MasterCraft 54-4790-6 Owner's Manual

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Multi-attachment Rotary Tool System
54-4790-6
Imported by Trileaf Distribution Trifeuil Toronto, Canada M4S 2B8
SPECIFICATIONS
Motor:
Permanent magnet, 120 V AC, 60 Hz, 2 A
Variable speeds:
5,000 to 35,000 RPM (no load)
Collets:
1/8, 3/32, 1/16" (3, 2.5, 1.5 mm)
Weight:
1 lb 12 oz (780 g)
TOLL FREE HELPLINE 1-800-689-9928
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Specifications ………….…………………………………………………………………..
1
Table of contents …………………………………………………………………….……
2
Safety warnings …………………………………………………………………………...
3–4
Eye, ear, and 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
Extension cord safety ……………………………………………………………….……
8
Symbols ……………………………………………………………………………………
9
Diagram and location of parts …………………………………………………………...
10–11
Accessories and Contents …………………………………………………………….. ..
12
Accessories ……………………………………………………………………………….
12
Contents ……………………………………………………………………………………
12–13
Contents of the accessory kit ……………………………………………………………
14–16
Description and use of the accessory kit……………………………………………….
16–17
Assembly and Operating instructions …………………………………………………..
18–35
Changing the collet ……………………………………………………….….…………...
18
Installing accessories …………………………………………………………. ………...
18–19
Connecting the flexible shaft to the tool …………………………………….. ………...
19–20
Changing the collet and accessories in the flexible shaft ……………….…... ………
20
Assembling the rotary tool stand ………………………………………………. ………
21
Installing the right angle attachment ………………………………………… ………...
22–23
Installing the angle guide and the vacuum adapter ………………………………. ….
23–24
Installing the sander attachment …………………………………………….. …………
24–25
Installing sandpaper …………………………………………………………... ………...
26
Installing the pad onto the sander ………………………………………………………
26–27
Sanding wood ……………………………………………………………………………..
27
Sanding tips ……………………………………………………………………………….
27–28
Installing the mini circular saw attachment …………………………………………….
28–29
Installing a saw blade …………………………………………………….….…………...
30
Cutting wood ………………………………………………………………….…………...
31–32
Assembling the LED worklight …………………………………………………………..
32
Selecting the proper speed…………………………….…………………………………
33
Digital motor control ………………………………………………………….…………...
34
ON/OFF switch ……………………………………………………………….…………...
34
Adjusting the speed ………………………………………………………………………
34–35
Speed memory ……………………………………………….…………………………...
35
Maintenance ……………………………………………………………………………….
36
Exploded view ……………………………………………………………………………..
37
Parts list ……………………………………………………………………………………
38
Warranty ……………………………………………………………………….…………..
39
TABLE OF CONTENTS
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EYE, EAR, AND LUNG PROTECTION
This Owner's Manual contains the following information:
General Safety Rules Specific Safety Rules and Symbols Functional Description Assembly Instructions Operating Instructions Maintenance Accessories
!
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
it breaks while the wearer is operating a power tool.
KEEP THIS OWNER'S MANUAL IN A SAFE PLACE FOR FUTURE REFERENCE
WARNING: Use hearing protection, especially when operating the tool for an extended period and when performing a noisy operation.
!
SAFETY WARNINGS
CAUTION: Read this Owner's Manual carefully before using this tool or any of its accessories, and follow all Safety Rules and Operating instructions.
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ELECTRICAL SAFETY
WARNING: Use proper circuit protection in order to avoid electrical
hazards, fire hazards, or damage to the rotary tool.
This rotary tool is wired at the factory for 110–120 V operation. It must be connected to a 110–120 V 15 A time-delayed fuse or circuit breaker. In order to avoid shock or fire, replace the power cord immediately if it is worn, cut, or damaged in any way.
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.
!
SAFETY WARNINGS
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GENERAL SAFETY RULES
WARNING: Read all instructions
carefully and understand them completely. Failure to follow all of the
instructions listed below may result in electric shock, fire, and/or serious personal injury.
WORK AREA
Keep the work area clean and well lit. Cluttered benches and dark areas invite accidents.
Do not operate a power tool in a potentially explosive environment, such as in the presence of flammable liquids, gas, or dust. Power tools create sparks that may ignite the dust or fumes.
Keep bystanders, children, and visitors away while operating a power 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 outlet 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 in order 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 extension cord that is marked “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 could 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.
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POWER TOOL SAFETY
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PERSONAL SAFETY – cont’d
Avoid accidental start-ups. Verify that the switch is in the OFF position before plugging the tool in. 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 it is 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 and other 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 Tools must be serviced 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
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WARNING: For safety reasons,
read this Owner's Manual carefully and understand it thoroughly before plugging in the rotary tool.
Hold the tool by the insulated gripping surfaces when performing any operation where the cutting tool may coming into contact with hidden wiring or its own power
cord. Contact with a “live” wire will make
the exposed metal parts of the tool “live”,
which could shock the operator. Verify that the work surface is free of nails
and other foreign objects. Cutting into a nail may cause the bit and the tool to jump, and could damage the bit.
Do not hold the workpiece in one hand and the tool in the other hand while using the tool. Do not place the hands near or below the cutting surface. It is much safer to clamp the material and to guide the tool using both hands.
Do not lay the workpiece on a hard surface such as concrete, stone, etc. The protruding cutting bit may cause the tool to jump.
Wear safety goggles and a dust mask. Work only in a well-ventilated area. Using personal safety devices and working in a safe environment reduces the risk of injury.
Verify that the collet nut and all other adjustment devices are securely tightened after changing bits and accessories or making adjustments. Loose adjustment devices may be thrown violently when the tool is turned ON.
Be sure to use the correct collet size. If the collet size is larger than the accessory's shank, it will not grip the shank properly, which could result in injury to the operator or damage to the tool.
Inspect accessory bits, grinding stones, cut-off wheels, etc. for damage before each use. A damaged accessory can break during use, which could cause serious injury.
Do not use dull or damaged bits. Handle sharp bits with care. A damaged bit can snap during use. A dull bit requires more force in order to push the tool, which could cause the bit to break.
Do not touch the bit during or immediately after use. After use, the bit is hot enough to burn bare skin.
Do not operate the flexible shaft with a
bend radius of less that 6” (15.2 cm). A
shorter bend radius will damage the flexible shaft and the motor of the rotary tool.
SPECIFIC SAFETY RULES
!
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WARNING: Keep the extension cord clear of the work area. Position the
cord so that 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 rotary tool, 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 ton 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 rotary tool at lower voltage will damage the motor.
MINIMUM GAUGE (AWG) EXTENSION
CORDS
(120 V use only)
Ampere Rating
Total length in feet
More Than
Not More Than
25’ 50’ 100’ 150’ 0 6
18
16
16
14 6 10
18
16
14
12
10
12
16
16
14
12
12
16
14
12
Not Applicable
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EXTENSION CORD SAFETY
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9
V
Volts
A
Amperes
Hz
Hertz
W
Watts
kW
Kilowatts
Microfarads
L
Litres
kg
Kilograms
H
Hours
N/cm2
Newtons per square centimeter
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 earthing terminal, Class I tools
Revolutions or reciprocations per minute
Diameter
Off position
Arrow
Warning symbol
WARNING: Some of the following symbols may appear on the rotary
tool. Study these symbols and learn their meaning. Proper interpretation of these symbols will allow for more efficient and safer operation of this tool.
!
SYMBOLS
This symbol indicates that this tool is listed by Underwriters Laboratories as meeting both Canadian and U.S. requirements.
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DIAGRAM AND LOCATION OF PARTS
Rotary tool
clamp
Release
lever
Carry bag
Accessory
storage trays
Rotary tool
hanger
Bit storage
Flexible shaft
hanger
Flexible shaft locking collar
Motor
controls
Rotary
tool
Spindle
lock
Spindle
nut
Collet
nut
Flexible shaft
collet nut
Flexible shaft
mounting nut
Flexible shaft
Cooling
vents
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DIAGRAM AND LOCATION OF PARTS
Connecting
adapter
Blade guard
Mini circular saw
attachment
Right angle attachment
Vacuum
adaptor
Sanding
attachment
LED
worklight
Connecting
collar
Height
adjusting screw
Rotary tool
connector
Angle adjustment
screw
Angle guide
Clamping
lever
Guard
rotation lock
ON/OFF
button
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AVAILABLE ACCESSORIES
WARNING: Use only accessories
that are recommended for this rotary tool. Follow the instructions that accompany the accessories. The use of improper accessories may result in injury to the operator or damage to the rotary tool.
Before using any accessory, carefully read the instructions or the owner’s manual for the accessory.
Grinding stones
Cut-off wheels
Polishing wheels
Wire brushes
Bristle brushes
Sanding drums
Cutting bits
Drill bits
Dressing stones
WARNING: If any part is missing or damaged, do not plug the rotary tool into the outlet until the missing or damaged part has been replaced.
CONTENTS Carefully unpack the rotary tool and all of
its components. Compare the contents
against the following chart entitled “Rotary
Tool Components”.
NOTE: See the illustrations of the rotary tool and accessories on the following pages.
WARNING: In order to avoid the risk of fire or toxic reaction, do not use gasoline, naphtha, acetone, lacquer thinner, or similar highly volatile solvents to clean the rotary tool.
! ! !
ACCESSORIES AND CONTENTS
ROTARY TOOL COMPONENTS
KEY
DESCRIPTION
QTY
A
Rotary cutting tool
1
B
Detail sanding pad
1
C
Contour sanding pads
Wedge
Convex
Concave
1 1 1
D
Batteries for the LED worklight
2
E
Stand assembly
1
F
LED worklight assembly
1
G
Flexible shaft
1
H
Slide-out storage containers with accessories
See the following pages for the list of accessories
2
I
Tote bag
1
J
Angle attachment with vacuum adaptor
1
K
Circular saw attachment
1
L
Sander attachment
1
M
Right angle attachment
1
Owner’s Manual (not shown)
1
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CONTENTS
0
A
D
B
C
E
F
G
H
I
J
K
L
M
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Illustration
Item
Description / Size
Qty
Aluminium oxide grinding stone
Cylinder 3/8" (9 mm)
1
Aluminium oxide grinding stone
Circular grinding stone 5/8" (16 mm) radial
1
Aluminium oxide grinding stone
Cylinder with pointed end 1/4" (6 mm)
1
Aluminium oxide grinding stone
Parabolic 3/8" (9 mm)
1
Aluminium oxide grinding stone
Grinding wheel 1" (25 mm)
1
Aluminium oxide grinding stone
Cone 5/8" (16 mm)
1
Aluminium oxide grinding stone
Abrasive wheel 3/4" (19 mm)
2
Silicon carbide grinding stone
Cylinder with pointed end 3/16" (5 mm)
1
Silicon carbide grinding stone
Cylinder with pointed end 3/32" (2.5 mm)
1
Silicon carbide grinding stone
Wheel 3/8" (9 mm)
1
Silicon carbide grinding stone
Wheel 5/8" (16 mm)
1
Silicon carbide wheel
Abrasive wheel 3/4" (19 mm)
2
Super duty cut-off wheel
Fibreglass-reinforced wheel 1 1/4 " (32 mm)
3
Heavy duty cut-off wheel
15/16 x .031" (24 x .8 mm) thick
60
Regular duty cut-off Wheel
15/16 x .025" 24 x .6 mm) thick
60
Bristle brush
3/4" (19 mm) radial
1
Bristle brush
1/2" (13 mm) axial
1 Stainless steel brush
1/2" axial (13 mm)
1
Stainless steel brush
3/4" (19 mm) radial
1
Brass brush
1/2" (13 mm) axial
1
Felt polishing wheel
1/2" (13 mm)
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ACCESSORY KIT CONTENTS
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15
Illustration
Item
Description / Size
Qty
Felt polishing wheel
1" (25 mm)
1
Felt polishing tip
Pointed tip 3/8" (9 mm)
1
Cloth wheel
1" (25 mm)
1 Sanding band
60 grit 1/4" (6 mm)
10
Sanding band
120 grit 1/4" (6 mm)
10
Sanding band
60 grit 1/2" (13 mm)
10
Sanding band
120 grit 1/2" (13 mm)
10
Drum sander
1/4"(6 mm) with 1/8" (3 mm) shank
1
Drum sander
1/2" (13 mm) with 1/8" (3 mm) shank
1
Sanding disc
100 grit 3/4" (19 mm)
80
Sanding disc
220 grit 3/4" (19 mm)
80
Sanding disc
240 grit 3/4" (19 mm)
80
Flap wheel
1/4" (6 mm)
1
Diamond wheel point
Taper point 3/32" (2.5 mm)
1
Diamond wheel point
Ball 5/64" (2 mm)
1
Diamond wheel point
Ball 11/64" (4.5 mm)
1
Carbide grout cutter
1/16" (1.5 mm)
1
HSS cutter
Cylinder 1/8" (3 mm)
1
Collet
1/8" (3 mm)
1 Collet
3/32" (2.5 mm)
1
Collet
1/16" (1.5 mm)
1
ACCESSORY KIT CONTENTS
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Illustration
Item
Description / Size
Qty
Screw mandrel
1/8" (3 mm)
10
Mandrel
For felt wheels 1/8" (3 mm)
10
Wrench
For collet nut and drum sander
1
Dressing stone
Rectangular 3/8 x 1" (9 x 25 mm)
1
Hook & loop sandpaper
For detail sander
4
Hook & loop sandpaper
For contour sanders
6
Circular saw blade
48 teeth
2
L-key
For attachments
1
Description
Uses
High-speed steel cutter
Shaping, hollowing, grooving, slotting, and making tapered holes in soft metals, plastics, and wood.
Carbide grout cutter
Cutting wall and floor grout.
Multi-purpose bit
Cutting wood, plastic, fibreglass, drywall, laminate, and aluminium and vinyl siding.
Screw mandrel
Holding sanding discs, felt wheels, polishing wheels, grinding wheels, and cut-off wheels.
Mandrel for emery­impregnated polishing wheel
Holding the emery-impregnated polishing wheel.
Mandrel for cloth wheel
Holding sanding discs, polishing wheels, grinding wheels, and cut-off wheels.
Collet
Holding accessories in position.
Collet wrench
Tightening & loosening the collet nut and the screw for drum sanders.
Dressing stone
Cleaning grinding wheels and stones, and shaping or reshaping stones for desired applications.
L-key
Locking the flexible shaft in position when loosening or tightening the collet nut.
Aluminum oxide
Grinding stones Grinding wheels Abrasive wheels
Sharpening, de-burring, removing rust , and general­purpose grinding of most materials, including metals, castings, welded joints, and rivets.
ACCESSORY KIT CONTENTS
DESCRIPTION AND USE OF ACCESSORIES
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17
Description
Uses
Silicon carbide
Stones Wheels
General-purpose grinding of stone, glass, ceramics, porcelain, and non-ferrous metals.
Cut-off wheel
Cutting, grooving, and trimming all kinds of materials, including metal, wood, and ceramics; cutting screws and rusted bolts, making slots in screw heads, trimming castings, etc.
Polishing wheel
Emery-
impregnated
Cleaning and polishing coarse surfaces. Polishing wheel
Felt & cloth
Polishing most metal surfaces and plastics. Can be
used with a polishing compound.
Bristle brush
Light de-burring, cleaning, and polishing of silverware, jewellery, and other precious metals. Can be used with a polishing compound.
Stainless steel brush
Light de-burring, cleaning, and polishing of corrosion­resistant materials like pewter, aluminium, and stainless steel. Does not cause "after-rust".
Brass brush
Light de-burring, cleaning, and polishing of soft metals such as gold, copper, brass, etc. Non-sparking, and does not scratch.
Sanding band
Rough shaping and smoothing of wood and fibreglass, removing rust from metal surfaces, and shaping rubber surfaces. Sanding bands are easily replaceable on drums.
Sanding wheel
Rough shaping and smoothing of wood and fibreglass, removing rust from metal surfaces, shaping rubber surfaces, etc.
Flap wheel
Grinding and polishing flat or contoured surfaces. Finishing surfaces after heavier sanding and material removal has been completed.
Diamond wheel point
Cutting, sawing, and carving hard materials such as marble, concrete, brick, porcelain, ceramics, hard epoxy, and soft and hard wood.
Engraving Cutter
Detailed engraving, carving, and routing in wood, fibreglass, plastic, and soft metals.
Tungsten-carbide cutter
Shaping, smoothing, and removing material from hardened steel, stainless steel, cast iron, non-ferrous metals, fired ceramics, plastics, hard wood, and other hard materials.
Hook & loop detail sheets
Sanding wood. Used with the detail sander.
Sandpaper for contour sander
Sanding wood. Used with the contour sander.
Circular blade
Cutting wood. Used with the mini circular saw.
DESCRIPTION AND USE OF ACCESSORIES
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18
CHANGING THE COLLET Different accessories require the use of
different sized collets. The most common collet sizes are 1/8, 3/32, and 1/16" (3, 2.5, and 1.5 mm). It is important to ensure that the collet size matches the shank of the accessory.
WARNING: If the collet is too
large for the accessory, the accessory could be thrown from the tool, which could cause serious injury.
1. Turn the switch to the OFF position, and disconnect the plug from the outlet.
2. Depress the spindle lock button (1), and slowly turn the collet nut (2) until the spindle lock button locks the spindle in place (Fig. 1).
3. Hold the spindle lock button down, and turn the collet nut counter-clockwise using the collet wrench until it comes free.
4. Remove the collet (3) by pulling it out of the spindle (4).
5. Insert the replacement collet into the spindle, and tighten the collet nut by turning it clockwise while holding the spindle lock button down. NOTE: Do not tighten the collet nut without an accessory installed in the collet. Doing so will damage the collet.
INSTALLING ACCESSORIES
1. Turn the switch to the OFF position, and disconnect the plug from the outlet.
!
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 1
Page 19
19
INSTALLING ACCESSORIES – cont’d
2. Depress the spindle lock button (1), and slowly turn the collet nut (2) until the spindle lock button locks the spindle in place (Fig. 2).
3. Hold the spindle lock button down, and turn the collet nut counter-clockwise until the collet is loose inside the collet nut.
4. Insert the shank of the accessory (3) into collet.
NOTE: Verify that the proper collet is used for the accessory. If the collet is too large, replace it with the next smaller size.
5. Press the spindle lock button, and engage it in the spindle. While holding the spindle lock button down, turn the collet clockwise by hand in order to tighten it .
NOTE: Do not use pliers to tighten the collet nut. Use the collet wrench that is provided. Over-tightening the collet will damage the tool.
6. Pull on the accessory in order to verify that it is held securely in position.
CONNECTING THE FLEXIBLE SHAFT TO THE TOOL
WARNING: Do not bend the
flexible shaft to a radius of less than 6”
(15.2 cm) when using it with the rotary tool. Store the flexible shaft carefully when it is not in use, avoiding sharp bends.
!
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 2
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20
CONNECTING THE FLEXIBLE SHAFT TO THE TOOL – cont’d
1. Remove the collet nut (1) and the spindle nut (2) from the tool by turning them counter-clockwise (Fig. 3).
2. Remove the collet from motor shaft (3).
3. Insert the the inner cable of the flexible shaft (4) into the motor shaft until the stopper (5) comes into contact with the motor shaft.
4. Thread the flexible shaft collet nut (6) onto the motor shaft by turning it clockwise. Tighten it using the collet wrench.
5. Thread the flexible shaft nut (7) onto the tool housing (8) by turning it clockwise.
NOTE: Tighten the flexible shaft nut by hand only. Do not use pliers or a wrench.
CHANGING THE COLLET AND ACCESSORIES IN THE FLEXIBLE SHAFT
In order to change the collet or to install an accessory in the flexible shaft, follow the steps listed in the sections entitled
“Changing the collet” and “Installing accessories”. In order to lock the shaft in
place, pull back on the flexible shaft grip (1) and rotate the collet until the shaft grip locks the shaft in place (Fig. 4). The flexible shaft grip will return to its normal position when it is not being held in the locked position.
NOTES:
a) Do not attempt to loosen or tighten the collet without locking the shaft in place as described above. Doing so will damage the flexible shaft. b) Do not over-tighten the collet nut.
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 4
Fig. 3
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21
ASSEMBLING THE ROTARY TOOL STAND
The rotary tool stand is used to hold the rotary tool while using the flexible shaft.
1. Insert the bottom end of the tool holder (1) into the matching slots (2) in the base of the stand (3) (Fig. 5).
NOTE: Rotate the tool holder in order to position the tool clamp (4) toward the front of the base.
2. Rotate the tool holder 90° clockwise in order to secure it to the base.
3. Install the flexible shaft on the rotary tool (Fig. 3).
4. Pull out on the tool holder clamp lever (5) in order to open the tool holder clamp (4) (Fig. 6).
5. Insert the flexible shaft (7) through the tool holder clamp, and insert the rotary tool (6) into its clamp (4).
NOTE: Verify that the rotary tool is inserted fully into the clamp.
6. Push the tool holder clamp lever toward the tool until it snaps into place and holds the tool securely in place.
7. If the tool is left installed in the stand with the flexible shaft installed, hang the collet end of the flexible shaft in the slotted holder (8) that is located at the right side of the stand.
8. Accessories can be stored in the base of the stand, in the spaces that are provided (9).
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 5
Fig. 6
Page 22
22
INSTALLING THE RIGHT ANGLE ATTACHMENT
1. Remove the collet nut and the collet from the motor shaft.
NOTE: Engage the spindle lock button in order to hold the spindle in place while loosening and tightening the collet nut.
2. Remove the spindle nut (1) from the tool by turning it counter-clockwise (Fig. 7).
3. Insert the short end of the drive shaft (2) into the motor shaft (3) until the stopper (4) comes into contact with the shaft.
4. Slide the collet nut (6) over the drive shaft (5), and thread it onto the motor shaft by turning the collet nut clockwise. Tighten the collet nut using the collet wrench.
5. Remove the right angle attachment adaptor (7) and the collar (8) from the right angle attachment (9) by turning the collar counter-clockwise.
6. Fasten the right angle attachment adaptor and the collar to the tool (10) by turning the right angle attachment adaptor clockwise.
NOTE: Tighten by hand only. Do not use pliers or a wrench.
7. Insert the end of the drive shaft into the hole in the right angle attachment (11).
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 7
Page 23
23
INSTALLING THE RIGHT ANGLE ATTACHMENT – cont’d
NOTE: Rotate the right angle attachment collet nut (12) while pushing the right angle attachment onto the adaptor until the square end of the drive shaft is inserted into the corresponding square in the right angle attachment.
8. Once the drive shaft is fully engaged into the right angle attachment, lock the right angle attachment to the adaptor by turning the adaptor collar clockwise.
NOTE: Tighten by hand only. Do not use pliers or a wrench.
Follow the basic procedures that are described in the section entitled Changing the collet and accessories in the flexible shaft (Fig. 4) in order to change the collet and accessories in the right angle attachment. In order to lock the spindle, rotate the collet nut (12) until the L-key (13) can be inserted into the hole in the shaft (14) (Fig. 7A).
INSTALLING THE ANGLE GUIDE AND THE VACUUM ADAPTER
The angle guide is used to hold the tool at a specific angle while cutting or grinding.
1. Remove the spindle nut (1) from the tool by turning it counter-clockwise (Fig. 8).
2. Install the appropriate bit in the rotary tool (Fig. 2).
3. Install the angle guide (2) onto the tool by turning the base clockwise onto the threaded portion of the tool spindle (3).
NOTE: Do not overtighten.
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 7A
Fig. 8
Fig. 7
Page 24
24
INSTALLING THE ANGLE GUIDE – cont’d
4. In order to set the cutting angle, loosen the two angle-adjusting thumb screws (4) that are located on the sides of the base, move base to desired angle, and then retighten the thumb screws.
NOTE: Do not overtighten the thumb screws.
5. In order to set the cutting depth, loosen the height-adjusting thumb screw (5), slide the tool up or down in the base until it is at the desired cutting depth, and then retighten the thumb screw.
6. When working with dusty applications, attach a vacuum to the vacuum adaptor (6) (Fig 8A). In order to install the vacuum adaptor, insert the small end of the adaptor (7) into the vacuum port (8) that is located on the side of the angle guide.
NOTE: Align the two slots (9) in the vacuum adaptor with the corresponding keys (10) in the vacuum port. Turn the vacuum adaptor clockwise in order to lock it in position.
INSTALLING THE SANDER ATTACHMENT
1. Remove the collet nut (1) and the collet from the motor shaft (2) (Fig. 9).
NOTE: Engage the spindle lock button in order to hold the spindle in place while loosening and tightening the collet nut.
2. Remove the spindle nut (3) from the tool by turning it counter-clockwise.
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 8
Fig. 9
Fig. 8A
Page 25
25
INSTALLING THE SANDER ATTACHMENT – cont’d
3. Insert the short end of the drive shaft (4) into the motor shaft until the stopper (5) comes into contact with the shaft.
4. Slide the collet nut over the drive shaft, and thread it onto the motor shaft by turning the collet nut clockwise. Tighten the collet nut using the collet wrench.
5. Remove the sander attachment adaptor (6) and the collar (7) from the sander attachment by turning the collar counter­clockwise.
6. Fasten the sander attachment adaptor and the collar to the tool (8) by turning the sander attachment adaptor clockwise.
NOTE: Tighten by hand only. Do not use pliers or a wrench.
7. Insert the square end of the drive shaft (9) into the hole in the sander attachment (10).
NOTE: Rotate the drive shaft while pushing the sander attachment onto the adaptor until the square end of the drive shaft is inserted into the corresponding square in the sander attachment.
8. Once the drive shaft is inserted fully into the sander attachment, secure the sander attachment to the adaptor by turning the adaptor collar clockwise onto the sander attachment threads (11).
NOTE: Tighten by hand only. Do not use pliers or a wrench.
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 9
Page 26
26
INSTALLING SANDPAPER
In order to properly adhere to the accessories, the sandpaper that is used for the detail and contour sander accessories must be of the hook & loop design. The following instructions describe how to apply the sandpaper to each type of sanding accessory.
Detail sander pad
Sandpaper pads are pre-cut to fit the triangular shape of the detail sander accessory. In order to apply the sandpaper, align the pre-cut sandpaper (1) with the bottom of the detail sander accessory, and press it firmly onto the base (2) (Fig. 10).
Contour sanding pads
Sandpaper pads are pre-cut into rectangular pieces that will fit the shape of the various contour sander accessories. In order to apply the sandpaper, align the pre-cut sandpaper with the “hooked” bottom and side surfaces of the selected contour accessory, and press it firmly onto the hooked surfaces (Fig. 11, 12 & 13).
NOTES:
a) Apply the sandpaper to the accessory so that it extends to the top of the rubber pad. b) If the sheet of sandpaper is too large to fit the contour accessory properly, trim the sandpaper to the proper size using an old pair of scissors.
INSTALLING THE PAD ONTO THE SANDER
1. Rotate the pad locking lever (1) counter­clockwise in order to open the pad clamp (2) (Fig. 14).
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Page 27
27
INSTALLING THE PAD ONTO THE SANDER – cont’d
2. Insert the top of the pad and the sandpaper into the open clamp.
NOTE: Verify that the top of the pad is centered in the clamp, and that the clamp grips the sandpaper.
3. Rotate the pad clamp lever clockwise in order to secure the pad and sandpaper in position.
SANDING WOOD
WARNING: Wear safety goggles,
hearing protection, and a dust mask when performing sanding operations. Failure to use adequate protection may result in serious injury.
Use the sander in the same manner as any other finishing sander.
SANDING TIPS
1. Use coarse sandpaper to remove material from gouges and rough areas more quickly. Coarse paper lasts longer, and is less likely to get clogged up with wood resin and surface finishes.
2. Use fine sandpaper for a smoother finish.
3. In order to improve sanding action, verify that the sandpaper is firmly pressed onto the “hook” area of the sanding pad.
4. Turn rotary tool on before the sandpaper comes into contact with the workpiece.
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ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 14
Page 28
28
SANDING TIPS – cont’d
NOTE: Setting the rotary tool at a faster speed will produce smoother sanding action.
5. Keep the rotary tool moving while the sandpaper is in contact with the workpiece in order to avoid removing excess material from the workpiece.
INSTALLING THE MINI CIRCULAR SAW ATTACHMENT
1. Remove the collet nut (1) and the collet from the motor shaft (2) (Fig. 15).
NOTE: Engage the spindle lock button in order to hold the spindle in place while loosening and tightening the collet nut.
2. Remove the spindle nut (3) from the tool by turning it counter-clockwise.
3. Insert the short end of the drive shaft (4) into the motor shaft until the stopper (5) comes into contact with the shaft.
4. Slide the collet nut over the drive shaft (9), and thread it onto the motor shaft by turning the collet nut clockwise. Tighten the collet nut using the collet wrench.
5. Remove the saw attachment adaptor (6) and the collar (7) from the circular saw attachment by turning the collar counter­clockwise.
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 15
Page 29
29
INSTALLING THE MINI CIRCULAR SAW ATTACHMENT – cont’d
6. Fasten the saw attachment adaptor and the collar to the tool (8) by turning the saw attachment adaptor clockwise.
NOTE: Tighten by hand only. Do not use pliers or a wrench.
7. Insert the square end of the drive shaft (9) into the hole in the saw attachment (10).
NOTE: Rotate the saw blade screw (11) while pushing the saw attachment onto the adaptor until the square end of the drive shaft is inserted into the corresponding square in the saw attachment.
8. Position the saw blade to the LEFT side of the rotary tool. The hexagonal positioning locks will engage when the body of the saw attachment is in the proper position.
9. Once the drive shaft and positioning locks are fully engaged, secure the saw attachment to the adaptor by turning the adaptor collar clockwise.
NOTE: Tighten by hand only. Do not use pliers or a wrench. Loosen adaptor collar when removing the circular saw attachment from the rotary tool.
10. Rotate the saw guard assembly until the bottom sliding surface of the guard assembly and the rotary tool are in the desired position. In order to rotate the guard assembly, press the release button (12) and rotate the guard assembly until the release button snaps into the next locked position.
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 15
Page 30
30
INSTALLING A SAW BLADE
1. Lock the saw attachment shaft in place. in order to lock the shaft in place, rotate the screw that holds the blade onto the shaft until the hole in the shaft is aligned with the hole in the saw attachment body (1) (Fig. 16). Insert the L-Key (2) through the holes in order to lock the shaft in place.
NOTE: Do not attempt to loosen or tighten the blade screw without locking the shaft as described above. Doing so will damage the flexible shaft.
2. Remove the saw blade screw (1), the locking washer (2), and the large washer (3) by turning the screw clockwise using a 5/16" (8 mm) wrench (Fig. 16A). The screw has a left-hand thread.
3. Rotate the blade guard lever (4) forward.
4. Place the saw blade onto the spindle (5).
NOTE: Verify that the teeth on the bottom of the saw blade are pointing forward.
5. Secure the saw blade in position by replacing the large washer, the locking washer, and the saw blade screw in the proper order.
NOTES:
a) Place the hollow side of the large washer against saw blade. b) Lock the saw blade shaft using the L-Key. c) Tighten the saw blade screw by turning it counter-clockwise. The screw has a left­hand thread. d) Do not overtighten the saw blade screw. Doing so will damage the threaded spindle.
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 16A
Fig. 16
Page 31
31
CUTTING WOOD
WARNING: Wear safety goggles, hearing protection, and a dust mask when performing sawing operations. Failure to use adequate protection could result in serious injury.
WARNING: Do not place hands near or below the cutting line.
The mini circular saw attachment is designed to make smooth cuts in extremely thin pieces of wood. Verify that the saw blade is not in contact with anything, and that the operator's hands are clear of the blade before turning the rotary tool on.
1. Turn rotary tool on.
2. Set the speed to 25,000 RPM.
3. Position the saw attachment on the edge of the workpiece, with the blade aligned with the cutting line.
4. Slowly move the blade toward the cutting line until it comes into contact with the workpiece.
5. Once the blade begins to cut, move the blade into the workpiece at a slow and steady pace, following the cutting line.
NOTE: The mini circular saw attachment is designed to cut straight lines only. It is not designed to cut curves.
Moving the saw at a slow and steady pace will produce a smooth cut. Forcing the blade to cut too quickly will cause it to overheat, which will result in burn marks on the wood, a rough cut, and a dull blade.
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ASSEMBLY AND OPERATING INSTRUCTIONS
Page 32
32
CUTTING WOOD – cont’d
WARNING: Once the cutting
operation is complete, verify that the saw blade has come to a complete stop before setting the rotary tool down.
WARNING: Do not touch the blade
immediately after cutting, because it will be hot enough to cause burns.
ASSEMBLING THE LED WORKLIGHT
This rotary tool is equipped with a free­standing LED worklight that can be placed on any flat surface near the workpiece. The flexible arm can be bent in order to focus the light on the desired location. Install the batteries into the base of the LED worklight as follows:
1. Turn the worklight upside down.
2. Remove the battery cover (1) from the base of the worklight (2) by lifting the side where the slot (3) is located (Fig. 17).
3. Install two AAA alkaline batteries (4) into the battery compartment.
NOTE: Position the batteries with the positive (+) end of each battery as illustrated in the picture that is in the battery compartment.
4. Re-install the cover of the battery compartment.
5. Turn the LED worklight on or off using the ON/OFF button (5) that is located on the top of the base (Fig. 17A). Push the button once in order to turn the light on. Push it again to turn the light off.
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ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 17
Fig. 17A
Page 33
33
SELECTING THE PROPER SPEED
The different types of operations that can be performed require that the rotary tool be used at different speeds. The following chart outlines some of the basic speed settings:
OPERATION
SPEED
(RPM)
Sanding
13,000
Cutting metal
35,000
Sanding wood
13,000
Cutting hard metal
29,000
Engraving metal
27,000
Sawing
25,000
De-burring
19,000
Drilling holes
17,000
Removing rust
13,000
Sharpening
9,000
Polishing
9,000
WARNING: 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 rotary tool.
Verify the following every time the rotary tool is used:
1. All accessories that are being used are in good condition and are not damaged in any way.
2. The workpiece is properly secured and the accessory is securely installed.
3. The operator is wearing safety glasses. Failure to observe these safety rules will significantly increase the risk of injury.
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ASSEMBLY AND OPERATING INSTRUCTIONS
Page 34
34
DIGITAL MOTOR CONTROL
This rotary tool features advanced digital controls, including an LCD (liquid crystal display) speed indicator and a speed memory function. The following sections describe how these functions work.
ON/OFF SWITCH
WARNING: Verify that the bit is
securely installed in the collet and that the cutting accessory is not in contact with anything before turning the switch to the “ON” position.
1. Push the left side of the switch in order to turn it to the "ON" position (1) (Fig. 18).
NOTE: The tool will start, and the digital display (2) will indicate the speed that was previously set. The indicated speed will be
between “05” and “35” (5,000 and 35,000
RPM).
2. Push the right side of the switch in order to turn it to the "OFF" position (3) (Fig. 19).
NOTE: The digital display will go blank. ADJUSTING THE SPEED
The speed of the tool can be adjusted from 5,000 RPM to 35,000 RPM in order to accommodate the various types of operations.
NOTE: The motor is equipped with a soft start feature. When the switch is turned to the "ON" position, the motor will start slowly, and will increase in speed until the preset speed is attained.
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 18
Fig. 19
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Page 35
35
ADJUSTING THE SPEED – cont’d
1. Turn the switch to the "ON" position. The rotary tool will start slowly, and will increase in speed until the preset speed is attained. The display will read between “05” and “35” (5,000 and 35,000 RPM).
2. In order to increase the speed of the
tool, press the “+” speed control button (4)
once (Fig. 20). The speed of the tool will increase by “02” (2,000 RPM).
3. Continue to increase the speed of the tool by pressing the “+” speed control button several times (Fig. 21). The speed
of the tool will increase by “02” (2,000 RPM) each time the “+” speed control
button is pressed, until it reaches the maximum speed of “35” (35,000 RPM).
4. In order to decrease the speed of the tool, press the “–” speed control button (5).
NOTE: Each time the “–“ speed control
button is pressed, the speed of the tool will decrease by “02” (2,000 RPM).
SPEED MEMORY
The digital controls of this rotary tool include a “memory” function. When the tool is turned on, the tool will automatically start at the speed that was set the last time the tool was turned off. This function is particularly useful when the tool is turned off in order to change cutting bits.
Adjust the speed to the desired setting each time the tool is turned on.
ASSEMBLY AND OPERATING INSTRUCTIONS
Fig. 20
Fig. 21
Page 36
36
WARNING: When servicing, use only identical replacement parts. The use of any other part may create a hazard or damage the rotary tool.
Do not abuse power tools. Abusive practices can damage the tool and the workpiece.
WARNING: Do not attempt to modify this rotary tool or to create accessories. Any such alteration or modification is considered to be misuse, and could result in a hazardous condition that may lead to serious injury. Doing so will also void the warranty.
CLEANING Do not use solvents to clean plastic parts.
Many plastics are susceptible to damage from various types of commercial solvents. 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.
Power tools are subjected to accelerated wear and possible premature failure when they are used on fiberglass boats and sports cars, wallboard, spackling compounds, or plaster. The chips and grindings from these materials are extremely abrasive to some parts of power tools, including bearings, brushes, commutators, etc. Therefore, it is recommended that this tool not be used for extended work on any fiberglass material, wallboard, spackling compound, or plaster. If this rotary tool is used on these materials for an extended period, it must be cleaned frequently by blowing it out with an air jet.
WARNING: Wear safety goggles or safety glasses that have side shields
whenever performing any operation with a rotary tool. It is also critical to wear
safety goggles or safety glasses that have side shields, as well as a dust mask, when blowing dust out of the tool using an air jet. Failure to observe these safety precautions could result in permanent eye or lung damage.
LUBRICATION
All of the bearings in this rotary tool have been lubricated with a sufficient quantity of high-grade lubricant for the life of the tool under normal conditions. No further lubrication is required.
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MAINTENANCE
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Page 37
37
EXPLODED VIEW
Page 38
38
WARNING: When servicing, use only Mastercraft® replacement parts. The use of
any other parts may create a safety hazard or cause damage to the rotary tool. Any attempt to repair or replace electrical parts on this rotary tool may create a safety
hazard unless repairs are performed by a qualified technician. For more information, call the Toll-Free Helpline, at 1-800-689-9928.
Always order by PART NUMBER, not by key number.
Key #
Part #
Part Name
Quantity
1
313300
Accessory collar
1 2 215100
Collet nut
1 3 216506
1/8" collet
1
4
213016
Output shaft
1
5
520008
Bearing 626RS
2 6 314009
Fan 1 7
134008
Armature
1 8 138008
Stator
1
9
321006
Bearing sleeve
1
10
500843
Screw M3 x 10
2
11
504000
Spring washer 3
2
12
503008
Small washer 3
2
13
215014
Locking pin
1
14
221286
Washer
1
15
240824
Locking pin spring
1
16
312934
Spindle lock button
1
17
300076
Housing (right)
1
18
234033
Aluminium cover (right)
1
19
500001
Tapping screw ST2.9 x 16
6
20
162853
Rectifying PCB
1
21
500409
Tapping screw ST2.2 x 16
3
22
162852
V.S. PCB
1
23
242553
Hanging loop
1
24
312098
Back cover
1
25
317013
"-" speed control button
1
26
317012
"+" speed control button
1
27
500006
Tapping screw ST2.9 x 12
2
28
224455
Cord clamp
1
29
322006
Cord guard
1
30
160205
Cord set
1
31
314527
Brush holder support
2
32
222827
Brush holder
2
33
342027
Carbon brush
2
34
300076
Housing (left)
1
35
234033
Aluminium cover (left)
1
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PARTS LIST
Page 39
39
Rev 1.3 13/07/2008
WARRANTY
*Limited 5-year Replacement Warranty This Mastercraft Maximum product carries a five (5) year replacement
warranty against defects in workmanship and materials. Mastercraft Canada agrees to replace the defective product free of charge with the same model or one of equal value or specification, within the stated warranty period, when returned by the original purchaser with proof of purchase. The case carries a two (2) year replacement warranty against defects in workmanship and materials. This product is not guaranteed against wear or breakage due to misuse and/or abuse.
This product is not guaranteed if used for industrial or commercial purposes.
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