MasterCraft MAXIMUM 054-7135-0 User manual

TM
IMPORTANT:
Please read this manual carefully before using
this product, and save it for reference.
INSTRUCTION
MANUAL
Heavy-duty Sander/Polisher
Model No. 054-7135-0

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TABLE OF CONTENTS
TECHNICAL SPECIFICATIONS 4
GENERAL POWER TOOL SAFETY WARNINGS 5
SAFETY INSTRUCTIONS FOR ALL OPERATIONS 8
SYMBOLS 11
PARTS LIST 12
ACCESSORIES 13
KNOW YOUR SANDER / POLISHER 14
OPERATING INSTRUCTIONS 15
WORKING HINTS FOR YOUR POLISHER 18
MAINTENANCE 19
TROUBLESHOOTING 20
WARRANTY 21
TABLE OF CONTENTS
NOTE: If any parts are missing or damaged, or if you have any
questions, please call our toll-free helpline at 1-800-689-9928
SAVE THESE INSTRUCTIONS
This manual contains important safety and
operating instructions. Read all instructions and
follow them with use of this product.

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TECHNICAL SPECIFICATIONS
VOLTAGE 120 V 60 Hz AC
AMPS 10A
VARIABLE SPEEDS 1000–3000 RPM (no load)
PAD SIZE 7” (17.8 cm)
PAD TYPE Hook and loop fastening system
SPINDLE THREAD 5/8”-11 UNC
CORD LENGTH 10’ (3 m)
WEIGHT 7 lb 3 oz (3.2 kg)
TECHNICAL SPECIFICATIONS

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GENERAL POWER TOOL SAFETY WARNINGS
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.
WARNING!
Some dust created by power sanding, sawing, grinding,
drilling and other construction activities contains chemicals
known to the state of California to cause cancer, birth
defects or other reproductive harm. Some examples of
these chemicals are:
• Lead from lead-based paints,
• Crystalline silica from bricks and cement and other
masonry products,
• Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how
often you do this type of work. To reduce your exposure
to these chemicals, work in a well ventilated area, and
work with approved safety equipment, such as those dust
masks that are specially designed to filter out microscopic
particles.
WARNING!
Read all safety warnings and instructions. Failure to follow
the warnings and instructions may result in electric shock,
fire and/or serious injury.
Save all warnings and instructions for future reference.
• The term power tool in the warnings refers to your
electric (corded) power tool or battery-operated
(cordless) power tool.
WARNING!
This product may contain lead, phthalates or other
chemicals known to the state of California to cause cancer,
birth defects and other reproductive harm. Please wash
your hands after use.
FPO
FPO
FPO

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ELECTRICAL SAFETY
• Power tool plugs must match the outlet. Never modify the plug in any way. Do not
use any adapter plugs with grounded power tools. Unmodified plugs and matching
outlets will reduce risk of electric shock.
• Avoid body contact with grounded surfaces such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is 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 an RCD 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.
• Remove any adjusting key or wrench before turning the power tool on. A wrench or
a key left attached to a rotating part of the power tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This enables better
control of the power tool in unexpected situations.
• Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing
and gloves away from moving parts. Loose clothes, jewellery or long hair can be
caught in moving parts.
• If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of a dust collection
device 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.
GENERAL POWER TOOL SAFETY WARNINGS

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• 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 and in the manner intended for the particular type of power tool,
taking into account the working conditions and the work to be performed. Use of
the power tool for operations other than 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.
GENERAL POWER TOOL SAFETY WARNINGS

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SAFETY INSTRUCTIONS FOR ALL OPERATIONS
Safety warnings common for polishing operations:
• This power tool is intended to function as a sander/polisher. 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.
• Do not use accessories which are not specifically designed and recommended by
the tool manufacturer. The fact that an accessory item may fit the power tool is not
an assurance of 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 diameter and the thickness of your accessory must be within the
capacity rating of your power tool. Incorrectly sized accessories cannot be
adequately guarded or controlled.
• Threaded mounting of accessories must match the sander/polisher spindle thread.
For accessories mounted by FLANGES, the arbour hole of the accessory must fit
the locating diameter of the FLANGE. Accessories that do not match the mounting
hardware of the power tool will run out of balance, vibrate excessively and may
cause loss of control.
• Do not use a damaged accessory. Before each use inspect the accessory such
as abrasive wheels for chips and cracks, backing pad for cracks, tears or excess
wear, wire brush for loose or cracked wires. If power tool or accessory is dropped,
inspect 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 application, use face shield,
safety goggles or safety glasses. As appropriate, wear dust mask, hearing
protectors, gloves and workshop apron capable of stopping small abrasive or
workpiece fragments. The eye protection must be capable of stopping flying debris
generated by various operations. The dust mask or respirator must be capable of
filtering out particles generated by your operation. Prolonged exposure to high
intensity noise may cause hearing loss.
• Keep bystanders a safe distance away from work area. Anyone entering the work
area must wear personal protective equipment. Fragments of workpiece or of
a broken accessory may fly away and cause injury beyond immediate area of
operation.
• Position the cord clear of the spinning accessory. If you lose control, the cord may
be cut or snagged and your hand or arm may be pulled into the spinning accessory.
• Never lay the power tool down until the accessory has come to a complete stop.
The spinning accessory may grab the surface and pull the power tool out of your
control.
SAFETY INSTRUCTIONS FOR ALL OPERATIONS

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SAFETY INSTRUCTIONS FOR ALL OPERATIONS
• Do not run the power tool while carrying it at your side. Accidental contact with the
spinning accessory could snag your clothing, pulling the accessory into your body.
• Regularly clean the power tool’s air vents. The motor’s fan will draw the 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.
FURTHER SAFETY INSTRUCTIONS FOR ALL OPERATIONS
Kickback and related warnings:
Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad,
brush or any other accessory. Pinching or snagging causes rapid stalling of the rotating
accessory which in turn causes the uncontrolled power tool to be forced in the direction
opposite of the accessory’s rotation at the point of the binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of
the wheel that is entering into the pinch point can dig into the surface of the material
causing the wheel to climb out or kick out. The wheel may jump toward or away from
the operator, depending on direction of the wheel’s movement at the point of pinching.
Abrasive wheels may also break under these conditions.
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 arm to allow you
to resist kickback forces. Always use 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. Accessory may kickback over
your hand.
• Do not position your body in the area where power tool will move if kickback
occurs. Kickback will propel the tool in 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 and bouncing have a tendency to
snag the rotating accessory and cause loss of control or kickback.
• Do not attach a saw chain, woodcarving blade or toothed saw blade. Such blades
create frequently kickback and cause loss of control.
ADDITIONAL SAFETY INSTRUCTIONS FOR POLISHING OPERATIONS
Safety warnings specific for polishing operations:

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• Do not allow any loose portion of the polishing bonnet or its attachment strings
to spin freely. Tuck away or trim any loose attachment strings. Loose and spinning
attachment strings can entangle your fingers or snag on the workpiece.
SAFETY INSTRUCTIONS FOR ALL OPERATIONS

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SYMBOLS
SYMBOLS
To reduce the risk of injury, user must read
instruction manual
Double insulation
Warning
Wear ear protection
Wear eye protection
Wear dust mask
Don’t use in the rain

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PARTS LIST
No. Description
1 Spindle lock button
2 Front handle
3
Variable speed control
4 Rear handle
No. Description
5 On/off switch
6 Lock-on switch
7 Hook-and-loop pad
1 2 3 4
Not all the accessories illustrated or described are included in
standard delivery.
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ACCESSORIES
80 Grit sanding disc with hook-and-loop backing 3
Wool bonnet 1
Hook-and-loop pad 1
ACCESSORIES
We recommend that you purchase your accessories from the same
store that sold you the tool. Use good quality accessories marked
with a well-known brand name. Choose the type according to the
work you intend to undertake. Refer to the accessory packaging for
further details. Store personnel can assist you and offer advice.

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KNOW YOUR SANDER / POLISHER
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14 15
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48
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No. Description
1 Cord & plug
2 Cord protector
3 Self-tapping screw
4 Cord clamp
5 Capacitor
6 Constant speed unit
7 On/off switch
8 Carbon brush (pair)
9 Brand label
10 Brush
12 Self-tapping screw
13 Brush cover
14 Left/right handle
15 Self-tapping screw
17 Rated label
18 Housing
19 Stator
20 Baffle
21 Bearing sleeve
22 Self-tapping screw
23 Bearing race
24 Dustproof ring
25 Rotor
26 Bearing press plate
No. Description
27 Felt seal
28 Bearing race
29 Ring
30 Washer
31 Gear case
32 Side handle
33 Screw
34 Lock button
35 Compression spring
36 Snap ring
37 Self tapping screw
38 Needle bearing race
39 O-ring
40 Gear
41 Ring
42 Steel sleeve
43 Bearing race
44 Dustproof cover
45 Output shaft
46 Bearing holder
47 Washer
48 Self-tapping screw
49 Base plate

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PLACE THE BONNET (Fig. A)
Place the required bonnet securely over the hook-and-loop
pad and make sure it’s centrosymmetric, otherwise the
polisher vibrates badly.
SPREAD THE POLISH (Fig. B)
Spread about a tablespoonful of polish evenly over the entire
surface of the pad cover. Do not apply polish directly to car.
This first application should do about 1/3 of an average size
car. For the second and third applications of polish, repeat
as above. The pad cover will not adsorb as much when
reloading.
FITTING THE SANDING PAPER (Fig. C)
Sanding paper is easily attached on the pad of your polisher.
Fit the paper over the plate so that it covers the entire area,
push and slightly twist to make sure the coated sanding
paper is even on the plate. Make sure the sanding paper
is even with the edges and that it’s centrosymmetric,
otherwise the polisher vibrates badly. Remove the abrasive
paper by pinching an edge and peeling off.
LOCK-ON SWITCH (Fig. D)
Depress on/off switch (5) then lock-on button (6). Your
switch is now locked on for continuous use. To switch off
your tool just release the on/off switch.
OPERATING INSTRUCTIONS
NOTE: Before using the tool, read the instruction book
carefully.
ab
1
Fig. A
Fig. B
Fig. D
Fig. E
Fig. F
Fig. I
Fig. J
Fig. G1
Fig. K
Fig. G2
Fig. H
ab
1
Fig. A
Fig. B
Fig. D
Fig. E
Fig. F
Fig. I
Fig. J
Fig. G1
Fig. K
Fig. G2
Fig. H
Fig. C

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OPERATING INSTRUCTIONS
VARIABLE SPEED CONTROL (Fig.E)
The speed increases as you turn the switch to a higher
number and decreases at a lower number.
HAND GRIP AREAS (Fig. F)
Always hold your car polisher firmly with both hands when
operating.
INSTALLING THE FRONT HANDLE (Fig. G1, G2)
For your personal safety, use the front handle at all times.
Tighten the screw with the hex key clockwise.
WARNING!
• Make sure the protrusion (b) on the handle is locked in the
groove (a) of the machine to secure the handle.
FPO
ab
1
Fig. A
Fig. B
Fig. D
Fig. E
Fig. F
Fig. I
Fig. J
Fig. G1
Fig. K
Fig. G2
Fig. H
ab
1
Fig. A
Fig. B
Fig. D
Fig. E
Fig. F
Fig. I
Fig. J
Fig. G1
Fig. K
Fig. G2
Fig. H
ab
1
Fig. A
Fig. B
Fig. D
Fig. E
Fig. F
Fig. I
Fig. J
Fig. G1
Fig. K
Fig. G2
Fig. H

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OPERATING INSTRUCTIONS
SPINDLE LOCK BUTTON (Fig. H)
Press in the spindle lock button and rotate the hook-and-look
pad by hand until it is locked.
ATTENTION: The spindle lock button must only be
used when changing a pad. Never press it when the
pad is rotating.
Remove the plug from the socket before carrying out
the adjustment.
TO REPLACE THE BRUSHES (Fig. I)
Remove the brush holder with the use of a screwdriver.
Check the length of the brush and replace if under 7 mm.
When brushes need replacement always renew both
brushes, even if one is still more than 7 mm long. Put the
brush holder into the body. Tighten the brush holder.
Check that the tool is working before use and allow it to run
for a few minutes to enable the brushes to stabilize.
TO USE THE CAR POLISHER (Fig. J)
Hold extension cord over the shoulder and do flat surfaces
first, i.e., hood, trunk lid and roof. Cover areas quickly with
broad sweeping strokes in a crisscross pattern. Do not press
down on polisher. The machine without any pressure will
automatically do the best job.
FINAL WORK (Fig. K)
Use long, sweeping strokes in a criss-cross pattern to bring
out the shine. Do not over-press the polisher.
ab
1
Fig. A
Fig. B
Fig. D
Fig. E
Fig. F
Fig. I
Fig. J
Fig. G1
Fig. K
Fig. G2
Fig. H

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WORKING HINTS FOR YOUR POLISHER
• At all times, let the polisher do the work—do not not force it or apply excessive
pressure to the polisher. Preferably, use a light circular motion. Pressing too hard
will slow down the machine’s movement and affect the quality of the work.
• The most common error is applying applying too much wax. If pad adsorbs too
much wax, it will not last as long, and polishing will be more difficult and will take
longer.
• If bonnet continually comes off pad, please try with a new bonnet.
• If wax seems difficult to buff, you may have used too much wax.
WORKING HINTS FOR YOUR POLISHER

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MAINTENANCE
MAINTENANCE
Remove the plug from the socket before carrying out any adjustment, servicing or
maintenance.
Your power tool requires no additional lubrication or maintenance. There are no user
serviceable parts in your power tool. Never use water or chemical cleaners to clean
your power tool. Wipe clean with a dry cloth. Always store your power tool in a dry
place. Keep the motor ventilation slots clean. Keep all working controls free of dust.
Occasionally you may see sparks through the ventilation slots. This is normal.
If the supply cord is damaged, it must be replaced by the manufacturer, its service
agent or similarly qualified persons in order to avoid a hazard.

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TROUBLESHOOTING
TROUBLESHOOTING
• If your power tool does not start, check the plug on the power supply first.
• If the polisher does not abrade surface, check the bonnet. If the bonnet has been
worn, replace with new bonnet and try again.
• If a fault can not be rectified, return the tool to an authorized dealer for repair.