSTRUCTION
MANUAL
TAbLe Of CONTeNTS
Technical Specifications
Safety Guidelines
Key Parts Diagram
Important Information
Assembly Instructions
Operating Instructions
Maintenance
Troubleshooting
Part list
Warranty
NOTe:
If any parts are missing or damaged, or if you have any questions, please call our toll-free helpline at
1-800-689-9928
SAve THeSe INSTRUCTIONS
• This manual contains important safety and operating instructions. Read all instructions and follow them with use of this product.
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5–10
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15–16
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22–23
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TeCHNICAL SPeCIfICATIONS
Rated Voltage
Rated Power Input
Single speed
Disc size
Arbor size
Weight
120V~, 60Hz
12A
11,000 RPM
5" (125 mm)
5/8" (16 mm)
8 lb 3 oz (3.7 kg)
RULeS fOR SAfe OPeRATION
KNOW yOUR TOOL
To operate this angle grinder, carefully read this Instruction Manual and all labels affixed to the tool. Keep this Manual available for future reference.
IMPORTANT
This angle grinder should only be serviced by a qualified service technician. For more information, call the toll free helpline at 1-800-689-9928.
ReAd ALL INSTRUCTIONS CARefULLy
SAve THeSe INSTRUCTIONS geNeRAL POWeR TOOL SAfeTy WARNINgS
WARNINg!
Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
SAve ALL WARNINgS ANd INSTRUCTIONS fOR fUTURe RefeReNCe.
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
WORK AReA SAfeTy
• Keep the work area clean and well lit. Cluttered or dark areas invite accidents.
• do not operate power tools in explosive atmospheres, such as in the presence
of flammable liquids, gases or dust. Power tools create sparks, which may ignite the dust or fumes.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
eLeCTRICAL SAfeTy
• Power tool plugs must match the outlet. Never modify the plug in any way. do
not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce the risk of electric shock.
• Avoid body contact with earthed or grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
• do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep the cord away from heat, oil, sharp edges or moving
parts. Damaged or entangled cords increase the risk of electric shock.
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• When operating a power tool outdoors, use an extension cord suitable for
outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
• If operating a power tool in a damp location is unavoidable, use a ground-fault
circuit interrupter (gfCI) protected supply. Use of a GFCI reduces 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 the 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.
• Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection, used for appropriate conditions, will reduce personal injuries.
• Prevent unintentional starting. ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the
tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents.
• Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
• do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• dress properly. do not wear loose clothing or jewellery. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
• If devices are provided for the connection of dust extraction and collection
facilities, ensure that these are connected and properly used. Use of these devices can reduce dust-related hazards.
POWeR TOOL USe ANd CARe
• do not force the power tool. Use the correct power tool for your application.
The correct power tool will do the job better and more safely at the rate for which it was designed.
• do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
• disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing
power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
• Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool.
Power tools are dangerous in the hands of untrained users.
• Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• Use the power tool, accessories, tool bits, etc. in accordance with these instructions, taking into account the working conditions and the work to be
performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
SeRvICe
• Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power tool is maintained.
SAfeTy WARNINgS fOR gRINdINg
• This power tool is intended to function as a grinder.
Read all safety warnings, instructions, illustrations and specifications provided with this power tool.
Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury .
• Operations such as sanding, wire brushing, polishing or cutting-off are not recommended to be performed with this power tool.
Operations for which the power tool was not designed may create a hazard and cause personal injury .
• do not use accessories that are not specifically designed and recommended by the tool manufacturer.
Just because the accessory can be attached to your power tool, it does not assure safe operati on.
• The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool.
Accessories running faster than their rated speed can break and fly ap art.
• The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool.
Incorrectly sized accessories cannot be adequately guarded or controll ed.
• The arbors of wheels, flanges, backing pads or any other accessory must properly fit the spindle of the power tool.
Accessories with arbor holes that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.
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• do not use a damaged accessory.
Before each use, inspect the accessory, such as abrasive wheels, for chips and cracks. If the power tool or accessory is dropped, inspect it for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute. Damaged accessories will normally break apart during this test time.
• Wear personal protective equipment.
Depending on the application, use a face shield, safety goggles or safety glasses. As appropriate, wear a dust mask, hearing protectors, gloves and a workshop apron capable of stopping small abrasive or workpiece fragments. Eye protection must be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtering particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.
• Keep bystanders a safe distance away from the work area.
Anyone entering the work area must wear personal protective equipment. Fragments of a workpiece or of a broken accessory may fly away and cause injury beyond the immediate area of operation.
• Hold the power only tool by the insulated gripping surfaces when performing an operation where the cutting accessory may contact hidden wiring or its own cord.
If a cutting accessory contacts a “live” wire, it may cause the exposed metal parts of the power tool to become“live” and shock the operator.
• Position the cord clear of the spinning accessory.
If you lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory.
• Never lay the power tool down until the accessory has come to a complete stop.
The spinning accessory may grab the surface and pull the power tool out of your control.
• do not run the power tool while carrying it at your side.
Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.
• Regularly clean the power tool’s air vents.
The motor’s fan will draw dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.
• do not operate the power tool near flammable materials.
Sparks could ignite these materials.
• do not use accessories that require liquid coolants.
Using water or other liquid coolants may result in electrocution or shock.
• The label on your tool may include the following symbols. The symbols and their definitions are as follows:
V ..................... Volts
A ..................... Amperes
Hz ................... Hertz
W .................... Watts
min ................. Minutes
............... Alternating current
............. Direct current
n
0
................... No-load speed
............... Class II Construction
…/min ........... Revolutions or reciprocation per minute
............... Grounding terminal
BPM ............... Beats per minute
.............. WARNING – To reduce the risk of injury, user must read instruction manual.
AddITIONAL SAfeTy INSTRUCTIONS fOR gRINdINg OPeRATIONS
• Use only wheel types that are recommended for your power tool and use only the specific guard designed for the selected wheel.
Wheels for which the power tool was not designed cannot be adequately guarded and are unsafe.
• The guard must be securely attached to the power tool and positioned for maximum safety, so the least amount of wheel is exposed towards the operator.
The guard helps to protect the operator from broken wheel fragments, accidental contact with wheel and sparks that could ignite clothing.
• Wheels must be used only for recommended applications.
For example: do not grind with the side of a cut-off wheel. Abrasive cut-off wheels are intended for peripheral grinding; side forces applied to these wheels may cause them to shatter.
• Always use undamaged wheel flanges that are of correct size and shape for your selected wheel.
Proper wheel flanges support the wheel, thus reducing the possibility of wheel breakage. Flanges for cut-off wheels may be different from grinding wheel flanges.
• do not use worn down wheels from larger power tools.
Wheels intended for larger power tools are not suitable for the higher speed of a smaller tool and may burst.
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KICKbACK ANd ReLATed WARNINgS
Kickback is the result of power tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions, as given below.
• Maintain a firm grip on the power tool and position your body and arms to allow you to resist kickback forces.
Always use the auxiliary handle, if provided, for maximum control over kickback or torque reaction during startup. The operator can control torque reactions or kickback forces if proper precautions are taken.
• Never place your hand near the rotating accessory.
The accessory may kickback over your hand.
• do not position your body in the area where the power tool will move if kickback occurs.
Kickback will propel the tool in the direction opposite to the wheel’s movement at the point of snagging.
• Use special care when working corners, sharp edges, etc.
Avoid bouncing and snagging the accessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.
• do not attach a saw chain, wood carving blade or toothed saw blade.
Such blades create frequent kickback and loss of control.
PACKAge CONTeNTS
Angle grinder, side handle, wrench, instruction manual
Key PARTS dIAgRAM
6
7
8
4 3 2 1
9 7
10
4
5
6
2
3
NO.
1
PART
Cord guard
Power-supply indicator light
ON/OFF trigger switch
Lock-off/Lock-on button
Side handle
Spindle-lock button
8
9
NO.
7
10
11
PART
Inner flange
Grinding disc
Disc guard
Wrench
Outer flange
11
5
11
FPO
WARNINg!
• Remove the grinder from the carton and examine it carefully. Do not discard the carton or any packaging material until all parts are examined.
FPO
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IMPORTANT INfORMATION
Before attempting to use this tool, become familiar with all of its operating features and safety requirements. For optimum performance and safety, read the following operating instructions carefully before using.
POWeR-SUPPLy INdICATOR LIgHT
The indicator light will be lit when the plug is connected to the socket, and will be off when it is unplugged.
WARNINg!
• Do not allow familiarity with the angle grinder to make you careless. A fraction of a second of carelessness is enough to cause severe injury.
• To avoid injury, always turn the tool off and disconnect the angle grinder from the power outlet before installing or changing the grinding disc.
FPO
ASSeMbLy INSTRUCTIONS
INSTALLINg ANd ReMOvINg THe gRINdINg dISC fig 1
To insTall a disc (fig 1 and 2):
1. Disconnect the plug from the electrical outlet. Make sure that the guard (1) is securely in place.
2. Remove the outer flange (5).
3. Check that the inner flange (2) is properly seated on the spindle. It will click into place on the spindle and will cause the spindle to rotate when the inner flange is rotated.
4. Check the rated speed on the grinding disc (4). Do not use a disc with a rated speed lower than the speed shown on the grinder’s nameplate.
5. Place the disc on the spindle.
6. Replace the outer flange, with the flat side of the flange facing the disc.
7. Press the spindle-lock button (6) to prevent the spindle from moving.
8. While pressing the spindle-lock button, tighten the threaded outer flange (5) by turning it clockwise with the wrench supplied (7).
fig 2
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NOTe:
• The maximum disc thickness is 1/4 " (6.5 mm), and the spindle opening is
7/8 " (22.3 mm).
WARNINg!
• Use only grinding wheels for which the maximum safe operating speed is rated at or above 12200 rpm. Never use damaged or imbalance grinding wheels. Grinding wheel type 27 is recommended for use with this grinder (fig 2).
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5
4
2
1
3
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FPO
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To remove a disc (fig 1 and 2):
1. Disconnect the plug from the electrical outlet.
2. While pressing the spindle-lock button, loosen the threaded outer flange (5) by turning it counter-clockwise with the wrench supplied (7).
3. Remove the threaded outer flange.
4. Remove the disc (4) from the spindle (3).
AdJUSTINg THe gRINdINg dISC gUARd (fig 3)
Adjust the guard to protect the operator’s hands and to direct grinding debris away from the operator.
1. Disconnect the plug from the electrical outlet.
2. Loosen the clamp screws.
3. Position the guard at the required angle.
4. Tighten the clamp screws.
fig 3
INSTALLINg THe SIde HANdLe (fig 4)
The side handle should always be used during operation.
The side handle can be used in any of three positions. Note the positions of the threaded openings. Screw the side handle into the right side, the left side, or the top of the grinder.
fig 4
OPeRATINg INSTRUCTIONS
ON/Off SWITCH ANd LOCK bUTTON (ON/Off): (fig 5) fig 5
TO TURN THe TOOL ON:
1. To start the tool, push the Lock button
(2), and while holding it in, apply pressure to the trigger switch (1).
Release the Lock button (2).
2. To stop the tool, release the trigger switch (1). The switch reverts to the
Locked OFF position.
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1
TO TURN THe TOOL ON ANd LOCK THe SWITCH ON fOR
CONTINUOUS OPeRATION:
1. To start the tool, push the Lock button (2), and while holding it in, apply pressure to the trigger switch (1) to start the tool.
2. Push the lock button (2) in all the way to engage the Lock ON function.
3. To stop the tool, press and then release the trigger switch (1). The switch reverts to the Locked OFF position.
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WARNINg!
• Do not depress the spindle lock until the spindle has completely stopped moving.
NOTICe:
• The tool is always locked OFF unless the lock button and trigger switch are engaged to turn it on.
• The starting torque creates a sudden jerk.
• Do not turn the angle grinder “ON” or “OFF” while the grinder is in contact with the workpiece. It will decrease the life of the trigger switch and could cause damage to the workpiece.
FPO
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geNeRAL OPeRATION
1. For best control, hold the angle grinder firmly with one hand gripping the side handle and the other gripping the rubber-coated grip on the body of the angle grinder.
2. Always position the guard so that the exposed grinding disc is pointing away from the operator.
3. After starting the tool, apply the grinding disc to the workpiece.
4. Tilt the angle grinder at a 10° to 15° angle for easy handling and smooth grinding (fig 6). This will make it easier to remove the disc from the workpiece and will prevent unnecessary overloading.
5. Apply the grinding disc to the work surface using light, steady pressure for grinding efficiency.
6. When using a new grinding disc, do not move the disc in a forward direction
(A) on the workpiece. Doing so will cause the edge of the disc to cut into the surface of the workpiece. While grinding, the direction of movement should be backward, toward the operator (B in fig 6).
fig 6
MAINTeNANCe
Before cleaning or performing any maintenance, the tool should be unplugged from the power supply. Using compressed air may be the most effective cleaning method. Always wear safety goggles when cleaning tools using compressed air.
Do not let brake fluid, gasoline, petroleum-based products, penetrating oil, etc., come into contact with plastic parts. These substances contain chemicals that can damage, weaken or destroy plastic.
CHANgINg CARbON bRUSHeS
When brushes become worn, the tool will automatically stop, preventing damage to the motor. Brush replacement should be performed by a qualified service technician.
When replacing the brushes, make sure that the rib of the brush holder aligns with the groove on the side of the brush
(fig 7).
fig 7
Rib
Groove
17
A
10°-15°
B
FPO
WARNINg!
• Do not apply unnecessary pressure. The weight of the tool applies adequate pressure. Excessive or sudden pressure will overload the motor, cause a drop in the speed and put dangerous stress on the grinding disc, possibly causing breakage and injury.
WARNINg!
• When servicing, use only identical replacement parts. The use of any other parts may create a hazard or cause damage to the product. For more information, call the toll-free helpline, at
1-800-689-9928.
• 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 with another tool.
• 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.
• If the supply cord is damaged, it must be replaced by a specially prepared cord available through the service organization.
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TROUbLeSHOOTINg
Problem
Motor does not start
Tool vibrates or shakes
Possible causes Solution
Tool is not plugged in Check that all cords are plugged in
Fuse
Check the time-delayed fuse or circuit breaker
Damaged disc
Loose disc
Replace disc
Tighten arbor bolt
If the problem remains unsolved after performing the checks described above, call the toll-free helpline, at 1-800-689-9928.
exPLOded vIeW
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No. Part No.
3
4
1
No. Part No.
2
3123640000
description
Lock-on/lockoff button
3660071000 Spring
3550107000 Bushing
5660003000 E-Ring
5 5610106000 Tapping screw
description
26 3120322000 Dust cover
27 5700008000 Ball bearing
28 3120993000 Bearing holder
29 5620034000 Screw
30 3420622000
Right aluminium cover
31 2240114000 Power nameplate 6
7
3420624000 Gear case
5700033000
Needle bearing
3550901000 Gear 8
9 5610097000
Threadforming screw
10 3700447000 Washer
11 5700015000 Ball bearing
12 3700528000 Felt block
32 3123639000 Motor housing
33 3700486000 Plate
34 4960009000 Carbon brush
13
3550580000
3550104000
Spindle
14 5680024000 Cup half key
15 3420623000
Gear case cover
16 5650007000 Spring washer
17 5620042000 Screw
18 3700106000 Wave washer
19 3700111000 Guard
20 5630039000 Nut
21 3550105000 Pinion
22 5700015000 Ball bearing
23 3700100000 Clamp
24 5620068000 Screw
25 2750156000 Rotor
35 2800034000 Brush holder
36 5650034000 Plain washer
37 5610006000 Tapping screw
38 3420621000
Left aluminium cover
39 2240113000 Trademark plate
40 2820653000
Internal wire assembly
41 2820652000
Internal wire assembly
42 3700099000 Terminal
43 2740119000 Stator
44 3120321000 Fan baffle
45 5610052000 Tapping screw
46 3700893000 Clamp
47 5620034000 Screw
48 2820067000 Inner flange
3550333000
49 Outer flange
3550109000
50 3700135000 Flange screw
No. Part No.
51 3123624000
description
Right brush cover
52 3320547000 Right handle
53 3123707000
Transparence cap
54 4870340000 Switch
55 4540017000
Power supply indicator
56 4930017000 Connector
57
58
5610024000
3120234000
Tapping screw
Cord anchorage
No. Part No.
description
59 3121050000 Cord guard
60 4810002000 Power cord & plug
61 3123641000 Left brush cover
62 3320546000 Left handle
63 4930061000
Shark-teeth terminal
64 4860004000 Inner wire
65 4930047000 Ring terminal
66 2490136002 Nylon string
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5-yeAR LIMITed WARRANTy
This Mastercraft Maximum product is guaranteed against defects in workmanship and materials for a period of 5 years from the date of original retail purchase, with the exception of the following components: a) Component A: Batteries, chargers and carrying case, which are guaranteed against defects in workmanship and materials for a period of 2 years from the date of original retail purchase; b) Component B: Accessories, which are guaranteed against defects in workmanship and materials for a period of 1 year from the date of original retail purchase.
Subject to the conditions and limitations described below, this product, if returned to us with proof of purchase within the stated warranty period, and if covered under this warranty, will be repaired or replaced (with the same model or one of equal value or specification), at our option. We will bear the cost of any repair or replacement and any labour costs relating thereto.
This warranty is subject to the following conditions and limitations:
a) A bill of sale verifying the purchase and purchase date must be provided; b) This warranty will not apply to any product or part thereof that is worn or broken, or that has become inoperative due to abuse, misuse, accidental damage, neglect or lack of proper installation, operation or maintenance (as outlined in the applicable owner’s manual or operating instructions), or that is being used for industrial, professional, commercial or rental purposes; c) This warranty will not apply to normal wear and tear or to expendable parts or accessories that may be supplied with the product and that are expected to become inoperative or unusable after a reasonable period of use; d) This warranty will not apply to routine maintenance and consumable items, including but not limited to fuel, lubricants, vacuum bags, blades, belts, sandpaper, bits, fluids, tune-ups or adjustments; e) This warranty will not apply where damage is caused by repairs made or attempted by others (i.e.: persons not authorized by the manufacturer); f) This warranty will not apply to any product that was sold to the original purchaser as a reconditioned or refurbished product (unless otherwise specified in writing); g) This warranty will not apply to any product or part thereof if any part from another manufacturer is installed therein or if any repairs or alterations have been made or attempted by unauthorized persons; h) This warranty will not apply to normal deterioration of the exterior finish, including but not limited to scratches, dents, paint chips, or to any corrosion or discolouring by heat, abrasive and chemical cleaners; and i) This warranty will not apply to component parts sold by and identified as the product of another company, which shall be covered under the product manufacturer’s warranty, if any.
Additional Limitations
This warranty applies only to the original purchaser, and may not be transferred.
Neither the retailer nor the manufacturer shall be liable for any other expense, loss or damage, including but not limited to any indirect, incidental, consequential or exemplary damages arising in connection with the sale, use or inability to use this product.
Notice to Consumer
This warranty gives you specific legal rights, and you may have other rights, which may vary from province to province. The provisions contained in this warranty are not intended to limit, modify, take away from, disclaim or exclude any statutory warranties set forth in any applicable provincial or federal legislation.
IMPORTed by MASTeRCRAfT CANAdA TORONTO, CANAdA M4S 2b8
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