Chicago Electric 66615 Installation 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

Page 2 For technical questions, please call 1-800-444-3353. SKU 66615
SAVE THIS MANUAL
Keep this manual for the safety warnings
and precautions, assembly, operating,
inspection, maintenance and cleaning
procedures. Write the product’s serial number
in the back of the manual near the assembly
diagram (or month and year of purchase if
product has no number). Keep this manual
and the receipt in a safe and dry place for
future reference.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling, and
all other information provided with
this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that follow
this symbol to avoid possible
injury or death.
DANGER indicates a
hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING indicates a
hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION, used with
the safety alert
symbol, indicates a hazardous
situation which, if not avoided,
could result in minor or moderate
injury.
NOTICE is used to
address practices not
related to personal injury.
CAUTION, without the
safety alert symbol, is
used to address practices not
related to personal injury.
General Power Tool Safety Warnings
WARNING Read all safety warnings
and 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.
The term ″power tool″ in the warnings
refers to your mains-operated (corded)
power tool or battery-operated
(cordless) power tool.
Work area safety1.
Keep work area clean and well lit.a.
Cluttered or dark areas invite accidents.
Do not operate power tools inb.
explosive atmospheres, such as in the
presence of ammable liquids, gases
or dust. Power tools create sparks
which may ignite the dust or fumes.
Keep children and bystandersc.away while operating a power tool.
Distractions can cause you to lose
control.
Electrical safety2.
Power tool plugs must match thea.
outlet. Never modify the plug in
any way. Do not use any adapter
plugs with grounded power tools.
Unmodied plugs and matching outlets
will reduce risk of electric shock.
Avoid body contact with groundedb.
surfaces such as pipes, radiators,
ranges and refrigerators. There is an
REV 10b

Page 3For technical questions, please call 1-800-444-3353.SKU 66615
increased risk of electric shock if your
body is grounded.
Do not expose power tools to rain orc.wet conditions. Water entering a power
tool will increase the risk of electric
shock.
Do not abuse the cord. Never used.
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 toole.
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 dampf. location is unavoidable, use a Ground
Fault Circuit Interrupter (GFCI)
protected supply. Use of a GFCI
reduces the risk of electric shock.
Personal safety3.
Stay alert, watch what you area.
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 safety equipment. Always wearb.
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.
Prevent unintentional starting. Ensurec.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.
Remove any adjusting key or wrenchd.
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 propere.
footing and balance at all times. This
enables better control of the power tool
in unexpected situations.
Dress properly. Do not wear loosef. clothing or jewelry. Keep your hair,
clothing and gloves away from
moving parts. Loose clothes, jewelry or
long hair can be caught in moving parts.
If devices are provided for theg.
connection of dust extraction and
collection facilities, ensure these are
connected and properly used. Use of
these devices can reduce dust-related
hazards.
Only use safety equipment that hash.
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 specic
hazards in the work area.
Power tool use and care4.
Do not force the power tool. Usea.
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 theb.
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 powerc.source and/or the battery pack from
REV 10b

Page 4 For technical questions, please call 1-800-444-3353. SKU 66615
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 reachd.
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 fore.
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.f.
Properly maintained cutting tools with
sharp cutting edges are less likely to
bind and are easier to control.
Use the power tool, accessories andg.
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.
Service5.
Have your power tool serviced by aa.
qualied 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
This power tool is intended to1. function as a sander or polisher. Read
all safety warnings, instructions,
illustrations and specications
provided with this power tool. Failure
to follow all instructions listed below

serious injury.
Operations such as grinding, wire2. 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.
Do not use accessories which3.
are not specically designed
and recommended by the tool
manufacturer. Just because the
accessory can be attached to your power
tool, it does not assure safe operation.
The rated speed of the accessory4. must be at least equal to the
maximum speed marked on the power
tool. Accessories running faster than

apart.
The outside diameter and the5. thickness of your accessory must
be within the capacity rating of
your power tool. Incorrectly sized
accessories cannot be adequately
guarded or controlled.
The arbor size of wheels, anges, 6. backing pads or any other accessory
must properly t 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.
Do not use a damaged accessory.7. Before each use inspect the
accessory such as abrasive wheels
for chips and cracks, backing pad
REV 10b

Page 5For technical questions, please call 1-800-444-3353.SKU 66615
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.
Wear personal protective equipment.8. 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 ying debris
generated by various operations.
The eye protection must be capable

various operations. The dust mask or

particles generated by your operation.
Prolonged exposure to high intensity
noise may cause hearing loss.
Keep bystanders a safe distance away9. from work area. Anyone entering
the work area must wear personal
protective equipment. Fragments of
work piece or of a broken accessory

immediate area of operation.
Hold power tool by insulated gripping10. surfaces only, when performing an
operation where the accessory may
contact hidden wiring or its own cord.

may make exposed metal parts of the

Position the cord clear of the spinning11. accessory. If you lose control, the cord
may be cut or snagged and your hand
or arm may be pulled into the spinning
accessory.
Never lay the power tool down until12. the accessory has come to a complete
stop. The spinning accessory may grab
the surface and pull the power tool out of
your control.
Do not run the power tool while13. carrying it at your side. Accidental
contact with the spinning accessory
could snag your clothing, pulling the
accessory into your body.
Regularly clean the power tool’s air14. vents. The motor’s fan will draw the
dust inside the housing and excessive
accumulation of powdered metal may
cause electrical hazards.
Do not operate the power tool near15.
ammable materials. Sparks could
ignite these materials.
Do not use accessories that require16. liquid coolants. Using water or other
liquid coolants may result in electrocution
or shock.
Maintain labels and nameplates on17. the tool. These carry important safety
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
Avoid unintentional starting. Prepare to18. begin work before turning on the tool.
Do not depress the spindle lock when19. starting or during operation.
Do not leave the tool unattended when20. it is plugged into an electrical outlet.
Turn off the tool, and unplug it from its
electrical outlet before leaving.
REV 10b

Page 6 For technical questions, please call 1-800-444-3353. SKU 66615
Use clamps (not included) or other21. 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.
This product is not a toy. Keep it out of22. reach of children.
People with pacemakers should23. consult their physician(s) before use.

to heart pacemaker could cause
pacemaker interference or pacemaker
failure. In addition, people with
pacemakers should:


on.

electrical shock.

grounded. Ground Fault Circuit
Interrupter (GFCI) should also be
implemented – it prevents sustained
electrical shock.
WARNING: Some dust created by power24. sanding, sawing, grinding, drilling, and
other construction activities, contains
chemicals known [to the State of
California] to cause cancer, birth defects
or other reproductive harm. Some
examples of these chemicals are:


cement or other masonry products

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

microscopic particles. (California Health
& Safety Code § 25249.5, et seq.)
WARNING: Handling the cord on this25. 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.)
The warnings, precautions, and26. 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.
Kickback and Related Warnings
Kickback is a sudden reaction to a
pinched or snagged rotating wheel, backing
pad, brush or any other accessory. Pinching
or snagging causes rapid stalling of the
rotating accessory which in turn causes the
uncontrolled power tool to be forced in the
direction opposite of the accessory’s rotation
at the point of the binding.
For example, if an abrasive wheel is
snagged or pinched by the workpiece, the
edge of the wheel that is entering into the
pinch point can dig into the surface of the
material causing the wheel to climb out or
kick out. The wheel may 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.
Kickback is the result of power tool

or conditions and can be avoided by taking
proper precautions as given below.
REV 10b

Page 7For technical questions, please call 1-800-444-3353.SKU 66615
Maintain a rm grip on the power 1. tool and position your body and
arm to allow you to resist kickback
forces. Always use auxiliary handle, if
provided, for maximum control over
kickback or torque reaction during
start-up. The operator can control
torque reactions or kickback forces, if
proper precautions are taken.
Never place your hand near the2. rotating accessory. Accessory may
kickback over your hand.
Do not position your body in the3. area where power tool will move
if kickback occurs. Kickback will
propel the tool in direction opposite to
the wheel’s movement at the point of
snagging.
Use special care when working4. 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.
Do not attach a saw chain5. woodcarving blade or toothed saw
blade. Such blades create frequent
kickback and loss of control.
Safety Warnings Specic for
Sanding Operations
Do not use excessively oversized1. 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.
Safety Warnings Specic for
Polishing Operations
Do not allow any loose portion of the1. 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 ngers or snag on the
workpiece.
If waxing and polishing, make sure the2. object being polished is free from burrs
and other foreign matter which could
damage the Bonnets (52, 53).
Vibration Safety
This tool vibrates during use. Repeated

temporary or permanent physical injury,
particularly to the hands, arms and shoulders.

Anyone using vibrating tools regularly1.

be examined by a doctor and then have

medical problems are not being caused
or worsened from use. Pregnant
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

soon as possible.
Do not smoke during use. Nicotine2. reduces the blood supply to the hands


Wear suitable gloves to reduce the3. vibration effects on the user.
REV 10b

Page 8 For technical questions, please call 1-800-444-3353. SKU 66615
Use tools with the lowest vibration when4. there is a choice between different
processes.
5. of work.
Grip tool as lightly as possible (while still6.

do the work.
To reduce vibration, maintain the tool7. as explained in this manual. If any
abnormal vibration occurs, stop use
immediately.
SAVE THESE
INSTRUCTIONS.
GROUNDING
TO PREVENT
ELECTRIC SHOCK
AND DEATH FROM INCORRECT
GROUNDING WIRE
CONNECTION:
Check with a qualied 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 t
the outlet, have a proper outlet
installed by a qualied
electrician.
Double Insulated Tools: Tools with
Two Prong Plugs
Outlets for 2-Prong Plug
Tools marked “Double Insulated” do not1. require grounding. They have a special

OSHA requirements and complies with
the applicable standards of Underwriters

Standard Association, and the National
Electrical Code.
Double insulated tools may be used in2. either of the 120 volt outlets shown in the
preceding illustration.
(See Outlets for 2-Prong Plug.)
Extension Cords
Grounded1. tools require a three wire
extension cord. Double Insulated
tools can use either a two or three wire
extension cord.
As the distance from the supply outlet2. 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.)
The smaller the gauge number of the3. 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

Page 9For technical questions, please call 1-800-444-3353.SKU 66615
When using more than one extension4. cord to make up the total length, make
sure each cord contains at least the
minimum wire size required.
(See Table A.)
If you are using one extension cord for5. more than one tool, add the nameplate
amperes and use the sum to determine
the required minimum cord size.
(See Table A.)
If you are using an extension cord6. outdoors, make sure it is marked with the

is acceptable for outdoor use.
Make sure the extension cord is properly7. wired and in good electrical condition.
Always replace a damaged extension

electrician before using it.
Protect the extension cords from sharp8. objects, excessive heat, and damp or
wet areas.
RECOMMENDED MINIMUM WIRE GAUGE
FOR EXTENSION CORDS* (120/240 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD
LENGTH
25’ 50’ 75’ 100’ 150’
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 
12.1 – 16.0 14 12 10  
16.1 – 20.0 12 10 
TABLE A * Based on limiting the line
voltage drop to ve volts at 150%
of the rated amperes.
Symbology
Double Insulated
Canadian Standards Association

V~ Volts Alternating Current
AAmperes
n0 
(RPM)
REV 10b

Page 10 For technical questions, please call 1-800-444-3353. SKU 66615
SPECIFICATIONS
 
No load speed 1000~3500 RPM
Maximum Accessory Size 7” Diameter
Mounting Disc Type 
Variable Speed Switch 
Display Unit of Measure RPM x 100
Accessories Polishing Bonnet
Foam Bonnet

UNPACKING
When unpacking, make sure that the
item is intact and undamaged. If any parts
are missing or broken, please call Harbor

possible.
INSTRUCTIONS FOR PUTTING
INTO USE
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.
ASSEMBLY
FIGURE B
SPINDLE
LOCK (34)
MOUNTING
DISC (51)
AUXILIARY HANDLE (36)
GEAR BOX
(32)
1. To attach the Mounting Disc (51) to the
Polisher, press and hold the Spindle

onto the Spindle (50) of the tool. Then

To attach the Auxiliary Handle (36),2.

mounting hole located on either side of
the Gear Box (32).

Page 11For technical questions, please call 1-800-444-3353.SKU 66615
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.
Tool Set Up
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch (11) off
and unplug the Polisher from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
To Attach The Polishing Bonnet, Foam
Bonnet, And Sanding Disc:
FIGURE A
FOAM
BONNET
(53)
POLISHING
BONNET (52)
SANDING
DISC (54)
1. The face of the Mounting Disc (51) and
backs of the Polishing Bonnet (52),
Foam Bonnet (53), and Sanding Disc

(See Figures A and B.)
To attach the Polishing Bonnet , Foam2. Bonnet, or Sanding Disc to the Mounting

onto the Mounting Disc.
(See Figures A and B.)
Make sure the accessory is placed3. evenly on the Mounting Disc and is
secure before turning on the tool.
Work Piece and Work Area Set Up
Designate a work area that is clean and1.

access by children or pets to prevent
injury and distraction.
Route the Power Cord (5) along a safe2. 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.
Secure loose work pieces using a vise3. or clamps (not included) to prevent
movement while working.
There must not be hazardous objects,4. such as utility lines or foreign objects,
nearby that will present a hazard while
working.
Make sure to read and understand all5. instructions and safety precautions as
outlined in the manufacturer’s manual for
the object you will polish or sand.
If waxing and polishing, make sure the6. object being waxed and polished is free
from burrs and any other foreign matter
which could damage the Bonnets (52,
53).

Page 12 For technical questions, please call 1-800-444-3353. SKU 66615
General Operating Instructions
To Wax An Object:
Attach the Foam Bonnet (53) to the1. Mounting Disc (51) as previously
discussed in this manual.
NOTE: Prior to waxing an object, make sure
the surface has been thoroughly cleaned
and is free of dust, dirt, oil, grease, etc.
Apply about two tablespoons of polishing2. 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.
Plug the Power Cord (5) into the nearest3. 120 volt, grounded, electrical outlet.
In order to keep the Power Cord (5) out4. of the way, hang it over your shoulder.
IMPORTANT: Start and stop the Polisher

surface of the object being waxed.
Failure to do so may result in the Foam
Bonnet (53) being thrown from the
Mounting Disc (51).
5. Then turn the Power Switch (11) to its
“ON” position. (See Figure C.)
DISPLAY
(10)
POWER
SWITCH (11)
– SPEED
BUTTON (12) + SPEED
BUTTON (13)
FIGURE C
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.)
The Display (10) will indicate the tool’s7. speed.
NOTE: 
start the tool at its lowest speed to avoid
throwing wax off the Foam Bonnet (53).
Then increase the speed as needed.
Begin applying polishing liquid or wax8. to the object. Apply the polishing liquid


pattern. Apply the polishing liquid or wax
evenly over the surface of the object,
and add additional polishing liquid or wax
as needed.
After the polishing liquid or wax has been9. applied to the object’s surface, turn the
Power Switch (11) to its “OFF” position.
Then unplug the Power Cord (5).
(See Figure C.)
Remove the Foam Bonnet (53) from10. 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

Page 13For technical questions, please call 1-800-444-3353.SKU 66615
11. liquid or wax to dry on the object.
To Polish An Object:
Attach the Polishing Bonnet (52) to1. the Mounting Disc (51) as previously
discussed in this manual.
(See Figures A and B.)
Plug the Power Cord (5) into the nearest2. 120 volt, grounded, electrical outlet.
In order to keep the Power Cord (5) out3. of the way, hang it over your shoulder.
IMPORTANT: Start and stop the Polisher only

of the object being polished. Failure to
do so may result in the Polishing Bonnet
(52) being thrown from the Mounting
Disc (51).
4. Then turn the Power Switch (11) to its
“ON” position. (See Figure C.)
Increase the tool’s speed by pressing5. the + Speed Button (13). Decrease the
tool’s speed by pressing the – Speed
Button (13). (See Figure C.)
The Display (10) will indicate the tool’s6. speed.
Begin polishing the object by lightly7.

residue in broad sweeping strokes in a

until all the residue is removed.
IMPORTANT: Apply minimal pressure on the
Polisher to avoid damaging the surface
of the object.
After the polishing liquid or wax has8. 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.)
Remove the Polishing Bonnet (52)9. 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.
(See Figures A and B.)
To Sand An Object:
Attach the Sanding Disc (54) to the1. Mounting Disc (51) as previously
discussed in this manual.
(See Figures A and B.)
Plug the Power Cord (5) into the nearest2. 120 volt, grounded, electrical outlet.
In order to keep the Power Cord (5) out3. of the way, hang it over your shoulder.
4. Then turn the Power Switch (11) to its
“ON” position. (See Figure C.)
Increase the tool’s speed by pressing5. the + Speed Button (13). Decrease the
tool’s speed by pressing the – Speed
Button (13). (See Figure C.)
The Display (10) will indicate the tool’s6. speed.
Once the Sanding Disc (54) is turning7. at the desired speed, sand the object
evenly with gentle, broad, sweeping

During the sanding process, it may8. be necessary to occasionally stop the
Polisher, disconnect it from its electrical
outlet, remove the worn sandpaper and
replace with new sandpaper.
When the sanding process is complete,9. turn the Power Switch (11) to its “OFF”
position. Then unplug the Power Cord
(5). (See Figure C.)

Page 14 For technical questions, please call 1-800-444-3353. SKU 66615
MAINTENANCE AND
SERVICING
Procedures not specically
explained in this manual must
be performed only by a qualied
technician.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch (11) off
and unplug the Polisher from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
TO PREVENT SERIOUS INJURY
FROM TOOL FAILURE:
Do not use damaged equipment.
If abnormal noise or vibration
occurs, have the problem
corrected before further use.
Inspection, Maintenance, and
Cleaning
BEFORE EACH USE, inspect the1. 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.
AFTER USE,2. 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

washed in cold water with detergent.

medium heat.
CARBON BRUSH MAINTENANCE:3. IMPORTANT: Cleaning or replacing
the Carbon Brushes (19) should
only be done by a qualied service
technician.
The Carbon Brushes (19) maya. require maintenance when the motor
performance of the tool decreases or
stops working completely. To maintain
the Brushes:
b. (2,9).
Remove the two Carbon Brushes (19)c. from the housing. Keep track of which
orientation the old Carbon Brushes
were in to prevent needless wear if they
will be reinstalled.
If either Carbon Brush (19) is wornd.
both
Carbon Crushes.
To clean old Carbon Brushes (19)e. before reusing them, rub the contact
areas with a pencil eraser.
Reinsert the old Carbon Brushes (19) inf. the same orientation to reduce wear.
When installing the Carbon Brushesg. (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.
Note: New Carbon Brushes (19) tend to

conform to the Motor’s Armature.
4. WARNING! If the Power Cord (5) of
this Polisher is damaged, it must be
replaced only by a qualied service
technician.

Page 15For technical questions, please call 1-800-444-3353.SKU 66615
Troubleshooting
Problem Possible Causes Likely Solutions
Tool will not start. Cord not connected.1.
No power at outlet.2.
Internal damage or wear. (Carbon3. brushes or switch, for example.)
Check that cord is plugged in.1.
Check power at outlet. If outlet is2. 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.
Have technician service tool.3.
Tool operates slowly. Excess pressure applied to workpiece.1.
Power being reduced by long or small2. diameter extension cord.
Decrease pressure, allow tool to do the1. work.
Eliminate use of extension cord. If an2. extension cord is needed, use one with
the proper diameter for its length and load.
See Extension Cords in GROUNDING
section.
Performance
decreases over time. Carbon brushes worn or damaged. 
Excessive noise or
rattling. Internal damage or wear. (Carbon brushes or bearings, for example.) Have technician service tool.
Overheating. Forcing tool to work too fast.1.
Blocked motor housing vents.2.
Motor being strained by long or small3. diameter extension cord.
Allow tool to work at its own rate.1.
2.

while blowing dust out of motor using
compressed air.
Eliminate use of extension cord. If an3. 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.
Too much polishing liquid or wax has1. been applied.
Bonnet saturated.2.
Reduce the amount of polishing liquid or1. wax used.
Use a clean bonnet.2.
Tool not properly
sanding. Sandpaper is dull.1.
Wrong grit of sandpaper used.2.
Replace sandpaper.1.
2. depending on the job.
Follow all safety precautions whenever diagnosing or servicing the tool.
Disconnect power supply before service.

Page 16 For technical questions, please call 1-800-444-3353. SKU 66615
Part Description Qty.
1 Screw 5
2 Right Handle 1
4 Circuit Board 1
5 Power Cord & Plug 1
6 Cord Stress Relief 1
7 Cord Retaining Bracket 1
8 Screw 2
9 1
10 Display 1
11 Power Switch 1
12 – Speed Button 1
13 + Speed Button 1
14 Control Cover 1
15 Screw 4
16 Bracket 2
17 Brush Holder 2
18 Brush Sheath 2
19 Carbon Brush 2
22 Motor Housing 1
23 Stator 1
24 Bearing Holder 1
25 Rear Bearing 1
26 Screw 2
27 Bushing 1
28 Rotor 1
29 Screw 3
Part Description Qty.
30 Bracket 1
31 Front Bearing 1
32 Gear Box 1
33 Screw 4
34  1
35 Spring 1
36 Auxiliary Handle 1
37 Oil Seal 1
38 Retaining Ring 1
39 Washer 1
40 Retaining Ring 1
41  1
42 Screw 3
43 Washer 3
44 Fixed Board 1
45 Bearing 1
46 Connecting Board 1
47 Washer 4
48 Screw 4
49 Key 1
50 Spindle 1
51 Mounting Disc 1
52 Polishing Bonnet 1
53 Foam Bonnet 1
54 Sanding Disc 1
PLEASE READ THE FOLLOWING CAREFULLY


DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE






PARTS LIST
REV 10b

Page 17For technical questions, please call 1-800-444-3353.SKU 66615
ASSEMBLY DIAGRAM
34
35
37
38
39
36
40
41
42
43
44
45
46
47
48
49
50
51
52
33
32 31
30
29 28
27
19
18
17
16
15
1
2
14
13
12
4
11
10
9
22
23
24
25
26
8
7
6
5
Foam Bonnet (53) not shown.
Sanding Disc (54) not shown.
(See Figure A, page 9.)
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.

Page 18 For technical questions, please call 1-800-444-3353. SKU 66615
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




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.

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.

rights and you may also have other rights
which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009
Camarillo, CA 93011 • [phone]