MasterCraft 054-1240-4 Instruction Manual

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INSTRUCTION MANUAL

RANDOM ORBIT SANDER

054-1240-4

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If any parts are missing or damaged, or if you have any questions, please call our toll-free helpline at 1-800-689-9928.

Read and understand this instruction manual thoroughly before using the product. It contains important information for your safety as well as operating and maintenance advice.

Keep this instruction manual for future use. Should this product be passed on to a third party, then this instruction manual must be included.

RANDOM ORBIT SANDER 054-1240-4

TECHNICAL SPECIFICATIONS 4

SAFETY GUIDELINES 5–11

KEY PARTS DIAGRAM 12

OPERATING INSTRUCTIONS 13–17

MAINTENANCE 18

EXPLODED VIEW 19

PARTS LIST 20

WARRANTY 21–22

RANDOM ORBIT SANDER 054-1240-4

TABLE OF CONTENTS

This symbol designates that this tool is listed with Canadian requirements by ETL Testing Laboratories, Inc. Conforms to UL Std. 60745-1, 60745-2-4. Certied to CAN/CSA Std. C22.2 No. 60745-1, 60745-2-4.

3042597 JD2522U

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Rating 120 V, 60 Hz, AC

Amperes 2.0 AMP

No load speed 12,000 OPM

Disc diameter 5" (

12.7 mm

)

Weight 3 lb 6 oz

(1.53 kg)

TECHNICAL SPECIFICATIONS

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.

This instruction manual includes the following:

• General Safety Rules • Operation

• Specic Safety Rules and Symbols • Maintenance

• Functional Description • Accessories

• Assembly

EYE, EAR & LUNG PROTECTION

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.

WARNING: Use hearing protection, particularly during extended periods of

operation of the tool, or if the operation is noisy.

WEAR A DUST MASK THAT IS DESIGNED TO BE USED WHEN OPERATING A POWER TOOL IN A DUSTY ENVIRONMENT.

SAVE THESE INSTRUCTIONS FOR REFERENCE

SAFETY GUIDELINES

RANDOM ORBIT SANDER 054-1240-4

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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 specically designed to lter out microscopic particles.

Electrical safety

WARNING: To avoid electrical hazards, re hazards or damage to the tool, use

proper circuit protection.

This tool is wired at the factory for 120 V AC operation. It must be connected to a 120 V AC, 15 A circuit that is protected by a time-delayed fuse or circuit breaker. To avoid shock or re, replace power cord immediately if it is worn, cut or damaged in any way.

Power tool safety

WARNING: Read all safety warnings and all instructions. Failure to follow the

warnings and instructions may result in electric shock, re 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 ammable

liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.

SAVE THESE INSTRUCTIONS FOR REFERENCE

SAFETY GUIDELINES

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. Unmodied 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 ground fault circuit interrupter (GFCI) 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 inuence 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 nger on

the switch or energizing power tools that have the switch on invites accidents.

SAVE THESE INSTRUCTIONS FOR REFERENCE

SAFETY GUIDELINES

RANDOM ORBIT SANDER 054-1240-4

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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 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 qualied repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

SAVE THESE INSTRUCTIONS FOR REFERENCE

SAFETY GUIDELINES

Specic safety rules

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 specic potential hazards related to this tool. Following this rule will reduce the risk of electric shock, re, 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

sanding disc or bufng pad and when cleaning the tool.

Do not wear gloves, neckties or loose clothing.

Secure the workpiece. Use clamps or a vice 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.

SAVE THESE INSTRUCTIONS FOR REFERENCE

SAFETY GUIDELINES

RANDOM ORBIT SANDER 054-1240-4

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SAFETY GUIDELINES

Extension cord safety

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 below 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 qualied 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 A 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 (120 V use only)

Amperage rating Total length

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

SAFETY GUIDELINES

RANDOM ORBIT SANDER 054-1240-4

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

efcient and safer operation of this tool.

... 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

0 ………….. Off position

……. Directional arrow

……... Warning symbol

……. Wear your safety glasses

……... Wear hearing protection

Symbols

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 OPM ….. Oscillations per minute Min ……. Minutes S ………... Seconds

or AC …... Alternating current

.. Three-phase alternating

current

.. Three-phase alternating current with neutral

...... Read all safety warnings

and instructions

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No. Description No. Description

1 Palm grip 6 ON/OFF switch

2 Dust bag assembly 7 60 grit sanding disc

3 Motor vents 8 80 grit sanding disc

4 8 hole hook & loop sanding base 9 120 grit sanding disc

5 Hook & loop fastening system

RANDOM ORBIT SANDER 054-1240-4

NOTE: The drawings in the assembly and operating section of this manual may differ slightly from the tool you purchased.

Installing a sanding disc

To install a sanding disc, rmly press the sanding disc (1) onto the hook & loop pad (2) (Fig. 1).

NOTES:

a) Place the sanding disc so the holes in the disc line up with the matching holes in the hook & loop pad. b) Press the sanding disc rmly onto the hook & loop pad.

To remove the sanding disc (1), simply peel the disc away from the hook & loop pad (2) (Fig. 2).

On/off switch

To turn the switch ON, press the left hand side of the switch (1) (Fig. 3). To turn the switch OFF, press the right hand side of the switch (2).

Connecting the dust bag assembly to the sander

1. Slide the dust bag connector (1) into the

dust port (2) in the rear of the sander

(Fig. 4).

NOTE: Make sure the dust bag connector

key (3) mates with the dust port key way (4).

2. When the dust bag connector is pressed

fully into the dust port, turn the dust bag

approximately 15° clockwise to lock the

dust bag onto the sander.

g. 1

g. 2

g. 3

g. 4

KEY PARTS DIAGRAM

OPERATING INSTRUCTIONS

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OPERATING INSTRUCTIONS

RANDOM ORBIT SANDER 054-1240-4

Cleaning the dust bag

Remove the dust bag assembly (1) from the dust port by rotating it COUNTER CLOCKWISE approximately 15° and pulling it out of the dust port (Fig. 5). Carefully shake the dust bag assembly with the end cap opening (2) pointing downward to remove the sanding dust. Reinstall the dust bag assembly as noted in Fig 4.

OPERATING INSTRUCTIONS

g. 5

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. Sander cord is not damaged.

2. Sanding disc is in good condition and properly installed on the sander.

3. The workpiece is properly secured and free from any foreign objects.

4. Safety glasses, safety goggles, or face shield is being worn.

5. Hearing protection and dust mask are being worn.

Failure to adhere to these safety rules can greatly increase the chances of serious injury.

WARNING

Sanding disc selection

Make sure you select the correct size and style of sanding disc for your sander. The correct disc will:

• Have a diameter of 5”

• Have a row of eight 3/8” holes that match

the hole pattern in the sander base

• Have a backing for use with the hook & loop disc attachment system.

Selecting the correct grit and type of sandpaper is extremely important in achieving a high quality sanded nish. Aluminum oxide, silicon carbide and other synthetic abrasives are best for power sanding. Natural abrasives such as int and

garnet are too soft for economical use in power sanding.

In general, coarse grit will remove most material. Fine grit will produce the best nish in all sanding operations. The condition of the surface to be sanded will determine which grit will do the best job.

NOTE: Where the sanding disc grits are shown numerically, higher numbers indicate ner grit and lower numbers indicate coarser grit.

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 nishing the surface. Always continue sanding with each grit until the surface is uniform.

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Sanding

Clamp or otherwise secure your workpiece to prevent it from moving under the sander while being sanded. Secure the workpiece in a vice if possible.

WARNING: Any unsecured

workpiece could be thrown toward the operator causing injury.

Place the sander on the workpiece so the complete sanding disc surface is in contact with the workpiece. Turn the sander ON by pressing on the left 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 random orbital motion of the sanding disc moves in tiny circles, it is not necessary to move the sander with the grain or in the same direction for successive passes (Fig. 6).

Upon completion of the sanding operation, turn sander OFF by pressing on the right hand side of the ON/OFF switch. Wait until the sanding disc comes to a complete stop before removing it from the workpiece.

WARNING: Your sander should

only be turned ON when the entire surface of the sanding disc is in contact with the workpiece. Failure to follow this sanding procedure could result in a loose sanding disc, which could result in possible injury. NOTE: Hold the sander with one hand on the hand grip (1) on top of the sander (Fig. 7). Be careful NOT to cover the cooling vents (2) with your hand. Covering the cooling vents could cause the motor to be damaged by overheating.

Clean the dust box often

Clean the dust bag often. It will be more efcient when it is not clogged with sanding dust. To clean the dust bag, see Fig. 5 on Page 14.

DO NOT FORCE THE SANDER. The weight of the sander usually provides adequate pressure. Let the sander and the sanding disc 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 nish on sanded work. Any nish 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 disc comes to a complete stop and remove it from the workpiece. Check to make sure your hands have not been covering the cooling vents. Let the motor cool before continuing the sanding operation.

OPERATING INSTRUCTIONS

RANDOM ORBIT SANDER 054-1240-4

g. 6

g. 7

Page 10

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 uids, 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 modication 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 berglass 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 berglass 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.

RANDOM ORBIT SANDER 054-1240-4

MAINTENANCE

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 sufcient amount of high-grade lubricant for the life of the unit under normal conditions. Therefore, no further lubrication is required.

EXPLODED VIEW

Page 11

WARNING: When servicing, use only Mastercraft

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 qualied technician. For more information, call the Toll-free Helpline, at 1-800-689-9928.

Always order by PART NUMBER, not by key number.

RANDOM ORBIT SANDER 054-1240-4

PARTS LIST

Key # Part # Part Name Qty

17 1010060020 Rotor 1

18 4010010054 Bearing 6000 2RS 1

19 3180040048 Vacuum adaptor 1

20 3150010087 Fan 1

21 2030030196 Counterbalance 1

22 6150030048 Dust Bag 1

23 2010130030 Eccentric seat 1

24 2030170007 Dustproof washer 1

25 2020130001 Bearing block 1

26 4010010084 Bearing 6000RS 1

27 2030020033 Washer 1

28 4020080004 Hexagon screw M5*16 1

29 2030160007 Large washer 1

30 1150020007 Rubber backing pad 1

31 4040030011 Spring washer 5 5

32 4020010081 Special screw M5*14 4

Key # Part # Part Name Qty

1 3011060024 Housing assembly 1

2 3150060005 Brush holder support 2

3 2030070001 Brush holder 2

4 1230010120 Carbon brush 2

5 3140080036 Switch cover 1

6 1061250001 Switch 1

7 1020060021 Stator 1

8 3140060001 Rubber buffer 2

9 4030010106 Tapping screw ST3.9*19 5

10 1250010002 Tapping screw 1

11 4030010099 Tapping screw ST3.9*14 2

12 3150020001 Cord clamp 1

13 3140010054 Cord guard 1

14 1190030006 Cord 1

15 4010010053 Bearing 607 2RS 1

16 3140020023 "O" ring 1

This Mastercraft® product is guaranteed for a period of three years from the date of original retail purchase against defects in workmanship and materials, except for the following components:

a. Component A: Batteries, chargers and carrying case, which are guaranteed for a period of two

years from the date of original retail purchase against defects in workmanship and materials;

b. Component B: Accessories, which are guaranteed for a period of one year from the date of original

retail purchase against defects in workmanship and materials.

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 specication), at our option. We will bear the cost of any repair or replacement and any costs of labour relating thereto.

These warranties are subject to the following conditions and limitations:

a. A bill of sale verifying the purchase and the purchase date must be provided; b. This warranty will not apply to any product or part thereof that is worn, 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 period 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, uids, 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 specied otherwise in writing);

YEAR ANS

LIMITED WARRANTY

†

DE GARANTIE LIMITÉE

†

WARRANTY

Page 12

RANDOM ORBIT SANDER 054-1240-4

g. This warranty will not apply to any product or part thereof if any part from another manufacturer is installed therein or any repairs or alterations have been made or attempted by unauthorized persons; h. This warranty will not apply to normal deterioration of the exterior nish, including, but not limited to, scratches, dents, paint chips, or to any corrosion or discolouring by heat, abrasive and chemical cleaners; and i. This warranty will not apply to component parts sold by and identied as the product of another company, which shall be covered under that product manufacturer’s warranty, if any.

Additional Limitations

This warranty applies only to the original purchaser, and cannot be transferred. Neither the retailer nor the manufacturer shall be liable for any other expense, loss or damage, including, without limitation, 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 specic 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.

Mastercraft is a superior line of products selected for their workmanship and materials. These products are designed to meet rigorous quality and performance standards, and are approved by our Quality Assurance laboratory.

TOLL-FREE HELPLINE: 1-800-689-9928

WARRANTY

Rev 1.12 14/08/2013