Chicago Electric Sander 66615 User Manual

7” ELECTRONIC POLISHER  
Model 66615  
SET uP aNd OPERaTINg INSTRuCTIONS  
Visit our website at: http://www.harborfreight.com  
Read this material before using this product.  
Failure to do so can result in serious injury.  
SaVE THIS MaNuaL.  
©
®
Copyright 2009 by Harbor Freight Tools . All rights reserved. No portion of this manual or any artwork  
contained herein may be reproduced in any shape or form without the express written consent of  
Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing  
improvements, actual product may differ slightly from the product described herein. Tools required for  
assembly and service may not be included.  
For technical questions or replacement parts, please call 1-800-444-3353.  
Manual Revised 10b  
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increased risk of electric shock if your  
body is grounded.  
tools that have the switch on invites  
accidents.  
c.do not expose power tools to rain or  
wet conditions. Water entering a power  
tool will increase the risk of electric  
shock.  
d.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.  
d.do not abuse the cord. Never use  
the cord for carrying, pulling or  
e.do not overreach. Keep proper  
footing and balance at all times. This  
enables better control of the power tool  
in unexpected situations.  
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.  
f. dress properly. do not wear loose  
clothing or jewelry. Keep your hair,  
clothing and gloves away from  
e.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.  
moving parts. Loose clothes, jewelry or  
long hair can be caught in moving parts.  
g.If devices are provided for the  
connection of dust extraction and  
collection facilities, ensure these are  
connected and properly used. Use of  
these devices can reduce dust-related  
hazards.  
f. If operating a power tool in a damp  
location is unavoidable, use a ground  
Fault Circuit Interrupter (gFCI)  
protected supply. Use of a GFCI  
reduces the risk of electric shock.  
h.Only use safety equipment that has  
been approved by an appropriate  
standards agency. Unapproved safety  
equipment may not provide adequate  
protection. Eye protection must be  
ANSI-approved and breathing protection  
must be NIOSH-approved for the specific  
hazards in the work area.  
3. Personal safety  
a.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.  
4. Power tool use and care  
b.use safety equipment. always wear  
eye protection. Safety equipment such  
as dust mask, non-skid safety shoes,  
hard hat, or hearing protection used  
for appropriate conditions will reduce  
personal injuries.  
a.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.  
b.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.  
c.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  
c.disconnect the plug from the power  
source and/or the battery pack from  
REV 10b  
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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.  
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.  
2. Operations such as grinding, wire  
brushing, or cutting-off are not  
recommended to be performed with  
this power tool. Operations for which  
the power tool was not designed may  
create a hazard and cause personal  
injury.  
d.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.  
e.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.  
3. do not use accessories which  
are not specifically designed  
and recommended by the tool  
manufacturer. Just because the  
accessory can be attached to your power  
tool, it does not assure safe operation.  
4. 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.  
f. Keep cutting tools sharp and clean.  
Properly maintained cutting tools with  
sharp cutting edges are less likely to  
bind and are easier to control.  
g.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.  
5. 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.  
5. Service  
6. The arbor size of wheels, flanges,  
backing pads or any other accessory  
must properly fit the spindle of the  
power tool. Accessories with arbor  
holes that do not match the mounting  
hardware of the power tool will run out  
of balance, vibrate excessively and may  
cause loss of control.  
a.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.  
Safety Warnings Common for  
Sanding or Polishing Operations  
7. do not use a damaged accessory.  
Before each use inspect the  
1. This power tool is intended to  
function as a sander or polisher. Read  
all safety warnings, instructions,  
accessory such as abrasive wheels  
for chips and cracks, backing pad  
REV 10b  
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for cracks, tear 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.  
11. 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.  
12. 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.  
13. 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.  
8. 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 work piece  
fragments. The eye protection must  
be capable of stopping flying debris  
generated by various operations.  
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.  
14. 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.  
15. do not operate the power tool near  
flammable materials. Sparks could  
ignite these materials.  
16. do not use accessories that require  
liquid coolants. Using water or other  
liquid coolants may result in electrocution  
or shock.  
17. Maintain labels and nameplates on  
the tool. These carry important safety  
information. If unreadable or missing,  
contact Harbor Freight Tools for a  
replacement.  
9. Keep bystanders a safe distance away  
from work area. anyone entering  
the work area must wear personal  
protective equipment. Fragments of  
work piece or of a broken accessory  
may fly away and cause injury beyond  
immediate area of operation.  
18. Avoid unintentional starting. Prepare to  
begin work before turning on the tool.  
10. Hold power tool by insulated gripping  
surfaces only, when performing an  
operation where the accessory may  
contact hidden wiring or its own cord.  
An accessory contacting a ″live″ wire  
may make exposed metal parts of the  
power tool ″live″ and shock the operator.  
19. Do not depress the spindle lock when  
starting or during operation.  
20. Do not leave the tool unattended when  
it is plugged into an electrical outlet.  
Turn off the tool, and unplug it from its  
electrical outlet before leaving.  
REV 10b  
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21. Use clamps (not included) or other  
practical ways to secure and support the  
workpiece to a stable platform. Holding  
the work by hand or against your body is  
unstable and may lead to loss of control  
and personal injury.  
microscopic particles. (California Health  
& Safety Code § 25249.5, et seq.)  
25. WARNING: Handling the cord on this  
product will expose you to lead, a  
chemical known to the State of California  
to cause cancer, and birth defects or  
other reproductive harm. Wash hands  
after handling. (California Health &  
Safety Code § 25249.5, et seq.)  
22. This product is not a toy. Keep it out of  
reach of children.  
23. People with pacemakers should  
consult their physician(s) before use.  
Electromagnetic fields in close proximity  
to heart pacemaker could cause  
pacemaker interference or pacemaker  
failure. In addition, people with  
pacemakers should:  
26. The warnings, precautions, and  
instructions discussed in this instruction  
manual cannot cover all possible  
conditions and situations that may occur.  
It must be understood by the operator  
that common sense and caution are  
factors which cannot be built into this  
product, but must be supplied by the  
operator.  
• Avoid operating alone.  
• Do not use with power switch locked  
on.  
• Properly maintain and inspect to avoid  
electrical shock.  
Kickback and Related Warnings  
• Any power cord must be properly  
grounded. Ground Fault Circuit  
Interrupter (GFCI) should also be  
implemented – it prevents sustained  
electrical shock.  
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.  
24. WARNING: Some dust created by power  
sanding, sawing, grinding, drilling, and  
other construction activities, contains  
chemicals known [to the State of  
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 either 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.  
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 or 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  
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.  
REV 10b  
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1. 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.  
Safety Warnings Specific for  
Polishing Operations  
1. 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.  
2. Never place your hand near the  
rotating accessory. Accessory may  
kickback over your hand.  
2. If waxing and polishing, make sure the  
object being polished is free from burrs  
and other foreign matter which could  
damage the Bonnets (52, 53).  
3. 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.  
Vibration Safety  
This tool vibrates during use. Repeated  
or long-term exposure to vibration may cause  
temporary or permanent physical injury,  
particularly to the hands, arms and shoulders.  
To reduce the risk of vibration-related injury:  
4. use special care when working  
corners, sharp edges etc. avoid  
bouncing and snagging the  
accessory. Corners, sharp edges or  
bouncing have a tendency to snag the  
rotating accessory and cause loss of  
control or kickback.  
1. Anyone using vibrating tools regularly  
or for an extended period should first  
be examined by a doctor and then have  
regular medical check-ups to ensure  
medical problems are not being caused  
or worsened from use. Pregnant  
5. do not attach a saw chain  
woodcarving blade or toothed saw  
blade. Such blades create frequent  
kickback and loss of control.  
women or people who have impaired  
blood circulation to the hand, past hand  
injuries, nervous system disorders,  
diabetes, or Raynaud’s Disease should  
not use this tool. If you feel any medical  
or physical symptoms related to vibration  
(such as tingling, numbness, and white  
or blue fingers), seek medical advice as  
soon as possible.  
Safety Warnings Specific for  
Sanding Operations  
1. do not use excessively oversized  
sanding disc paper. Follow  
manufacturer’s recommendations  
when selecting sanding paper. Larger  
sanding paper extending beyond the  
sanding pad presents a laceration  
hazard and may cause snagging, tearing  
of the disc or kickback.  
2. Do not smoke during use. Nicotine  
reduces the blood supply to the hands  
and fingers, increasing the risk of  
vibration-related injury.  
3. Wear suitable gloves to reduce the  
vibration effects on the user.  
REV 10b  
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4. Use tools with the lowest vibration when  
there is a choice between different  
processes.  
double Insulated Tools: Tools with  
Two Prong Plugs  
5. Include vibration-free periods each day  
of work.  
6. Grip tool as lightly as possible (while still  
keeping safe control of it). Let the tool  
do the work.  
7. To reduce vibration, maintain the tool  
as explained in this manual. If any  
abnormal vibration occurs, stop use  
immediately.  
Outlets for 2-Prong Plug  
1. Tools marked “Double Insulated” do not  
require grounding. They have a special  
double insulation system which satisfies  
OSHA requirements and complies with  
the applicable standards of Underwriters  
Laboratories, Inc., the Canadian  
SaVE THESE  
INSTRuCTIONS.  
Standard Association, and the National  
Electrical Code.  
gROuNdINg  
TO PREVENT  
ELECTRIC SHOCK  
aNd dEaTH FROM INCORRECT  
gROuNdINg WIRE  
CONNECTION:  
2. Double insulated tools may be used in  
either of the 120 volt outlets shown in the  
preceding illustration.  
(See Outlets for 2-Prong Plug.)  
Check with a qualified electrician  
if you are in doubt as to whether  
the outlet is properly grounded.  
do not modify the power cord  
plug provided with the tool.  
Never remove the grounding  
prong from the plug. do not use  
the tool if the power cord or plug  
is damaged. If damaged, have it  
repaired by a service facility  
before use. If the plug will not fit  
the outlet, have a proper outlet  
installed by a qualified  
Extension Cords  
1. Grounded tools require a three wire  
extension cord. Double Insulated  
tools can use either a two or three wire  
extension cord.  
2. As the distance from the supply outlet  
increases, you must use a heavier gauge  
extension cord. Using extension cords  
with inadequately sized wire causes a  
serious drop in voltage, resulting in loss  
of power and possible tool damage.  
(See Table a.)  
electrician.  
3. The smaller the gauge number of the  
wire, the greater the capacity of the cord.  
For example, a 14 gauge cord can carry  
a higher current than a 16 gauge cord.  
(See Table a.)  
REV 10b  
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4. When using more than one extension  
cord to make up the total length, make  
sure each cord contains at least the  
minimum wire size required.  
Symbology  
Double Insulated  
(See Table a.)  
Canadian Standards Association  
Underwriters Laboratories, Inc.  
Volts Alternating Current  
Amperes  
5. If you are using one extension cord for  
more than one tool, add the nameplate  
amperes and use the sum to determine  
the required minimum cord size.  
(See Table a.)  
V~  
a
6. If you are using an extension cord  
outdoors, make sure it is marked with the  
suffix “W-A” (“W” in Canada) to indicate it  
is acceptable for outdoor use.  
No Load Revolutions per Minute  
(RPM)  
n xxxx/min.  
0
7. Make sure the extension cord is properly  
wired and in good electrical condition.  
Always replace a damaged extension  
cord or have it repaired by a qualified  
electrician before using it.  
8. Protect the extension cords from sharp  
objects, excessive heat, and damp or  
wet areas.  
RECOMMENdEd MINIMuM WIRE gaugE  
FOR EXTENSION CORdS* (120/240 VOLT)  
EXTENSION CORd  
NaMEPLaTE  
LENgTH  
aMPERES  
(at full load)  
25’ 50’ 75’ 100’ 150’  
0 – 2.0  
2.1 – 3.4  
18  
18  
18  
18  
18  
14  
12  
18  
18  
18  
16  
14  
12  
10  
18  
18  
16  
14  
12  
10  
-
18  
16  
14  
12  
10  
-
16  
14  
12  
12  
-
3.5 – 5.0  
5.1 – 7.0  
7.1 – 12.0  
12.1 – 16.0  
16.1 – 20.0  
-
-
-
* Based on limiting the line  
voltage drop to five volts at 150%  
of the rated amperes.  
TaBLE a  
REV 10b  
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aSSEMBLY  
SPECIFICaTIONS  
auXILIaRY HaNdLE (36)  
Electrical Specifications 120 V~ / 60 Hz / 10 A  
No load speed  
1000~3500 RPM  
Maximum Accessory Size 7” Diameter  
Mounting Disc Type  
Variable Speed Switch  
7” Hook & Loop  
Sliding Button (+ & -)  
SPINdLE  
LOCK (34)  
Display Unit of Measure RPM x 100  
Accessories Polishing Bonnet  
FIguRE B  
gEaR BOX  
(32)  
Foam Bonnet  
Sanding Disc - 80 Grit  
MOuNTINg  
dISC (51)  
uNPaCKINg  
When unpacking, make sure that the  
item is intact and undamaged. If any parts  
are missing or broken, please call Harbor  
Freight Tools at 1-800-444-3353 as soon as  
possible.  
1. To attach the Mounting Disc (51) to the  
Polisher, press and hold the Spindle  
Lock (34). Screw the Mounting Disc  
onto the Spindle (50) of the tool. Then  
release pressure on the Spindle Lock.  
INSTRuCTIONS FOR PuTTINg  
INTO uSE  
2. To attach the Auxiliary Handle (36),  
screw the Handle firmly into the threaded  
mounting hole located on either side of  
the Gear Box (32).  
Read the ENTIRE IMPORTaNT  
SaFETY INFORMaTION  
section at the beginning of this  
manual including all text under  
subheadings therein before set up  
or use of this product.  
TO PREVENT  
SERIOuS INjuRY  
FROM aCCIdENTaL  
OPERaTION:  
Turn the Power Switch (11) off  
and unplug the Polisher from its  
electrical outlet before  
assembling or making any  
adjustments to the tool.  
Note: For additional information regarding the  
parts listed in the following pages, refer  
to the Assembly Diagram near the end of  
this manual.  
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onto the Mounting Disc.  
(See Figures a and B.)  
OPERaTINg INSTRuCTIONS  
Read the ENTIRE IMPORTaNT  
SaFETY INFORMaTION  
section at the beginning of this  
manual including all text under  
subheadings therein before set up  
or use of this product.  
3. Make sure the accessory is placed  
evenly on the Mounting Disc and is  
secure before turning on the tool.  
Work Piece and Work area Set up  
1. Designate a work area that is clean and  
well-lit. The work area must not allow  
access by children or pets to prevent  
injury and distraction.  
Tool Set up  
TO PREVENT  
SERIOuS INjuRY  
FROM aCCIdENTaL  
OPERaTION:  
2. Route the Power Cord (5) along a safe  
route to reach the work area without  
creating a tripping hazard or exposing  
the Power Cord to possible damage.  
The Power Cord must reach the work  
area with enough extra length to allow  
free movement while working.  
Turn the Power Switch (11) off  
and unplug the Polisher from its  
electrical outlet before  
performing any inspection,  
maintenance, or cleaning  
procedures.  
3. Secure loose work pieces using a vise  
or clamps (not included) to prevent  
movement while working.  
To attach The Polishing Bonnet, Foam  
Bonnet, and Sanding disc:  
FOaM  
BONNET  
(53)  
4. There must not be hazardous objects,  
such as utility lines or foreign objects,  
nearby that will present a hazard while  
working.  
FIguRE a  
5. Make sure to read and understand all  
instructions and safety precautions as  
outlined in the manufacturer’s manual for  
the object you will polish or sand.  
6. If waxing and polishing, make sure the  
object being waxed and polished is free  
from burrs and any other foreign matter  
which could damage the Bonnets (52,  
53).  
SaNdINg  
dISC (54)  
POLISHINg  
BONNET (52)  
1. The face of the Mounting Disc (51) and  
backs of the Polishing Bonnet (52),  
Foam Bonnet (53), and Sanding Disc  
(54) have a “hook-and-loop” design.  
(See Figures a and B.)  
2. To attach the Polishing Bonnet , Foam  
Bonnet, or Sanding Disc to the Mounting  
Disc simply press the accessory firmly  
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general Operating Instructions  
FIguRE C  
To Wax an Object:  
1. Attach the Foam Bonnet (53) to the  
Mounting Disc (51) as previously  
discussed in this manual.  
dISPLaY  
(10)  
POWER  
SWITCH (11)  
NOTE: Prior to waxing an object, make sure  
the surface has been thoroughly cleaned  
and is free of dust, dirt, oil, grease, etc.  
– SPEEd  
BuTTON (12)  
+ SPEEd  
BuTTON (13)  
2. Apply about two tablespoons of polishing  
liquid or wax (not included) evenly on  
the Foam Bonnet (53). Do not apply  
the polishing liquid or wax directly to  
the object’s surface. The amount of  
polishing liquid or wax needed will vary  
according to the object’s size. Avoid  
using too much polishing liquid or  
wax. The Foam Bonnet will not absorb  
as much polishing liquid or wax in  
subsequent applications.  
6. Increase the tool’s speed by pressing  
the + Speed Button (13). Decrease the  
tool’s speed by pressing the – Speed  
Button (13). (See Figure C.)  
7. The Display (10) will indicate the tool’s  
speed.  
NOTE: When first applying wax to the object,  
start the tool at its lowest speed to avoid  
throwing wax off the Foam Bonnet (53).  
Then increase the speed as needed.  
3. Plug the Power Cord (5) into the nearest  
120 volt, grounded, electrical outlet.  
4. In order to keep the Power Cord (5) out  
of the way, hang it over your shoulder.  
8. Begin applying polishing liquid or wax  
to the object. Apply the polishing liquid  
or wax to all flat surfaces with broad  
sweeping strokes in a figure eight  
pattern. Apply the polishing liquid or wax  
evenly over the surface of the object,  
and add additional polishing liquid or wax  
as needed.  
IMPORTaNT: Start and stop the Polisher  
only while it is held firmly against the  
surface of the object being waxed.  
Failure to do so may result in the Foam  
Bonnet (53) being thrown from the  
Mounting Disc (51).  
9. After the polishing liquid or wax has been  
applied to the object’s surface, turn the  
Power Switch (11) to its “OFF” position.  
Then unplug the Power Cord (5).  
(See Figure C.)  
5. Grip the Polisher firmly with both hands.  
Then turn the Power Switch (11) to its  
“ON” position. (See Figure C.)  
10. Remove the Foam Bonnet (53) from  
the Mounting Disc (51). With the Foam  
Bonnet in your hand, apply the polishing  
liquid or wax to all hard to reach areas of  
the object. (See Figures a and B.)  
REV 10b  
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11. Allow sufficient time for the polishing  
9. Remove the Polishing Bonnet (52)  
from the Mounting Disc (51). With the  
Polishing Bonnet in your hand, remove  
the polishing liquid or wax from all hard  
to reach areas of the object.  
liquid or wax to dry on the object.  
To Polish an Object:  
1. Attach the Polishing Bonnet (52) to  
the Mounting Disc (51) as previously  
discussed in this manual.  
(See Figures a and B.)  
To Sand an Object:  
(See Figures a and B.)  
1. Attach the Sanding Disc (54) to the  
Mounting Disc (51) as previously  
discussed in this manual.  
2. Plug the Power Cord (5) into the nearest  
120 volt, grounded, electrical outlet.  
(See Figures a and B.)  
3. In order to keep the Power Cord (5) out  
of the way, hang it over your shoulder.  
2. Plug the Power Cord (5) into the nearest  
120 volt, grounded, electrical outlet.  
IMPORTaNT: Start and stop the Polisher only  
while it is held firmly against the surface  
of the object being polished. Failure to  
do so may result in the Polishing Bonnet  
(52) being thrown from the Mounting  
Disc (51).  
3. In order to keep the Power Cord (5) out  
of the way, hang it over your shoulder.  
4. Grip the Polisher firmly with both hands.  
Then turn the Power Switch (11) to its  
“ON” position. (See Figure C.)  
4. Grip the Polisher firmly with both hands.  
Then turn the Power Switch (11) to its  
“ON” position. (See Figure C.)  
5. Increase the tool’s speed by pressing  
the + Speed Button (13). Decrease the  
tool’s speed by pressing the – Speed  
Button (13). (See Figure C.)  
5. Increase the tool’s speed by pressing  
the + Speed Button (13). Decrease the  
tool’s speed by pressing the – Speed  
Button (13). (See Figure C.)  
6. The Display (10) will indicate the tool’s  
speed.  
6. The Display (10) will indicate the tool’s  
speed.  
7. Once the Sanding Disc (54) is turning  
at the desired speed, sand the object  
evenly with gentle, broad, sweeping  
strokes in a criss-cross pattern.  
7. Begin polishing the object by lightly  
buffing off the polishing liquid or wax  
residue in broad sweeping strokes in a  
figure eight pattern. Continue polishing  
until all the residue is removed.  
8. During the sanding process, it may  
be necessary to occasionally stop the  
Polisher, disconnect it from its electrical  
outlet, remove the worn sandpaper and  
replace with new sandpaper.  
IMPORTaNT: Apply minimal pressure on the  
Polisher to avoid damaging the surface  
of the object.  
9. When the sanding process is complete,  
turn the Power Switch (11) to its “OFF”  
position. Then unplug the Power Cord  
(5). (See Figure C.)  
8. After the polishing liquid or wax has  
been removed from the object’s surface,  
slide the Power Switch (11) to its “OFF”  
position. Then unplug the Power Cord  
(5). (See Figure C.)  
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3. CARBON BRUSH MAINTENANCE:  
IMPORTaNT: Cleaning or replacing  
the Carbon Brushes (19) should  
only be done by a qualified service  
technician.  
MaINTENaNCE aNd  
SERVICINg  
Procedures not specifically  
explained in this manual must  
be performed only by a qualified  
technician.  
a. The Carbon Brushes (19) may  
require maintenance when the motor  
performance of the tool decreases or  
stops working completely. To maintain  
the Brushes:  
TO PREVENT  
SERIOuS INjuRY  
FROM aCCIdENTaL  
b. First remove Right and Left Handles  
OPERaTION:  
(2,9).  
Turn the Power Switch (11) off  
and unplug the Polisher from its  
electrical outlet before  
performing any inspection,  
maintenance, or cleaning  
procedures.  
c. Remove the two Carbon Brushes (19)  
from the housing. Keep track of which  
orientation the old Carbon Brushes  
were in to prevent needless wear if they  
will be reinstalled.  
d. If either Carbon Brush (19) is worn  
down by more than 1/2, replace both  
Carbon Crushes.  
TO PREVENT SERIOuS INjuRY  
FROM TOOL FaILuRE:  
do not use damaged equipment.  
If abnormal noise or vibration  
occurs, have the problem  
e. To clean old Carbon Brushes (19)  
before reusing them, rub the contact  
areas with a pencil eraser.  
corrected before further use.  
f. Reinsert the old Carbon Brushes (19) in  
the same orientation to reduce wear.  
Inspection, Maintenance, and  
Cleaning  
g. When installing the Carbon Brushes  
(19), make sure the carbon portions of  
the Carbon Brushes contact the Motor  
Armature, and that the Springs face  
away from the Motor. Also, make sure  
the Springs operate freely.  
1. BEFORE EACH USE, inspect the  
general condition of the Polisher.  
Check for loose screws, misalignment  
or binding of moving parts, cracked or  
broken parts, damaged electrical wiring,  
and any other condition that may affect  
its safe operation.  
Note: New Carbon Brushes (19) tend to  
spark when first used until they wear and  
conform to the Motor’s Armature.  
2. AFTER USE, clean external surfaces  
of the tool with clean cloth. do not  
immerse any part of the tool in liquid.  
Remove the Bonnet (52, 53) from the  
tool when not in use. This will allow  
the Bonnet to dry and retain its original  
shape. The Bonnets may be machine-  
washed in cold water with detergent.  
Then machine-dry the Bonnets at  
medium heat.  
4.  
WaRNINg! If the Power Cord (5) of  
this Polisher is damaged, it must be  
replaced only by a qualified service  
technician.  
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Troubleshooting  
Problem  
Tool will not start.  
Possible Causes  
1. Cord not connected.  
Likely Solutions  
1. Check that cord is plugged in.  
2. No power at outlet.  
2. Check power at outlet. If outlet is  
unpowered, turn off tool and check circuit  
breaker. If breaker is tripped, make sure  
circuit is right capacity for tool and circuit  
has no other loads.  
3. Internal damage or wear. (Carbon  
brushes or switch, for example.)  
3. Have technician service tool.  
Tool operates slowly. 1. Excess pressure applied to workpiece. 1. Decrease pressure, allow tool to do the  
work.  
2. Power being reduced by long or small 2. Eliminate use of extension cord. If an  
diameter extension cord.  
extension cord is needed, use one with  
the proper diameter for its length and load.  
See Extension Cords in GROUNDING  
section.  
Performance  
Carbon brushes worn or damaged.  
Have qualified technician replace brushes.  
decreases over time.  
Excessive noise or Internal damage or wear. (Carbon  
Have technician service tool.  
rattling.  
Overheating.  
brushes or bearings, for example.)  
1. Forcing tool to work too fast.  
1. Allow tool to work at its own rate.  
2. Blocked motor housing vents.  
2. Wear ANSI-approved safety goggles and  
NIOSH-approved dust mask/respirator  
while blowing dust out of motor using  
compressed air.  
3. Motor being strained by long or small  
diameter extension cord.  
3. Eliminate use of extension cord. If an  
extension cord is needed, use one with  
the proper diameter for its length and load.  
See Extension Cords in GROUNDING  
section.  
Polishing Bonnet  
does not remove all  
of the polishing liquid  
or wax.  
1. Too much polishing liquid or wax has  
been applied.  
1. Reduce the amount of polishing liquid or  
wax used.  
2. Bonnet saturated.  
2. Use a clean bonnet.  
Tool not properly  
sanding.  
1. Sandpaper is dull.  
1. Replace sandpaper.  
2. Wrong grit of sandpaper used.  
2. Change sandpaper to a finer or coarser grit  
depending on the job.  
Follow all safety precautions whenever diagnosing or servicing the tool.  
disconnect power supply before service.  
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PLEaSE REad THE FOLLOWINg CaREFuLLY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLy  
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLy. NEITHER THE MANUFACTURER OR  
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE  
OR SHE IS qUALIFIED TO MAkE ANy REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS qUALIFIED  
TO REPLACE ANy PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR  
ExPRESSLy STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAkEN By  
CERTIFIED AND LICENSED TECHNICIANS, AND NOT By THE BUyER. THE BUyER ASSUMES ALL RISk  
AND LIABILITy ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT  
PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.  
PaRTS LIST  
Part  
1
description  
Qty.  
5
1
1
1
1
1
2
1
1
1
1
1
1
4
2
2
2
2
1
1
1
1
2
1
1
3
Part  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
description  
Bracket  
Qty.  
1
1
1
4
1
1
1
1
1
1
1
1
3
3
1
1
1
4
4
1
1
1
1
1
1
Screw  
2
Right Handle  
Circuit Board  
Power Cord & Plug  
Cord Stress Relief  
Cord Retaining Bracket  
Screw  
Front Bearing  
Gear Box  
4
5
Screw  
6
Spindle Lock  
Spring  
7
8
Auxiliary Handle  
Oil Seal  
9
Left Handle  
Display  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
22  
23  
24  
25  
26  
27  
28  
29  
Retaining Ring  
Washer  
Power Switch  
– Speed Button  
+ Speed Button  
Control Cover  
Screw  
Retaining Ring  
Large Gear  
Screw  
Washer  
Bracket  
Fixed Board  
Bearing  
Brush Holder  
Brush Sheath  
Carbon Brush  
Motor Housing  
Stator  
Connecting Board  
Washer  
Screw  
Key  
Bearing Holder  
Rear Bearing  
Screw  
Spindle  
Mounting Disc  
Polishing Bonnet  
Foam Bonnet  
Sanding Disc  
Bushing  
Rotor  
Screw  
REV 10b  
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aSSEMBLY dIagRaM  
33  
34  
Record Product’s Serial Number Here:  
Note: If product has no serial number, record month and year of purchase instead.  
Note: Some parts are listed and shown for illustration purposes only, and are not available  
individually as replacement parts.  
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To take advantage of this warranty,  
the product or part must be returned to us  
with transportation charges prepaid. Proof  
of purchase date and an explanation of the  
complaint must accompany the merchandise.  
If our inspection verifies the defect, we  
will either repair or replace the product at  
our election or we may elect to refund the  
purchase price if we cannot readily and  
quickly provide you with a replacement. We  
will return repaired products at our expense,  
but if we determine there is no defect, or that  
the defect resulted from causes not within the  
scope of our warranty, then you must bear the  
cost of returning the product.  
LIMITEd 90 daY WaRRaNTY  
Harbor Freight Tools Co. makes every  
effort to assure that its products meet  
high quality and durability standards, and  
warrants to the original purchaser that this  
product is free from defects in materials and  
workmanship for the period of 90 days from  
the date of purchase. This warranty does not  
apply to damage due directly or indirectly,  
to misuse, abuse, negligence or accidents,  
repairs or alterations outside our facilities,  
criminal activity, improper installation, normal  
wear and tear, or to lack of maintenance. We  
shall in no event be liable for death, injuries  
to persons or property, or for incidental,  
contingent, special or consequential damages  
arising from the use of our product. Some  
states do not allow the exclusion or limitation  
of incidental or consequential damages,  
so the above limitation of exclusion may  
not apply to you. THIS WARRANTY IS  
ExPRESSLy IN LIEU OF ALL OTHER  
WARRANTIES, ExPRESS OR IMPLIED,  
INCLUDING THE WARRANTIES OF  
This warranty gives you specific legal  
rights and you may also have other rights  
which vary from state to state.  
3491 Mission Oaks Blvd. • PO Box 6009  
Camarillo, CA 93011 • (800) 444-3353  
MERCHANTABILITy AND FITNESS.  
Page 18  
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