Mastercraft Maximum 054-7221-4 Angle Grinder Instruction manual

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Mastercraft
MAXIMUM
HEAVY-DUTY ANGLE GRINDER
+
mode! no, 054-7221-4
1 a — | INSTRUCTION
IMPORTANT: MANUAL
Read and understand this instruction manual
thoroughly before using the product.
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HOSTS
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TABLE OF CONTENTS
Technical Specifications 4
Safety Guidelines 5-10
Key Parts Diagram 1
Important Information 12 N
Assembly Instructions 13-14 =
Operating Instructions - 15-16 =
Maintenance 17 у
Troubleshooting 18 ©
Part list 19-21 LL
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Warranty 22-23
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NOTE: !f 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.
= a TE Il r= —
model no. 054-7221-4 | contact us 1.800.689.9928
— —— 1 + BTR pm
TECHNICAL SPECIFICATIONS
Rated Voltage 120V~, 60Hz
Rated Power Input 12A
Single speed 11,000 RPM
Disc size 5" (125 mm)
Arbor size 5/8" (16 mm)
Weight 8 Ib 3 oz (3.7 kg)
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MAXIMUM
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 warniægs
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 outiet. 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.
» Avold 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.
e 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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SAFETY GUIDELINES
* 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-fauit
circult interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of
electric shock.
PERSONAL SAFETY
o 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 serióus 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.
e 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.
e Dress properly. Do not wear loose clothing or jewellery. Keep your halr,
clothing and gloves away from moving parts. Loose clothes, jewellery or long
hair can be caught in moving parts.
о № 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
o 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 [die power tools out of the reach of children and do not allow persons
unfamillar 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 repalred 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.
о 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 repalr person using only
identical replacement parts. This will ensure that the safety of the power toel
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 operation.
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 apart.
The outside dlameter and the thickness of your accessory must be within the
capacity rating of your power tool. Incorrectly sized accessories cannot be
adequately guarded or controlled.
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.
SAFETY GUIDELINES
SAFETY GUIDELINES
Do not use a damaged accessory. Before each use, inspect the accessory,
such as abrasive wheels, for chips and cracks. if the power tooi 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 nolse 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"iive” 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 puli 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 couid snag your clothing, pulling the accessory
into your body.
Regularly clean the power tool’s alr 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:
|" J Volts
FN Amperes
HZ neecccconaneronnoss Hertz
WWerenenononacianoner Watts
[191] FSO Minutes
(VU ennanencanacane Alternating current
A Direct current
No eecnonernacancacnes No-load speed
[=] penecavencanvao Class Il Construction
I 00000. Revolutions or reciprocation per minute
© orenuenconenos Grounding terminal
ВРМ ............... Beats per minute
O enaneneneraen 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.
o Wheels must be used only for recommended applications. For example: do
not grind with the side of a cut-off wheei. 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 wheeis 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.
SAFETY GUIDELINES
SAFETY GUIDELINES
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 start-
up. 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.
o 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
NO. PART
1 Cord guard
2 Power-supply indicator light
3 ON/OFF trigger switch
4 Lock-off/Lock-on button
5 Side handle
6 Spindle-lock button
A
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.
7
8
9
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CONC
Inner flange
Grinding disc
Disc guard
Wrench
Quter flange
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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.
IMPORTANT INFORMATION
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.
ETRE
MAXIMUM
ASSEMBLY INSTRUCTIONS
INSTALLING AND REMOVING THE
GRINDING DISC
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.
ASSEMBLY INSTRUCTIONS
8. While pressing the spindie-lock
button, tighten the threaded outer
flange (5) by turning it clockwise with
the wrench supplied (7).
NOTE:
* The maximum disc thickness is 1/4" (6.5 mm), and the spindie 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).
ASSEMBLY INSTRUCTIONS
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.
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.
* Do not depress the spindle lock until the spindle has completely
WARNING!
AN stopped moving.
MAXIMUM
OPERATING INSTRUCTIONS
ON/OFF SWITCH AND LOCK
BUTTON (ON/OFF): (fig 5) figs
TO TURN THE TOOL ON:
1. To start the tool, push the Lock button
(2), and while holding it in, apply yI
pressure to the trigger switch (1).
Release the Lock button (2).
2. To stop the tool, release the trigger 2 1
switch (1). The switch reverts to the
Locked OFF position.
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.
OPERATING INSTRUCTIONS
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.
a | TE
model no. 054-7221-4 | contact us 1.800.689.9928
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.
. Always position the guard so that the exposed grinding disc is pointing away
from the operator.
. 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.
. Apply the grinding disc to the work surface using light, steady pressure for
grinding efficiency.
. 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).
OPERATING INSTRUCTIONS
AN
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.
{retry
MAXIMUM
EL
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 chemicais 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).
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
Tool Is not plugged in Check that all cords are plugged in
Motor does ° , .
not start Fuse Check the time-delayed fuse or circuit
breaker
Tool vibrates Damaged disc Replace disc
or shakes . Loose 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,
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PART LIST
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15
16
17
18
19
20
21
22
23
24
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3123640000
3660071000
3550107000
5660003000
5610106000
3420624000
5700033000
3550901000
5610097000
3700447000
5700015000
3700528000
3550580000
3550104000
5680024000
3420623000
5650007000
5620042000
3700106000
3700111000
5630039000
3550105000
5700015000
3700100000
5620068000
2750156000
Lock-on/lock-
off button
Spring
Bushing
E-Ring
Tapping screw
Gear case
Needle
bearing
Gear
Thread-
forming screw
Washer
Ball bearing
Felt block
Spindle
Cup half key
Gear case
cover
Spring washer
Screw
Wave washer
Guard
Nut
Pinion
Ball bearing
Clamp
Screw
Rotor
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
3120322000
5700008000
3120993000
5620034000
3420622000
2240114000
3123639000
3700486000
4960009000
2800034000
5650034000
5610006000
3420621000
2240113000
2820653000
2820652000
3700099000
2740119000
3120321000
5610052000
3700893000
5620034000
2820067000
3550333000
3550109000
3700135000
Dust cover
Ball bearing
Bearing holder
Screw
Right aluminium
cover
Power nameplate
Motor housing
Plate
Carbon brush
Brush holder
Plain washer
Tapping screw
Left aluminium
cover
Trademark plate
Internal wire
assembly
Internal wire
assembly
Terminal
Stator
Fan baffle
Tapping screw
Clamp
Screw
Inner flange
Outer flange
Flange screw
51
52
53
54
55
56
57
58
3123624000
3320547000
3123707000
4870340000
4540017000
4930017000
5610024000
3120234000
DIET
Right brush
cover
Right handie
Transparence
cap
Switch
Power supply
indicator
Connector
Tapping
screw
Cord
anchorage
59
60
61
62
63
64
65
66
3121050000
4810002000
3123641000
3320546000
4930061000
4860004000
4930047000
2490136002
No. Part No. | Description
Cord guard
Power cord € plug
Left brush cover
Left handie
Shark-teeth
terminal
Inner wire
Ring terminal
Nyion string
PART LIST
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model no. 054-7221-4 | contact us 1.800.689.9928
i rer a
5-YEAR LIMITED WARRANTY
This Mastercraft Maximum product is guaranteed against defects =.
in workmanship and materlals for a period of 5 years from the YEAR LINITED
date of original retaif purchase, with the exception of the following ANS DE CARTE
components: LTÉE a
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 perlod 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);
9) This warranty will not apply to any product or part thereof if any part from
another manufacturer is installed therein or if any repalrs 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
o
MAXIMUM
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.
WARRANTY
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