MasterCraft 54-7238-6 Use and care manual

DETAIL SANDER/POLISHER
Model 54-7238-6
Operation and Safety Instructions
110-9901-002 6/01

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, Table of contents
SECTION
PAGE
I. Technical data ............................ 2
II. General safety rules ........................ 3
Ill. Specific safety rules for the detail sander/polisher
.. 5
IV. Electrical information ....................... 6
V. Know your sander ......................... 8
VI. Assembly and adjustments
................... 9
VII. Operation ............................... 11
VIII. Maintenance ............................. 14
IX. Troubleshooting guide ...................... 15
X. Warranty ............................... 16
I. Technical data
DETAIL SANDER/POLISHER
MODEL NUMBER: 54-7238-6
MOTOR:
Power Source: 120V
AC, 60Hz, 0.8A
'Single Speed: 12,000 OPM
Construction: BALL BEARING
Double Insulated: YES
BACKING
PAD:
Pad Type:
CORD:
NET WEIGHT:
CUL:
HOOK AND LOOP FASTENING SYSTEM
6' 6" (198cm), 2-PRONG POLARIZED
2 Lb 5 Oz (1.04 kg)
E184584
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II. General safety rules
Safety is a combination of common sense, staying alert and knowing how
to use your detail sander/polisher.
WARNING: TO AVOID MISTAKES THAT COULD CAUSE SERIOUS
INJURY, DO NOT PLUG
IN THE DETAIL SANDER/POLISHER UNTIL
THE FOLLOWING STEPS HAVE BEEN READ AND UNDERSTOOD.
1. READ and become familiar with this entire instruction manual.
LEARN the tool's applications, limitations, and possible hazards.
2. AVOID DANGEROUS CONDITIONS. DO NOT use power tools in wet
or damp areas or expose them to rain. Keep work areas well-lit.
3. DO NOT use power tools in the presence of flammable liquids or gases.
4. ALWAYS keep your work area clean, uncluttered, and well-lit. DO NOT
work
on floor surfaces that are slippery with sawdust or wax.
5. KEEP BYSTANDERS AT A SAFE DISTANCE FROM the work area,
especially when the tool is operating. NEVER allow children near the
tool.
6. DO NOT FORCE THE TOOL to do a job for which it was not designed.
7. DRESS FOR SAFETY. DO NOT wear loose clothing, gloves, neckties,
or jewellery (rings, watches) when operating tool. They can get caught
and draw
you into moving parts. ALWAYS wear non-slip footwear, and
tie back long hair.
8. WEAR A FACE MASK OR DUST MASK. The sanding operation
produces dust.
9. ALWAYS remove the power cord plug from the electric outlet when
making adjustments, changing parts, cleaning or working on the tool.
10. AVOID ACCIDENTAL START-UPS. Make sure the power switch is in
the OFF position before plugging
in the power cord.
11. DON'T OVERREACH. Keep proper footing and balance at all times.
Wear oil-resistant, rubber-soled footwear. Keep floor clear
of oil, scrap,
and other debris.
12. MAINTAIN TOOLS PROPERLY. ALWAYS keep tools clean and in
good working order. Follow instructions for lubricating and changing
accessories.
SAVE THESE SAFETY INSTRUCTIONS
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II. General safety rules - continued
13. CHECK FOR DAMAGED PARTS. Check for alignment of moving
parts, jamming, breakage,
or any other conditions that may affect the
tool's operation. Any part that is damaged should be properly repaired
or replaced before use.
14. MAKE WORKSHOP CHILDPROOF. Use padlocks, master switches,
and ALWAYS remove starter keys.
15. DO NOT operate tool ifyou are under the influence
of any drugs,
alcohol
or medication that could affect your ability to use the tool
properly.
WARNING: DUST GENERATED FROM CERTAIN MATERIALS CAN
BE HAZARDOUS TO YOUR HEALTH. ALWAYS OPERATE THE
DETAIL SANDER/POLISHER IN A WELL-VENTILATED AREA AND
PROVIDE FOR PROPER DUST REMOVAL. USE DUST COLLECTION
SYSTEMS WHENEVER POSSIBLE. WEAR A FACE MASK OR DUST
MASKWHEN THE SANDING OPERATION PRODUCES DUST.
ALWAYS WEAR EYE PROTECTION.
A sander can throw foreign objects into your eyes
which could cause permanent eye damage.
ALWAYS wear safety goggles (not glasses).
Ordinary eyeglasses have only impact resistant
lenses
... they are NOT safety goggles.
SAVE THESE SAFETY INSTRUCTIONS
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III. Specific safety rules for the
detail sander I polisher
1. IF YOU ARE NOT thoroughly familiar with the operation of the detail
sander/polisher, obtain advice from a qualified person.
2. MAKE SURE wiring codes and recommended electrical connections
are followed. The detail sander/polisheris double insulated. When
servicing, use only identical replacement parts.
3. NEVER turn the detail sander/polisher ON until all tools, scraps of
wood, and other debris are removed from the work surface.
4. SECURE YOUR WORK. Use clamps or a vise to hold your workpiece.
5. AVOID awkward hand positions. A sudden slip could cause your hand
to contact the sanding disc. Keep hands away from the sanding area.
6. NEVER USE A POWER SANDER FOR WET SANDING OR LIQUID
POLISHING. It may result in electrical shock causing serious
or fatal
injury.
7. INSPECT FOR and remove all nails and staples before sanding. DO
NOT sand over nails or staples, or other imbedded foreign material.
8. MAKE all adjustments with the power OFF and the tool disconnected
from the power source.
9. KEEP THE HANDLE DRY, CLEAN, AND FREE FROM OIL AND
GREASE. Always use a clean cloth when cleaning. Do not use
solvents, brake fluids, gasoline or other petroleum products to clean
the tool; they may damage plastic parts.
10. ALWAYS use sandpaper (not provided) that has a hook and loop
fastening system, and has holes matching the detail sander/polisher's
backing pad.
SAVETHESE SAFETY INSTRUCTIONS
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. IV. Electrical information
WARNING: TO AVOID ELECTRICAL HAZARDS, FIRE HAZARDS,
OR DAMAGE TO THE TOOL, USE PROPER CIRCUIT PROTECTION.
YOUR DETAIL SANDER/POLISHER IS WIRED AT THE FACTORY FOR
120V OPERATION. CONNECT TO A 120 V, 15 A CIRCUIT AND USE
A 15 A TIME DELAY FUSE OR CIRCUIT
BREAKER TO AVOID
SHOCK
OR FIRE, WHEN THE POWER CORD IS WORN, CUT OR
DAMAGED IN ANY WAY, HAVE IT REPLACED IMMEDIATELY.
DOUBLE INSULATED
This detail sander/polisher has a plug that looks like the one
shown below:
The detail sander/polisher is double
insulated to provide a double thick-
ness
of insulation between you and
the tool's electrical system.
All exposed metal parts are isolated
from the internal metal motor compo-
nents with protective insulation.
Fig. A
1. 2-prong plug 2. Properly grounded ou11e1
WARNING: TO AVOID INJURY, WHEN SERVICING THE DETAIL
SANDER/POLISHER USE ONLY IDENTICAL REPLACEMENT PARTS.
WARNING: DOUBLE INSULATION DOES NOT TAKE THE PLACE OF
NORMAL SAFETY PRECAUTIONS WHEN OPERATING THIS TOOL.
WARNING: TO AVOID ELECTROCUTION:
1. Use only identical replacement parts when servicing a tool with double
insulation. Servicing should be performed by a qualified technician.
2. Do not use power tools in wet or damp areas or expose them to rain.
This tool is intended for indoor use only.
GROUNDING INSTRUCTIONS
IN THE EVENT OF A MALFUNCTION OR BREAKDOWN, grounding pro-
vides the path
of leastresistance for electric current and reduces the risk
of electric shock. This tool is equipped with an electric cord that has a
POLARIZED plug. The plug MUST be plugged into a matching outlet that
is properly installed and grounded in accordance with ALL local codes
and ordinances.
DO NOT MODIFY THE PLUG PROVIDED.
If it will not fit the outlet, have
the proper outlet installed
by a qualified electrician.
SAVETHESE SAFETY INSTRUCTIONS
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I IV.
Electrical information - continued
CAUTION: IN ALL CASES, MAKE CERTAIN THE RECEPTACLE IN
QUESTION IS PROPERLY GROUNDED. IFYOU
ARE NOT SURE IF IT
IS, HAVE A CERTIFIED ELECTRICIAN CHECKTHE RECEPTACLE.
WARNING: THIS DETAIL SANDER/POLISHER IS FOR INDOOR USE
ONLY. DO NOT EXPOSE TO RAIN OR USE IN DAMP LOCATIONS.
GUIDELINES FOR USING EXTENSION CORDS
USE THE PROPER EXTENSION CORD. Make sure your extension cord is
in good condition. When using an extension cord, be sure to use one heavy
enough to carry the current your product will draw. An undersized cord will
cause overheating. The table below shows the correct size to use depend-
ing on cord length and nameplate ampere rating.
If in doubt, use the next
heavier gauge. The smaller the gauge number, the heavier the cord.
Minimum Gauge for Extension Cords (AWG)
(when using 120 volts only)
Ampere Rating Total Length
of Cord in Feet metres)
MoreThan
Not MoreThan 25' (7.6
m)
50' (15m) 100'(30.4 m) 150'(45.7 m)
0 6
18
16 16 14
6 10 18
16 14 12
10
12
16 16
14 12
12 16 14
12 Not Recommended
Make sure your extension cord is properly wired and in good electrical
condition. Always replace a damaged extension cord
or have it repaired by
a qualified person before using it. Protect your extension cords from sharp
objects, excessive heat and damp
or wet areas.
Use a separate electrical circuit for your tools. This circuit should not be less
than a #12 wire and should be protected with a 15 A time delay fuse. Before
connecting the motor to the power line, make sure the switch is in the OFF
position and the electric current is rated the same
as the current stamped on
the motor nameplate. Running
at a lower voltage will damage the motor.
WARNING: ALTHOUGH THIS TOOL IS DOUBLE INSULATED, THE
EXTENSION CORD AND RECEPTACLE MUST STILL BE GROUNDED
WHILE
IN USE TO PROTECT THE OPERATOR FROM ELECTRICAL
SHOCK. SAVETHESE SAFETY INSTRUCTIONS
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V. Know your detail sander I polisher
4
1. Power cord
2. Motor
3. ON/OFF switch
4. Base
5. Backing pad
6. Handle
7. Universal vacauum adaptor
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VI. Assembly and adjustments
UNPACKING (Fig. 1)
Remove the detail sander/polisher (1) and universal vacuum adaptor (2)
from the box and examine carefully.
NOTE: Do not discard box
or any packaging material until all parts are
examined.
Fig.1
2
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VI. Assembly and adjustments - continued
ASSEMBLY INSTRUCTIONS
The detail sander/polisher is assembled and ready for use. However, you
need to select and attach the appropriate accessory pad, and attach a
vacuum hose,
if required.
WARNING: IF ANY PART OF THE DETAIL SANDER/POLISHER IS
MISSING
OR DAMAGED, DO NOT PLUG IT IN UNTILTHE DAMAGED
PART IS REPAIRED OR REPLACED.
WARNING: TO AVOID INJURY, ALWAYS TURN THE SWITCH OFF
AND DISCONNECT THE DETAIL SANDER/POLISHER FROM THE
POWER OUTLET BEFORE INSTALLING OR CHANGING THE SAND-
PAPER
OR ADAPTOR AND VACUUM.
Installing and removing the Fig. 2
sandpaper (Fig. 2)
Use sandpaper that has a
hook and loop fastening
system and has holes
matching the sandpaper
backing pad. Sandpaper must
be purchased separately.
To install:
1. Remove all sanding dust
or dirt from the backing
pad (1).
2. Align the holes on the
sandpaper (2) with the
holes in the backing pad,
making sure it is centered
and the edges are aligned
with the edges
of the
backing pad.
3. Press the sandpaper to
the pad.
To remove:
Peel the sandpaper offthe backing pad.
Note: The holes in the sandpaper must line up with the backing pad holes
for the through-the-pad dust extraction system to function properly.
L----------------------10~---------------------

VI. Assembly and adjustments - continued
Installing Adaptor (Fig. 3)
1. The universal vacuum adaptor (1) is tapered; one end is smaller than
the other. Slide the small end
of the adaptor onto the vacuum port (2)
at the rear of the detail sander/polisher.
2. For best and safest results, attach a vacuum hose to the universal
vacuum adaptor.
3. Turn the vacuum ON before starting the detail sander/polisher.
Fig.3
1
b
VII. Operation
OPERATING INSTRUCTIONS
Switch (Fig. 4) Fig. 4 G
Your detail sander/polisher is
equipped with a rocker ON/OFF
switch (1), located on the front
of
the handle area.
1. To turn the detail sander/
polisher ON, push the top (I)
of the rocker switch.
2. To turn the detail sander/
polisher
OFF, push the bottom
(0) of the rocker switch. ___/
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2J
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1
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VII. Operation - continued
WARNING: FINISH SANDING CAN PRODUCE CLOUDS OF FINE
SANDING DUST THAT COULD IGNITE
IN THE PRESENCE OF
SPARKS
OR AN OPEN FLAME. TO AVOID INJURY, ALWAYS USE
YOUR DETAIL SANDER/POLISHER IN A WELL-VENTILATED AREA.
General Sanding (Fig. 5)
r----------------------------.
Fig. 5
WARNING: DO NOT USETORN OR SEVERELY WORN SANDPAPER.
YOU MAY DAMAGE YOUR WORK SURFACE OR SUFFER PHYSICAL
INJURY.
1. Make sure the workpiece is free of nails and other foreign objects that
could tear the sandpaper. Move the detail sander/polisher evenly over
the entire work surface. The weight
of the detail sander/polisher alone
is sufficient for normal use. Any excess pressure will alter the sanding
action, provide an uneven finish, and cause wear to both the detail
sander/polisher and sandpaper. Do not allow the detail sander/polisher
to remain
in one place on the work surface for too long or excessive
material will be removed.
2. Start the detail sander/polisher before applying it to the workpiece.
3. The detail sander/polisher should never be turned off while resting on
the workpiece. Lift the detail sander/polisher from the workpiece and
then turn
it off.
4. Do not use the detail sander/polisher without sandpaper, or the pad will
be damaged.
5.
For optimum performance, make sure your hand does not cover the
air vents on the detail sander/polisher, and make sure oil and water do
not come in contact with the motor.
6. Do not make any adjustments to the detail sander/polisher while it is
turned on.
WARNING: TO AVOID INJURY, ALWAYS UNPLUG THE DETAIL
SANDER/POLISHER BEFORE ATTACHING
OR REMOVING SANDING
DISCS
OR THE DUST BAG.
L---------------------~12~----------------------~
I
i

VII. Operation - continued
Sandpaper selection (purchase separately)
Sandpaper can be made from various grit materials. The grit material
and coarseness
of the sandpaper should be selected according to the
workpiece material.
Workpiece material Grit material
Fine woodwork Garnet
or aluminum ox1 e
Rough woodwork Aluminum zirconia or
ceram1c
Manufactured wood products Silicon carbide or aluminum oxide
Solid surfacing materials Silicon carbide or aluminum oxide
Metals Emery
or aluminum oxide
The sandpaper is also graded by coarseness. Start your work with an
abrasive gritjust coarse enough to remove the high spots and excessive
roughness. Follow with a second sanding using a grit one
or two grades
finer. Continue with successively finer grits until you obtain the desired
finish.
Do not switch from a coarse grit to a very fine grit in one step. It may be
difficult to remove the marks made by the coarse grit abrasive. Use the
finest grits practical for the roughing operation, and finish by using suc-
cessively finer grits.
Coarse Grit 60 -80
Initial sanding on rougher surfaces.
For fast stock removal.
Rough sanding and stripping
of painted and rusted surfaces.
Medium Grit
100- 140
Intermediate sanding.
Removal
of minor surface imperfections.
Fine Grit 150 -220
Fine sanding.
Sanding prior to staining, priming,
or sealing.
L-------------------------~13r---------------------~

VIII. Maintenance
WARNING: ALWAYS TURN OFF THE DETAIL SANDER/POLISHER
AND UNPLUG THE TOOL FROM THE OUTLET BEFORE MAINTAIN-
ING THE DETAIL SANDER/POLISHER.
GENERAL MAINTENANCE
Keep your detail sander/polisher clean and in good repair for maximum
performance and machine longevity. Before each use inspect the detail
sander/polisher, switch, and cord for damage. Check for damaged, miss-
ing,
or worn parts. Check for loose screws, misalignment, moving parts
that are jammed,
or any other conditions that may affect the operation. If
abnormal vibration or noise occurs, turn the tool off immediately and have
the problem corrected before further use. Do not use the detail
sander/polisher until properly repaired or replaced.
Cleaning
Clean dust and debris from the detail sander/polisher vents. Frequently
blow dust out
of the motor area, using an air compressor or dust vacuum.
Keep the tool clean, dry and free
of oil and grease. Use only mild soap
and a damp cloth to clean your tool. Certain cleaning agents and solvents
are harmful to plastic and other insulated parts. Do not use gasoline,
turpentine, lacquer thinner, paint thinner, chlorinated cleaning solvents,
ammonia, or household cleaning detergents containing ammonia.
WARNING: TO AVOID FIRE OR TOXIC REACTION, DO NOT USE
GASOLINE, NAPHTHA, ACETONE, LACQUER THINNER,
OR SIMILAR
HIGHLY VOLATILE SOLVENTS TO CLEAN THE DETAIL
SANDER/POLISHER.
Lubrication
The detail sander/polisher has been lubricated at the factory. Under nor-
mal use it will not need further lubrication until the motor brushes need
replacing.
Replacing carbon brushes
Replace the carbon brushes when they wear down to approximately
1/8" (3 mm), or sparking will occur.
Note: Both brushes should be replaced at the same time.
WARNING: TO AVOID INJURY, ELECTRIC SHOCK, OR DAMAGE
TO THE TOOL, NEVER IMMERSEYOUR DETAIL SANDER/POLISHER
IN A LIQUID OR ALLOW A LIQUID TO FLOW INSIDE THE TOOL.
L---------------------~14r---------------------~

IX. Troubleshooting
WARNING: FOR YOUR SAFETY THIS DETAIL SANDER/POLISHER
IS DOUBLE INSULATED. TO AVOID ELECTRICAL SHOCK, FIRE, OR
INJURY, USE ONLY PARTS IDENTICAL TO THOSE IN THE PARTS
LIST. REASSEMBLE EXACTLY AS THE ORIGINAL ASSEMBLY TO
AVOID ELECTRICAL SHOCK.
WARNING: TO AVOID MISTAKES THAT COULD CAUSE SERIOUS
INJURY, DO NOT PLUG IN THE DETAIL SANDER/POLISHER UNTIL
THE FOLLOWING STEPS HAVE BEEN READ AND UNDERSTOOD.
PROBLEM
Detail sander/
polisher will
not start.
Detail sander/
polisher has
excessive
vibration.
PROBABLE CAUSE
1. The detail sander/
polisher is not
plugged in.
2. The circuit breaker
is open or the
fuse is blown.
3. Worn brushes.
4. Unknown.
1. The sandpaper is
installed incorrectly.
2. The sanding pad
is worn.
3. Unknown.
REMEDY
• Make sure the detail
sander/polisher
is plugged into the
power outlet.
• Check the fuse box
and replace the fuse
or reset the breaker.
• Open the brush caps
and replace the
brushes
if worn
down to 1/8"
(3 mm).
• Do not operate.
Take
the detail sander/
polisher
to an
authorized service
technician.
• Make sure the
sandpaper is centered
on the pad and
adheres tightly.
• Check the pad for
wear and replace
if necessary.
•
Do not operate. Take
the detail sander/
polisher to an
authorized service
technician.
L-----------------------~15~--------------------~

X. Warranty
This power tool is guaranteed for a period ofthree {3) years against
defects
in workmanship and materials. Should this power tool become
defective within the stated warranty period, return it to the store with
proof of purchase, and it will be replaced or repaired free of charge.
This tool is not intended for commercial use.
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