master mechanic 134465 User manual

2 AMP 1/4 SHEET PALM SANDER
134465
Owner’s Manual
PRODUCT SPECIFICATIONS
Rating:
120V, 60Hz, AC
Amperes:
2 AMP
Oscillation speed:
13,000 OPM (no load)
Sanding pad size:
1/4 sheet
Weight:
3 lb 6 oz (1.53 kg)
Need Assistance?
Call us on our toll free customer support line:
1-866-349-8665 Monday –Friday from 9am to 5pm
Eastern Standard Time
Technical questions
Replacement parts
Parts missing from package
Manufactured For and Distributed By
True Value® Company, Chicago, IL
©2011 True Value Company
Made in China

2
Product specifications ………….…………………………………………………….
1
Table of contents ……………………………………………………………………...
2
General safety warnings ……………………………………………………………..
3–4
Eye, ear & lung protection ……………………………………………………………
3–4
Electrical safety ……………………………………………………………………….
4
Power tool safety ……………………………………………………………………...
5–6
General safety rules …………………………………………………………………..
5
Work area ………………………………………………………………….…………..
5
Electrical safety ……………………………………………………………………….
5
Personal safety ………………………………………………………………………..
5–6
Power tool use and care.……………………………………………………………..
6
Service …………………………………………………………………………………
6
Specific safety rules …………………………………………………………………..
7
Extension cord safety ………………………………………………………….……..
8
Symbols ………………………………………………………………………………..
9
Know your sander ……………………………………………………………............
10
Available accessories ………………………………………………………………...
10
Contents ……………………………………………………………………………….
11
Assembly and operating ……………………………………………………………..
12–17
Installing the dust box assembly …………………………………………………….
12
Removing & cleaning the dust box assembly ……………………………………...
12
Installing sandpaper …………………………………………………………………..
13–14
ON/OFF switch ………………………………………………………………………..
14
Sandpaper selection ………………………………………………………………….
15–16
Sanding ………………………………………………………………………………...
16–17
Maintenance …………………………………………………………………………..
18
Exploded view …………………………………………………………………………
19
Parts list ………………………………………………………………………………..
20–21
Warranty ……………………………………………………………………….………
22
TABLE OF CONTENTS

3
EYE, EAR & LUNG PROTECTION
This instruction manual includes the following:
General Safety Rules
Specific Safety Rules and Symbols
Functional Description
Assembly
Operation
Maintenance
Accessories
!
ALWAYS WEAR EYE PROTECTION THAT CONFORMS WITH CSA
REQUIREMENTS or ANSI SAFETY STANDARD Z87.1
FLYING DEBRIS can cause permanent eye damage. Prescription
eyeglasses ARE NOT a replacement for proper eye protection.
WARNING: Non-compliant eyewear can cause serious injury if
broken during the operation of a power tool.
SAVE THESE INSTRUCTIONS FOR REFERENCE
WARNING: Use hearing protection, particularly during extended
periods of operation of the tool, or if the operation is noisy.
!
GENERAL SAFETY WARNINGS
WARNING: Before using this tool or any of its accessories, read this
manual and follow all Safety Rules and Operating Instructions. The important
precautions, safeguards and instructions appearing in this manual are not
meant to cover all possible situations. It must be understood that common
sense and caution are factors which cannot be built into the product.
!

4
ELECTRICAL SAFETY
WARNING: To avoid electrical hazards, fire hazards or damage to the
tool, use proper circuit protection.
This tool is wired at the factory for 120V AC operation. It must be connected
to a 120V AC, 15 AMP circuit that is protected by a time-delayed fuse or
circuit breaker. To avoid shock or fire, replace power cord immediately if it
is worn, cut or damaged in any way.
GENERAL SAFETY WARNINGS
WEAR A DUST MASK THAT IS DESIGNED TO BE USED WHEN
OPERATING A POWER TOOL IN A DUSTY ENVIRONMENT.
WARNING: Dust that is created by power sanding, sawing, grinding,
drilling, and other construction activities may contain chemicals that are
known to cause cancer, birth defects, or other genetic abnormalities. These
chemicals include:
Lead from lead-based paints
Crystalline silica from bricks, cement, and other masonry products
Arsenic and chromium from chemically treated lumber
The level of risk from exposure to these chemicals varies, according to how
often this type of work is performed. In order to reduce exposure to these
chemicals, work in a well-ventilated area, and use approved safety
equipment, such as a dust mask that is specifically designed to filter out
microscopic particles.
!

5
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.
Work area safety
Keep 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 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 cord away from
heat, oil, sharp edges or moving parts.
Damaged or entangled cords increase the
risk of electric shock.
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 residual
current device (RCD) protected supply.
Use of a ground fault circuit interrupter
(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 a power tool
while you are 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 energizing power tools
that have the switch on invites accidents.
POWER TOOL SAFETY
!

6
PERSONAL SAFETY –cont’d
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 jewelry. Keep your hair,
clothing and gloves away from moving
parts. Loose clothes, jewelry or long hair
can be caught in moving parts.
If devices are provided for the
connection of dust extraction and
collection facilities, ensure these are
connected and properly used. Use of
dust collection 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 safer 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 and
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.
POWER TOOL SAFETY
SAVE THESE INSTRUCTIONS FOR REFERENCE

7
WARNING: Know your sander. Do
not plug in the sander until you have
read and understand this Instruction
Manual. Learn the tool’s applications
and limitations, as well as the specific
potential hazards related to this tool.
Following this rule will reduce the risk of
electric shock, fire, or serious injury.
Always wear eye protection.
Any power tool can throw
foreign objects into your eyes
and cause permanent eye
damage. ALWAYS wear safety goggles
(not glasses) that comply with ANSI safety
standard Z87.1. Everyday glasses have
only impact resistant lenses. They ARE
NOT safety glasses.
WARNING: Glasses or goggles
not in compliance with ANSI Z87.1
could cause serious injury when they
break.
WARNING: Always use a dust
mask when sanding.
WARNING: Always use hearing
protection when sanding, particularly
during extended periods of operation.
WARNING: Always unplug the
tool from the power source before
changing the sandpaper and when
cleaning the tool.
Do not wear gloves, neckties or loose
clothing.
Secure the workpiece. Use clamps or a
vise to hold the work when practical. It is
safer than using your hand and it frees
both hands to operate the tool.
Do not sand material too small to be
securely held.
Make sure there are no nails or foreign
objects in the part of the workpiece to be
sanded.
Always keep hands out of the path of the
sanding pad. Avoid awkward hand
positions where a sudden slip could cause
your hand to move into the path of the
sanding pad.
To avoid injury from accidental starting,
always remove the plug from the power
source before installing or removing
sandpaper or the dust duct bag.
SPECIFIC SAFETY RULES
!
!
!
!
SAVE THESE INSTRUCTIONS FOR REFERENCE
!

8
WARNING: Keep the extension
cord clear of the working area. Position
the cord so it will not get caught on the
workpiece, tools or any other obstructions
while you are working with the power tool.
Make sure any extension cord used with
this tool is in good condition. When using
an extension cord, be sure to use one of
heavy enough gauge to carry the current
the tool will draw. An undersized cord will
cause a drop in line voltage resulting in
loss of power and overheating.
The table at right shows the correct size to
use according to cord length and
nameplate ampere rating. If in doubt, use
the next heavier gauge. The smaller the
gauge number the heavier the cord.
Be sure your extension cord is properly
wired and in good condition. Always
replace a damaged extension cord or have
it repaired by a qualified electrician before
using it. Protect your extension cord from
sharp objects, excessive heat and damp or
wet areas.
Use a separate electrical circuit for your
power tools. This circuit must not be less
than 14 gauge wire and should be
protected with either a 15 AMP time
delayed fuse or circuit breaker. Before
connecting the power tool to the power
source, make sure the switch is in the OFF
position and the power source is the same
as indicated on the nameplate. Running at
lower voltage will damage the motor.
!
MINIMUM GAUGE (AWG)
EXTENSION CORDS (120V use only)
Amperage
rating
Total length
More
than
Not
more
than
25'
(7.5 m)
50'
(15 m)
100'
(30 m)
150'
(45 m)
0
6
18
16
16
14
6
10
18
16
14
12
10
12
16
16
14
12
12
16
14
12
Not Applicable
EXTENSION CORD SAFETY

9
This symbol designates that this tool is
listed with U.S. requirements by
ETL Testing Laboratories, Inc.
Conforms to UL Std. 60745-1 and
60745-2-4.
3042597
JD2583U
LISTED
V
Volts
A
Amperes
Hz
Hertz
W
Watts
kW
Kilowatts
Microfarads
L
Liters
kg
Kilograms
H
Hours
N/cm2
Newtons per square
centimeter
Pa
Pascals
OPM
Oscillations per minute
Min
Minutes
S
Seconds
or a.c.
Alternating current
Three-phase alternating
current
Three-phase alternating
current with neutral
Direct current
No load speed
Alternating or direct
current
Class II construction
Splash-proof
construction
Watertight construction
Protective grounding at
grounding terminal,
Class I tools
Revolutions or
reciprocations per
minute
Diameter
Off position
Arrow
Warning symbol
Wear your safety
glasses
SYMBOLS
WARNING: Some of the following symbols may appear on the sander.
Study these symbols and learn their meaning. Proper interpretation of these
symbols will allow for more efficient and safer operation of this tool.
!

10
AVAILABLE ACCESSORIES
WARNING: Use only sandpaper
that is recommended for this sander.
Follow the instructions that accompany
the accessories. The use of improper
accessories may result in injury to the
operator or damage to the sander.
Before using any accessory, carefully read
the instructions or the owner’s manual for
the accessory.
Sandpaper
WARNING: If any part is missing or
damaged, do not plug the sander into the
power source until the missing or damaged
part is replaced.
KNOW YOUR SANDER
ACCESSORIES
!
!
Backing
pad
Palm grip
Dust box
assembly
Sandpaper
clamp
Sandpaper
clamping lever
ON/OFF switch
Cooling
vents
Cooling
vents

11
CONTENTS
Carefully unpack the sander. Compare the
contents against the “SANDER
COMPONENTS” chart at right.
NOTE: See illustration of the sander
below.
WARNING: To avoid fire or toxic
reaction, never use gasoline, naphtha,
acetone, lacquer thinner or similar
highly volatile solvents to clean the
tool.
!
SANDER COMPONENTS
KEY
DESCRIPTION
QTY
A
Sander
1
B
Dust box assembly
1
C
Sandpaper
60 grit
80 grit
120 grit
8
8
4
D
Sandpaper hole punch
1
Owner’s Manual
1
CONTENTS

12
INSTALLING THE DUST BOX
ASSEMBLY
1. Insert the dust box assembly sleeve
(1) into the dust chute (2)
(Fig. 1).
NOTE: Make sure the tabs (3) insert into
the matching slots (4) in the dust chute.
2. Rotate the dust chute sleeve
CLOCKWISE approximately 15° to
lock it into place.
REMOVING & CLEANING THE DUST
BOX ASSEMBLY
The dust box assembly should be removed
periodically and emptied to prevent
excessive dust build up and to maintain
the effectiveness of the dust box.
1. Remove the dust box assembly (1)
from the dust chute by rotating it
COUNTER CLOCKWISE
approximately 15° and pulling it out of
the dust chute (Fig. 2).
2. Carefully shake the dust box
assembly with the end cap opening
(2) pointing downward to remove the
sanding dust.
NOTE: It is best to perform this function
outdoors over a trash can to prevent
sanding dust from escaping into the work
area.
3. Once the sanding dust is removed
from the dust box assembly, reinstall
the dust box assembly as noted in
Fig. 1.
ASSEMBLY AND OPERATING
Fig. 1
Fig. 2

13
INSTALLING SANDPAPER
WARNING: Unplug the sander
from the power source before installing
or changing sandpaper.
1. Lift up and outward on the front and
rear sandpaper clamp levers (1) at the
front and rear of the backing pad (2)
(Fig. 3).
2. Insert one end of the 1/4 sheet
sandpaper (3) with grit side up into the
open front sandpaper clamp (4),
making sure it is aligned with the
backing pad. Lift the sandpaper clamp
lever up and inward to lock the
sandpaper into the clamp.
3. Wrap the sandpaper sheet (3) over
backing pad and insert it into the open
rear sandpaper clamp (5) (Fig. 4).
NOTE: Make sure the sandpaper is pulled
tight over the backing pad for proper
sanding operation.
4. Lift the sandpaper clamp lever up and
inward to lock the sandpaper into the
clamp.
PUNCHING HOLES IN SANDPAPER
The sandpaper must have 8 holes
punched in it to allow the sanding dust to
escape from the working surface. The
pattern of these holes must match the hole
pattern on the sanding pad. If the
sandpaper you are using does not have
the holes punched, use the hole punch
supplied with the tool to pierce the
sandpaper in the correct locations.
ASSEMBLY AND OPERATING
!
Fig. 3
Fig. 4

14
PUNCHING HOLES IN SANDPAPER –cont’d
1. Install the sandpaper as shown in
Fig. 3 & 4.
2. Place the hole punch (1) on a sturdy
flat surface (Fig. 5).
3. Align the corner of the sanding pad (2)
with the corner of the hole punch (3).
This will ensure the holes are punched
in the correct location.
4. When sanding pad is correctly aligned
on the hole punch, press the sanding
pad firmly onto the hole punch.
NOTE: The sharp pegs (4) in the hole
punch will pierce the sandpaper in the
correct location.
ON/OFF SWITCH
To turn the switch ON, press the left hand
side of the ON/OFF switch (1) (Fig. 6). To
turn the switch OFF, press the right hand
side of the ON/OFF switch (2).
ASSEMBLY AND OPERATING
Fig. 5
Fig. 6

15
SANDPAPER SELECTION
Selecting the correct grit and type of
sandpaper is extremely important in
achieving a high quality sanded finish.
Aluminum oxide, silicon carbide and other
synthetic abrasives are best for power
sanding. Natural abrasives such as flint
and garnet are too soft for economical
use in power sanding.
For safety reasons, the operator
must read the sections of this
Owner’s Manual entitled "GENERAL
SAFETY WARNINGS", "POWER
TOOL SAFETY", "SPECIFIC SAFETY
RULES", "EXTENSION CORD
SAFETY" and "SYMBOLS" before
using this sander.
Verify the following every time the
sander is used:
1. Sandpaper is in good condition
and properly installed on the
sander.
2. The workpiece is properly
secured and free from any
foreign objects.
3. Safety glasses, safety goggles,
or face shield is being worn.
4. Hearing protection and dust
mask are being worn.
Failure to observe these safety rules
will significantly increase the risk of
injury.
WARNING
!
ASSEMBLY AND OPERATING

16
SANDPAPER SELECTION –cont’d
In general, coarse grit will remove the most
material and finer grit will produce the best
finish in all sanding operations. The
condition of the surface to be sanded will
determine which grit will do the best job. If
the surface is rough, start with a coarse
grit and sand until the surface is uniform.
Medium grit may then be used to remove
scratches left by the coarser grit. Fine grit
should be used for finishing the surface.
Always continue sanding with each grit
until the surface is uniform.
SANDING
Clamp or otherwise secure your workpiece
to prevent it from moving under the sander
while being sanded.
Place the sander on the workpiece so that
the complete sandpaper surface is in
contact with the workpiece. Turn the
sander ON by pressing on the right hand
side of the ON/OFF switch. Move the
sander slowly over the workpiece making
successive passes in parallel lines, circles
or crosswise movements. Because the
orbital motion of the sanding pad moves in
tiny circles, it is not necessary to move the
sander with the grain or in the same
direction for successive passes (Fig. 7).
Upon completion of the sanding operation,
turn the sander OFF by pressing on the left
hand side of the ON/OFF switch. Wait until
the sanding pad comes to a complete stop
before removing it from the workpiece.
ASSEMBLY AND OPERATING
Fig. 7

17
SANDING –cont’d
WARNING: Your sander should
only be turned ON when the entire
surface of the sanding pad is in contact
with the workpiece. Failure to follow
this sanding procedure could result in
loose sandpaper which could result in
possible injury.
NOTE: Hold the sander using the pad grip
on top of the sander. Be careful NOT to
cover the cooling vents with your hand.
Covering the cooling vents could cause the
motor to be damaged by overheating.
DO NOT FORCE THE SANDER. The
weight of the sander usually provides
adequate pressure. Let the sander and
sandpaper do the work. Applying added
pressure will slow the motor, increase the
wear on the sandpaper and greatly reduce
the sander speed. Excessive pressure will
overload the motor causing possible
damage from the motor overheating. It will
also create an inferior finish on sanded
work. Any finish or resin on wood will
soften from the frictional heat, causing
sandpaper to become clogged quickly. Do
not sand in one spot too long as the
sander’s rapid action may remove too
much material, making the surface
uneven.
Extended periods of sanding may tend to
overheat the motor. If this occurs, turn the
sander OFF, wait until the sanding pad
comes to a complete stop and remove it
from the workpiece. Check to make sure
your hand has not been covering the
cooling vents. Let the motor cool before
continuing the sanding operation.
ASSEMBLY AND OPERATING
!

18
GENERAL
WARNING: When servicing, use
only identical replacement parts. The
use of any other part may create a
hazard or cause product damage.
DO NOT use solvents when cleaning
plastic parts. Plastics are susceptible to
damage from various types of commercial
solvents and may be damaged by their
use. Use a clean cloth to remove dirt, dust,
oil, grease etc.
WARNING: Do not allow brake
fluids, gasoline, petroleum-based
products, penetrating oils, etc. to come
into contact with plastic parts. They
contain chemicals that can damage,
weaken or destroy plastic.
DO NOT abuse power tools. Abusive
practices can damage the tool and the
workpiece.
WARNING: DO NOT attempt to
modify tools or create accessories. Any
such alteration or modification is
misuse and could result in a hazardous
condition leading to possible serious
injury. It will also void the warranty.
It has been found that electric tools are
subjected to accelerated wear and
possible premature failure when they are
used on fiberglass boats and sports cars,
wallboard, spackling compounds or
plaster. The chips and grindings from
these materials are highly abrasive to
electric tool parts such as bearings,
brushes, commutators, etc. Consequently,
it is not recommended that this tool be
used for extended work on any fiberglass
material, wallboard, spackling compounds
or plaster. During any use on these
materials it is extremely important that the
tool is cleaned frequently by blowing it out
with an air jet.
WARNING: Always wear safety
goggles or safety glasses with side
shields during all sanding operations. It
is critical that you also wear safety
goggles or safety glasses with side
shields and a dust mask while blowing
dust out of the sander with an air jet.
Failure to take these safety precautions
could result in permanent eye or lung
damage.
LUBRICATION
All of the bearings in this tool are
lubricated with a sufficient amount of high-
grade lubricant for the life of the unit under
normal conditions. Therefore, no further
lubrication is required.
!
MAINTENANCE
!
!
!
!

19
EXPLODED VIEW

20
WARNING: When servicing, use only original equipment replacement parts. The
use of any other parts may create a safety hazard or cause damage to the sander.
Any attempt to repair or replace electrical parts on this sander may create a safety hazard
unless repairs are performed by a qualified technician. For more information, call the Toll-
free Helpline, at 1-866-349-8665 Monday –Friday from 9am to 5pm Eastern Standard
Time.
Always order by PART NUMBER, not by key number.
Key #
Part #
Part Name
Quantity
1
4010010035
Bearing 627
1
2
3140060001
Rubber cup
2
3
3140080029
Switch cover
1
4
1061150016
Switch
1
5
3150060005
Brush holder support
2
6
2030070001
Brush holder
2
7
1230010063
Carbon brush
2
8
1020080021
Stator
1
9
4010010034
Bearing 607
1
10
3011080019
Right housing
1
11
4030010106
Screw ST3.9x19
6
12
1250010002
Terminal block
1
13
4030010099
Screw ST3.9x14
2
14
3150020001
Cord clamp
1
15
3140010007
Cord guard
1
16
1190030028
Cord set
1
17
1010080021
Rotor
1
18
3140020023
O ring
1
19
2020100007
Aluminum fan
1
20
3180030020
Dust box cover
1
!
PARTS LIST