MasterCraft 54-1243-8 User manual

5" ANGLE GRINDER
54-1243-8
Owner’s Manual
PRODUCT SPECIFICATIONS
Rating:
120 V, 60 Hz AC
Amperes:
9 A
Speed:
11,000 RPM (no load)
Maximum disc diameter:
5" (127 mm)
Spindle threads:
5/8" –11UNC (15.875 mm)
Minimum disc thickness:
5/32" (3.9 mm)
Weight:
6 lb 7 oz (2.92 kg)
Need Assistance?
Call us on our toll free customer support line:
1-800-689-9928
Technical questions
Replacement parts
Parts missing from package
Imported by Mastercraft Canada Toronto, Canada M4S 2B8

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
Use and care of power tools .………………………………………………………..
6
Service …………………………………………………………………………………
6
Specific safety rules …………………………………………………………………..
7–8
Extension cord safety ………………………………………………………….……..
8
Symbols ………………………………………………………………………………..
9
Know your angle grinder ……………………………………………………………..
10
Accessories ……………………………………………………………………………
10
Contents ……………………………………………………………………………….
10–11
Assembly and operating ……………………………………………………………..
12–18
Installing the side handle …………………………………………………………….
12
Installing the guard ……………………………………………………………………
12–13
Installing a grinding disc ……………………………………………………………...
14
Positioning the guard …………………………………………………………………
15
Multiple function switch ………………………………………………………………
16
Grinding ………………………………………………………………………………..
17–18
Maintenance …………………………………………………………………………..
19
Exploded view ………………………………………………………………………...
20
Parts listing …………………………………………………………………………….
21–22
Warranty ……………………………………………………………………….………
23–24
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
CAUTION: Before using this tool or any of its accessories, read this
manual and follow all Safety Rules and Operating Instructions.
!

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 110–120 V operation. It must be
connected to a 110–120 V, 15 A 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
GENERAL SAFETY RULES
WARNING: Read and understand
all instructions. Failure to follow all
instructions listed below may result in
electric shock, fire and/or serious personal
injury.
WORK AREA
Keep your work area clean and well lit.
Cluttered benches and dark areas invite
accidents.
Do not operate power tools in potentially
explosive environments, such as in the
presence of flammable liquids, gas or dust.
Power tools create sparks that may ignite
dust or fumes.
Keep bystanders, children and visitors
away while operating the tool. Distractions
can cause the operator to lose control.
ELECTRICAL SAFETY
Double insulated tools are equipped with a
polarized plug (one blade is wider than the
other). This plug will only fit into a
polarized plug one way.
If the plug does not fit into the outlet
properly, reverse the plug. If it still does not
fit, contact a qualified electrician to install a
polarized outlet. Do not alter the plug in
any way. Double insulation eliminates the
need for the three-pronged grounded
power cord and grounded power supply
system.
Avoid contact between the operator's body
and grounded surfaces such as pipes,
radiators, ranges, and refrigerators. There
is an increased risk of electric shock if the
operator's body is grounded.
Do not expose power tools to rain or wet
conditions. Water entering the power tool
will increase the risk of electric shock.
Do not abuse the cord. Do not use the
power cord to carry the tool or to pull the
plug out of the outlet. Keep the power cord
away from heat, oil, sharp edges, and
moving parts. Replace a damaged power
cord immediately. A damaged power cord
increases the risk of electric shock.
When operating a power tool outdoors,
use an outdoor-rated extension cord type
“W-A” or “W”. These cords are rated for
outdoor use and they reduce the risk of
electric shock.
PERSONAL SAFETY
Stay alert, be aware of the surroundings,
and use common sense when operating a
power tool. Do not use a power tool while
tired or under the influence of drugs,
alcohol, or medication. A moment of
inattention while operating a power tool
may result in serious personal injury.
Dress properly. Do not wear loose clothing
or jewellery.
Contain long hair. Keep hair, clothing, and
gloves away from moving parts. Loose
clothing, jewellery, or long hair can get
caught in moving parts.
!
POWER TOOL SAFETY

6
PERSONAL SAFETY –cont’d
Avoid accidental start-ups. Verify that the
switch is in the OFF position before
plugging in the tool. Carrying a power tool
with a finger on the switch or plugging in a
tool that has the switch in the ON position
invites accidents.
Remove adjusting keys and wrenches
before turning the tool ON. A wrench or
key that is left attached to a rotating part of
the tool may result in personal injury.
Do not overreach. Keep proper footing and
balance at all times. Proper footing and
balance allows the operator to maintain
better control of the tool in unexpected
situations.
Use safety equipment. Always wear eye
protection.
Use a dust mask, non-skid safety shoes, a
hardhat, or hearing protection when
appropriate.
USE AND CARE OF POWER TOOLS
Use clamps or another practical means to
secure and support the workpiece to a
stable platform. Holding the work in a hand
or against the body is not stable, and may
lead to loss of control.
Do not force the tool. Use the correct tool
for the application. The correct tool will do
the job better and safer when used at the
rate that it was designed to work at.
Do not use a power tool if it cannot be
turned ON or OFF using the power switch.
A tool that cannot be controlled using the
switch is dangerous, and must be repaired.
Disconnect the plug from the outlet before
making any adjustments, changing
accessories, or storing the tool. Such
preventive safety measures reduce the risk
of accidental start-ups.
When power tools are not in use, store
them out of the reach of children or
untrained persons. Tools are dangerous in
the hands of untrained users.
Maintain tools with care. Keep cutting tools
sharp and clean. Properly maintained
cutting tools with sharp cutting edges are
less likely to bind, and are easier to
control.
Inspect the tool for misalignment or binding
of moving parts, broken parts, and any
other condition that may affect the
operation of the tool. If it is damaged, have
the tool serviced before using it. Many
accidents are caused by poorly maintained
tools.
Use only accessories that are
recommended by the manufacturer for this
model. Accessories that are suitable for
one tool may become hazardous when
used with another tool.
SERVICE
Tool servicing must be performed by
qualified personnel. Service or
maintenance performed by non-qualified
personnel could result in a risk of injury.
When servicing a tool, use only identical
replacement parts. Follow the instructions
in the Maintenance section of this Manual.
The use of unauthorized parts or failure to
follow the instructions in the Maintenance
section of this Manual may create a risk of
electric shock or injury.
POWER TOOL SAFETY

7
WARNING: Know your angle
grinder. Read the Owner’s Manual
carefully. 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: Wearing glasses or
goggles that do not comply with ANSI
Z87.1 could cause serious injury if they
break.
Always wear hearing protection and a dust
mask. Use only in a well-ventilated area.
Using personal safety devices and working
in a safe environment reduces the risk of
injury.
DANGER: Always unplug the tool
from the power source before changing
the grinding disc or cleaning the tool.
DANGER: Never place hands or
fingers near the grinding disc while the
tool is running. Severe injury will result.
WARNING: After prolonged use,
external metal parts will become hot to the
touch.
Always turn the switch OFF and wait for
the grinding disc to come to a complete
stop before putting the angle grinder down.
Grinding disc and guard must be securely
attached as described in this Owner’s
Manual before connecting the grinder to
the power source. Failure to do so will
increase the risk of serious injury if the
grinding disc shatters.
Make sure the guard is in good condition
and securely installed before operating
grinder.
Secure workpiece. Use clamps or a vice to
hold the work when practical. It’s safer
than using your hand and it frees both
hands to operate the tool.
Do not clamp grinder in vise or use as a
fixed grinder.
Grinding discs must be stored in a dry
location to prevent deterioration.
Before attaching the grinding disc, inspect
it for visible defects. If cracked, chipped or
warped do not install it.
Use only grinding discs in compliance with
ANSI Standard B7.1 and rated for a speed
greater than 11,000 RPM.
Do not remove the soft paper in the centre
of the grinding disc.
NOTE: If this paper has been previously
removed, insert some soft rubber or paper
between the grinding disc and the disc
flange to prevent damage to the grinding
disc.
Do not alter or enlarge the centre hole of
the grinding disc as this could result in
breaking it.
SPECIFIC SAFETY RULES
!
!
!
!
!
!

8
Do not over tighten the clamp nut on the
grinding disc. Excessive tightening may
cause the disc to crack and possibly
shatter during operation.
Do not use the grinder if the disc flange or
clamp nut is missing or if the spindle is
bent.
Check to make sure the power cord and
any extension cord are clear of the area to
be cut. Contact with ”live” wires could
shock the operator or cause a fire.
Hold tool by insulated gripping surfaces
when performing an operation where the
tool may contact hidden wiring or its own
cord. Contact with a “live” wire will make
exposed metal parts of the tool “live” and
shock the operator.
Always hold the grinder securely with two
hands while working and at all times when
it is running.
Never turn the grinder ON with the grinding
disc or any rotating parts touching the work
surface.
Never cover the air vents in the motor
housing with your hands while operating
the grinder.
WARNING: Keep the extension
cord clear of the work area. Position the
cord so it will not get caught on the
workpiece, a tool, or any other obstruction
while the power tool is in use.
If an extension cord is used with this angle
grinder, verify that it is in good condition.
When using an extension cord, be sure to
use one that is heavy enough to carry the
current that the tool will draw. An
undersized cord will cause a drop in line
voltage, which will result in a loss of power
and overheating.
The following table shows the correct size
to use according to cord length and the
amperage rating that is listed on the tool's
nameplate. When in doubt, use the next
heavier gauge. The smaller the gauge
number, the heavier the cord.
Verify that the extension cord is properly
wired and in good condition. Replace a
damaged extension cord immediately, or
have it repaired by a qualified electrician
before using it. Keep the extension cord
away from sharp objects, excessive heat,
and damp or wet areas.
Use a separate electrical circuit for power
tools. This circuit must consist of not less
than 14 gauge wire and should be
protected by either a 15 A time-delayed
fuse or a circuit breaker. Before connecting
the power tool to the outlet, verify that the
switch is in the OFF position, and that the
voltage of the power source is the same as
the voltage that is indicated on the tool's
nameplate. Running this angle grinder at
lower voltage will damage the motor.
EXTENSION CORD
SAFETY
!
SPECIFIC SAFETY RULES
MINIMUM GAUGE (AWG)
EXTENSION CORDS (120 V 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

9
V
Volts
A
Amperes
Hz
Hertz
W
Watts
kW
Kilowatts
Microfarads
L
Litres
kg
Kilograms
H
Hours
N/cm2
Newtons per square
centimetre
Pa
Pascals
Min
Minutes
S
Seconds
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
SYMBOLS
WARNING: Some of the following symbols may appear on the angle
grinder. Study these symbols and learn their meanings. Proper interpretation
of these symbols will allow for more efficient and safer operation of this tool.
!
This symbol designates that
this tool is listed with both
Canadian and U.S.
requirements by Underwriters
Laboratories.
HOMOLOGUE
95GA
E210256

10
AVAILABLE ACCESSORIES
WARNING: Use only grinding
discs that are recommended for this
angle grinder. Follow the instructions
that accompany the grinding discs. The
use of improper grinding discs may
result in injury to the operator or
damage to the angle grinder.
Before using any accessory, carefully read
the instructions or the owner’s manual for
the accessory.
Replacement grinding discs
WARNING: If any part is missing or
damaged, do not plug the tool into the
power source until the missing or damaged
part is replaced.
CONTENTS
Carefully unpack the angle grinder.
Compare the contents against the “ANGLE
GRINDER COMPONENTS” chart below.
WARNING: To avoid fire or toxic
reaction, never use gasoline, naphtha,
acetone, lacquer thinner or similar highly
volatile solvents to clean the tool.
KNOW YOUR ANGLE GRINDER
ACCESSORIES
!
Side handle
Air vents
Multiple function
switch
Guard
Spindle locking
button
Disc
flange
Disc
Quick release
guard clamp
lever
!
!
ANGLE GRINDER COMPONENTS
DESCRIPTION
QTY
A
Angle grinder
1
B
Disc guard
1
C
Grinding disc
1
D
Replacement motor
brushes
2
E
Side handle
1
F
Clamp nut wrench
1
Owner’s manual
1

11
CONTENTS

12
WARNING: Always disconnect
your angle grinder from the power
source when replacing grinding discs,
adjusting the guard, cleaning or when
the tool is not in use. Disconnecting the
angle grinder will prevent accidental
starting that could cause serious
personal injury.
INSTALLING THE SIDE HANDLE
1. Unplug the angle grinder from the
power source.
2. Install the side handle (1) by screwing
it clockwise into the left side (2) of the
gear housing (3) (Fig. 1).
NOTE: The handle can be installed on
either the left or right side of the grinder
gear housing, depending upon operator
preference (Fig. 6 & 7). The side handle
must always be used to prevent loss of
control and possible injury.
3. Tighten the side handle securely.
NOTE: Hand-tighten the side handle. Do
not over tighten.
INSTALLING THE GUARD
WARNING: The guard must be
installed before installing a grinding
disc or using the angle grinder. Failure
to do so could result in serious
personal injury.
1. Open the guard clamp (1) by pulling
outward on the clamp lever (2) to
allow the guard clamp to expand for
installation (Fig. 2).
ASSEMBLY AND OPERATION
!
!
Fig. 1
Fig. 2

13
INSTALLING THE GUARD –cont’d
2. Align the guard clamp key (3) with the
slot in the spindle housing (4).
3. Slide the guard clamp over the spindle
housing until the blade guard is fully
seated on the spindle housing.
NOTE: Rotate the guard so it is positioned
correctly depending upon the location of
the side handle in Fig. 5 & 6.
4. Lock the guard clamp onto the spindle
housing by pressing inward (5) on the
clamp lever until it firmly locks the
guard clamp onto the spindle housing
(Fig. 3).
5. Reinstall the disc flange and clamp
nut on the spindle to protect the
spindle threads.
ASSEMBLY AND OPERATION
Fig. 2
Fig. 3

14
INSTALLING A GRINDING DISC
WARNING: Use correct size
grinding disc. Never use a grinding disc
thinner than 5/32" (3.9 mm).
1. Depress the spindle lock button (1)
and rotate the clamp nut (2) until
spindle locks (Fig. 4).
2. Turn the clamp nut counter clockwise
and remove it from spindle.
NOTES:
a) If the clamp nut cannot be loosened by
hand, use the wrench (3) provided.
b) DO NOT remove the disc flange (4).
3. Make sure the flats on the bottom of
disc flange are engaged with the flats
on the spindle (5).
4. Place the grinding disc over the
spindle and onto the disc flange with
the concave side of the disc (6) facing
outward.
NOTE: Make sure the hole in the grinding
disc fits over the raised small diameter
portion of the disc flange (7).
5. Screw the clamp nut (2) onto the
spindle with the flat side of nut facing
away from the tool. Fit the raised small
diameter portion of the clamp nut into
the hole in the grinding disc.
NOTE: Finger tighten the clamp nut.
6. Depress the spindle lock button and
rotate the grinding disc clockwise until
the spindle locks.
7. Securely tighten the clamp nut with
the wrench provided.
ASSEMBLY AND OPERATION
!
!
Fig. 4

15
POSITIONING THE GUARD
WARNING: The guard must be
positioned correctly to protect the
operator. Rotate the guard to the
correct position as noted in Fig. 5 or
Fig. 6 at right. The guard placement
depends upon where your hand is
positioned on the handle.
!
ASSEMBLY AND OPERATION
Fig. 5
Handle on
left side
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 angle grinder.
Verify the following every time the
angle grinder is used:
1. Safety glasses, safety goggles,
or face shield is being worn.
2. Hearing protection and dust
mask are being worn.
3. The grinding disc is correct for
the type of material being
ground.
4. The grinding disc is in good
condition and is securely
tightened onto the spindle.
5. The power cord is clear of the
grinding disc path.
6. The workpiece is clear of any
foreign materials such as nails.
Failure to observe these safety rules
will significantly increase the risk of
injury.
WARNING
!
Fig. 6
Handle on
right side

16
DANGER: Never attach a wood
cutting or carving blade of any type to
this angle grinder. It is designed for
grinding metal only. Use for any other
purpose is not recommended and
creates a hazard which will result in
serious injury.
WARNING:Never cover air vents.
They must always be open for proper
motor cooling.
MULTIPLE FUNCTION SWITCH
This angle grinder is equipped with a
multiple function switch. The front part of
the switch (2) serves as both a lock-off
switch and a lock-on switch (Fig. 7). The
rear part of the switch turns the tool ON
and OFF.
Turning the tool ON
1. Place index and middle fingers on the
ON/OFF switch (1).
2. Slide your index finger forward and
press and hold the lock-off/lock-on
trigger (2) forward.
3. While pressing forward on the lock-
off/lock-on trigger, squeeze the
ON/OFF switch. The tool will start.
Locking the tool ON
1. While squeezing the ON/OFF switch
to keep the tool running, slide your
index finger forward to press and hold
the lock-off/lock-on trigger forward.
2. Release the ON/OFF switch. The tool
will continue to run without your
fingers on either the ON/OFF switch or
the lock-off/lock-on trigger.
3. To turn the tool off, squeeze and
release the ON/OFF switch.
ASSEMBLY AND OPERATING
!
!
Fig. 7

17
GRINDING
Always select and use grinding discs that
are recommended for the material to be
ground. Make sure that the minimum
operating speed of the grinding disc
selected is not less than 11,000 RPM.
Secure all work before beginning the
grinding operation.
Secure small workpieces in a vice or clamp
them to a workbench.
WARNING: Never use your angle
grinder with the guard removed. It has
been designed for use only with the
guard installed. Attempting to use the
angle grinder with the guard removed
will result in loose particles being
thrown against the operator resulting in
serious personal injury.
WARNING: Never use your
grinder without eye protection.
Following this rule will reduce the risk
of serious personal injury.
Efficient operation of the angle grinder
begins by controlling the pressure and
surface contact between the grinding disc
and the workpiece. Flat surfaces are
ground at an acute angle, normally
between 5° and 15° (Fig. 8).
For maximum control, hold the grinder in
front and away from you with both hands,
keeping the grinding disc clear of the
workpiece. One hand must be on the main
handle and the other hand must be on the
side handle. Start your grinder and let the
motor and grinding disc build up to full
speed. Gradually lower the grinder until the
grinding disc contacts the workpiece.
!
ASSEMBLY AND OPERATION
!
5° to 15°
Fig. 8

18
GRINDING –cont’d
For best results keep the grinder tilted at
an angle of between 5° and 15° and
continuously moving at a steady,
consistent pace. Move the grinder side to
side or forward and backward over the
work area. Keep the grinder moving so
that an excessive amount of material is not
removed from one area. If the grinder is
held in one spot too long, it will gouge and
cut grooves in the workpiece. If the grinder
is held at too sharp an angle, it will gouge
the workpiece because of the
concentration of pressure on a small area.
Use just enough pressure to keep the
grinder from chattering or bouncing. Heavy
pressure will decrease its speed and put a
strain on the motor. Normally, the weight of
the tool alone is adequate for most
grinding jobs. Use light pressure when
grinding jagged edges or loose bolts where
there is potential for the grinder to snag on
the metal edge.
Lift the angle grinder away from the
workpiece before turning it OFF.
When the angle grinder stops, place the
tool on its back with the grinding disc
facing upward. This will protect both the
surface and the grinding disc from being
damaged.
ASSEMBLY AND OPERATION

19
GENERAL
WARNING: When servicing, use
only identical replacement parts. The
use of any other parts may create a
hazard or cause damage to the product.
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. These
substances contain chemicals that can
damage, weaken or destroy plastic.
Keep the air vents cleared of any built up
dust to prevent the motor from
overheating. Remove accumulated dust
and debris regularly using a soft DRY
brush.
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.
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
!
!
!

20
EXPLODED VIEW
9
55
54
53
51 52
50
49
48
47
46
45 44 43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
20
22
19
18
17
16
15
14
13
12
11
9
8
76
5
4
3
2
1
10
21