Chicago Electric CHICAGO 46507 User manual

7” POLISHER/SANDER
Model 46507
ASSEMBLY AND
OPERATING INFORMATION
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at http://www.harborfreight.com
Copyright 2001 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.
For technical questions please call 1-800-444-3353
®

SPECIFICATIONS TABLE
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance, and cleaning procedures, parts list and
assembly diagram. Keep your invoice with this manual. Write the invoice
number on the inside of the front cover. Keep this manual and invoice in a safe
and dry place for future reference.
GENERAL SAFETY WARNINGS AND PRECAUTIONS
1. KEEP WORK AREA CLEAN AND DRY. Cluttered, damp or wet work areas
invite injuries.
2. KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handle
this product.
3. STORE IDLE EQUIPMENT. When not in use, tools and equipment should be
stored in a dry location to inhibit rust. Always lock up tools and equipment and
keep out of reach of children.
4. DO NOT USE THIS PRODUCT IF UNDERTHE INFLUENCE OF ALCOHOL OR
DRUGS. Read warning labels on prescriptions to determine if your judgment or
reflexes are impaired while taking drugs. If there is any doubt, do not attempt to
use this product.
5. USE EYE, BREATHING, AND HEARING PROTECTION. Wear ANSI approved
safety impact eye glasses, ANSI approved breathing protection, and ANSI
approved hearing protection when using this product. ANSI approved safety
impact eye glasses, dust masks, and hearing protectors are available from
Harbor Freight Tools.
SKU 46507 PAGE 2
Item Description
Electrical
Requirements 120V / 60 Hz / 11 Load Amp Double Insulated Motor
1,000 - 3,000 RPM Variable Speed
16 Gauge Power Cord
Spindle Thread 5/8”-11 Threads Per Inch
Handle Mounting Threaded, 3 Positions
Wool Cover Size 8”
Tool Length 17”
Tool Weight 8.40 Lbs. With Wool Cover
96GA
E210256
Rev 12/01

6. DRESS SAFELY. Non-skid footwear or safety shoes should be used when
working with this product. Do not wear loose clothing or jewelry as they can
become caught in moving parts. Wear a protective hair covering to prevent long
hair from becoming caught in moving parts. If wearing a long-sleeve shirt, roll
sleeves up above elbows.
7. INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.
8. DO NOT OVERREACH. Keep proper footing and balance at all times to prevent
tripping, falling, back injury, etcetera.
9. STAY ALERT. Watch what you are doing at all times. Use common sense. Do
not use this product when you are tired or distracted from the job at hand.
10. CHECK FOR DAMAGED PARTS. Before using this product, carefully check that
it will operate properly and perform its intended function. Check for damaged
parts and any other conditions that may affect the operation of this product.
Replace or repair damaged or worn parts immediately.
11. REPLACEMENT PARTS AND ACCESSORIES. When servicing, use only
identical replacement parts. Only use accessories intended for use with this
product. Approved accessories are available from Harbor Freight Tools.
12. MAINTAIN THIS PRODUCT WITH CARE. Keep this tool clean and dry for better
and safer performance.
13. MAINTENANCE: For your safety, service and maintenance should be performed
regularly by a qualified technician.
14. USE THE RIGHT PRODUCT FOR THE RIGHT JOB. There are certain
applications for which this product was designed. Do not use small equipment,
tools or attachments to do the work of larger industrial equipment, tools or
attachments. Do not use this product for a purpose for which it was not intended.
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
1. MAKE SURE THE POWER SWITCH (part #33) IS IN THE “OFF” POSITION
BEFORE PLUGGING IN THE POWER CORD (part #36).
2. DO NOT ABUSE THE POWER CORD. Do not use the Power Cord (part #36) to
pull the Plug from a power outlet. Keep Power Cord away from heat, oil, sharp
edges, and moving parts. Replace a damaged Power Cord immediately. Route
the Power Cord safely. Protect it from being damaged by other equipment in the
work area. Do not route the Power Cord where it can be walked on or tripped
over.
SKU 46507 PAGE 3

3. IFYOU USE AN EXTENSION CORD, MAKE SURE TO USE ONLY UL
APPROVED CORDS HAVING THE CORRECT GAUGE AND LENGTH.
(SEE FIGURE A.)
REQUIRED EXTENSION CORD GAUGE
Nameplate ExtensionCord Length
Amperes 25’ 50’ 75’ 100’ 150’ 200’
0 - 5 16 16 16 14 12 12
5.1 - 8 16 16 14 12 10 -
8.1 - 12 14 14 12 10 - -
12.1 - 15 12 12 10 10 - -
15.1 - 20 10 10 10 - - -
FIGURE A
4. MAINTAIN A SAFE WORK ENVIRONMENT. Do not use this tool in or near
damp or wet areas. Do not expose this product to rain. Keep work area well lit.
Make sure there is adequate surrounding work space. Use this tool in a well
ventilated area. Do not operate this tool in the presence of flammable liquids,
gases, or dust. To avoid accidental electric shock, do not let your body come in
contact with grounded surfaces such as pipes, radiators, ranges and
refrigerators.
5. DO NOT FORCETHE EQUIPMENT. This Polisher/Sander will do the work better
and safer at the speed and capacity for which it was designed.
6. REMOVE ALL ADJUSTING WRENCHES FROMTHE POLISHER/SANDER
BEFORETURNING IT ON.
7. AVOID UNINTENTIONAL STARTING. Make sure you are prepared to begin
work before turning the Power Switch (part #33) “ON”.
8. ALLOWTHE POLISHING DISC (part #44) ANDWOOL COVER (part #45), AS
WELL ASTHE RUBBER BACKING PLATE (#46) WHEN SANDING,TO SPIN
UPTO FULL SPEED BEFORE PRESSINGTHEM ONTOTHE WORKPIECE.
When turning off the Polisher/Sander, allow the Rubber Backing Plate or Polish-
ing Disc to spin down and stop on their own. Do not press against to stop them.
9. DO NOT FORCETHE POLISHING DISC (part #44) ANDWOOL COVER (part
#45), RUBBER BACKING PLATE (#46) WITH SANDPAPER DISC ONTOTHE
WORKPIECEWHEN USING. Apply moderate pressure, allowing the Polisher/
Sander to do the work without being forced.
10. MAKE SURETHE WORKPIECE IS FREE FROM BURRS AND ANY OTHER
FOREIGN OBJECTS WHICH COULD DAMAGE THE POLISHER/SANDER.
SKU 46507 PAGE 4

11. MAKE SURE THE WORKPIECE IS SUPPORTED AT ALL TIMES DURING
OPERATION. Use a Roller Stand (not provided) with larger workpieces if
necessary.
12. MAINTAIN CONTROL OFTHE WORKPIECE AT ALL TIMES. Whenever
possible, secure the workpiece with clamps, in a vise, etcetera.
13. ALWAYS DISCONNECTTHE POLISHER/SANDER FROM ITS ELECTRICAL
SUPPLY SOURCE WHEN NOT IN USE. Make sure to unplug the Polisher/
Sander when leaving the work area, moving the tool from one location to an-
other, handing the Polisher/Sander to another person, changing the Polishing/
Rubber Backing Plate disc.
14. THISTOOL IS INTENDEDTO BE USED ONLY AS A POLISHER AND AS A
SANDER. DO NOT ATTEMPTTO USETHISTOOL AS AN ANGLE GRINDER
OR IN ANY OTHERWAYTHAN ITS INTENDED PURPOSE. NEVER INSTALL
A CARBIDETIPPED OR STEEL CIRCULAR SAW BLADE FOR USE INTHIS
POLISHER/SANDER. NEVER INSTALL A WOOD CARVING BLADE, CARV-
ING DISC WITH CHAIN SAW CUTTERS, OR A CUTTING CARVING DISC ON
THIS POLISHER/SANDER.
15. WARNING: Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities, contain chemicals known (to the State of California)
to cause cancer, birth defects or other reproductive harm. Some examples of
these chemicals are: lead from lead-based paints, crystalline silica from bricks
and cement 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 microscopic particles.
(California Health & Safety Code 25249.5 et seq.)
16. WARNING: People with pacemakers should consult with their physician(s)
before using this product. Operation of equipment in close proximity to a heart
pacemaker could cause interference or failure of the pacemaker.
UNPACKING
When unpacking, check to make sure all parts shown on the Parts List (page 11) are
included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the cover of this manual as soon as possible.
SKU 46507 PAGE 5

ASSEMBLY INSTRUCTIONS
NOTE: For additional references to the parts listed below, refer to the Assembly
Diagram on page 11 of this manual.
To Attach The Polishing Disc And Wool Cover:
1. Caution: Prior to installing the Wool Compounding Bonnet (part #44), make sure
the Polisher/Sander is disconnected from its electrical power source.
2. Place the Adaptor (part #1) on the Spindle (part #3) of the Polisher/Sander, and
place theWool Compounding Bonnet (part #44) on the Adaptor (See Figure B,
and Assy. Diagram.)
3. Depress the Brake Pin (part #18) to keep the Spindle (part #3) from turning, and
hand screw the Adaptor (part #1) onto the Spindle. (See Figures B, C,and Assy.
Diagram.)
4. Then, use the Spanner (part #43) provided to keep the Adaptor (part #1) from
turning, and firmly hand tighten theWool Compounding Bonnet onto the Adaptor.
(See Figures B, C, and Assy. Diagram.)
ADAPTOR(#1)
SPINDLE(#3)
BRAKEPIN (#18)
WOOLCOMPOUNDINGBONNET(#44)
SWITCH (#33)
BRUSHCAP(#40)
CARBONBRUSH(#41)
BRUSHHOLDER(#42)
(Qty.2 EACH)
VARIABLE SWITCH (#31)
SWITCH LOCK
BACK HANDLE (#39)
FIGURE B
SKU 46507 PAGE 6 REV 09/02 REV 06/05
IMPORTANT
Carefully inspect the condition of the accessory before use and check the accessory
continually during use. If any damage is noted, stop immediately and replace the
accessory withan undamagedone. Harbor FreightTools cannot be held responsible
for damage caused by using a damaged accessory on this tool.

To Attach The Side Handle:
1. NOTE: The Side Handle (part #20) may be attached either on the right, left, or
top side of the Polisher/Sander. (See Figure C, and Assy. Diagram.)
2. To attach the Side Handle (part #20), remove the Rubber Plunge (part #19) from
either the right, left, or top side of the Polisher/Sander in order to expose the
threaded mounting hole. (See Figure C, and Assy. Diagram.)
3. Firmly hand tighten the threaded portion of the Side Handle (part #20) into the
desired mounting hole of the Polisher/Sander. (See Figure C, and Assy. Dia-
gram.)
MOUNTING
HOLE
BRAKE PIN (#18)
MOUNTING HOLE
SIDE HANDLE (#20)
WOOL COVER (#45)
BRUSH CAP (#40)
CARBON BRUSH (#41)
BRUSH HOLDER (#42)
VARIABLE SWITCH (#31)
BACK HANDLE (#39)
POWER CORD (#36)
MOUNTING HOLE
BRUSH CAP (#40)
CARBON BRUSH (#41)
BRUSH HOLDER (#42)
SWITCH
LOCK
FIGURE C
OPERATING INSTRUCTIONS
NOTE: For additional references to the parts listed below, refer to the Assembly
Diagram on page 12 of this manual.
SKU 46507 PAGE 8

SKU 46507 PAGE 7
To AttachThe Rubber Backing Plate And Sandpaper:
1. Caution: Prior to installing the Rubber Backing Plate (part #46), make sure the
Polisher/Sander is disconnected from its electrical power source.
2. Rest the tool on a flat surface. Depress the Brake Pin (#18) to keep the Spindle
(#3) from turning.
3. Screw the Rubber Backing Plate (46) onto the threaded end of the Spindle (#3)
until it is snug. (See diagram below)
4. Ahere Sandpaper Disc (not included) evenly across the Rubber Backing Plate.
The Rubber Backing Plate has a self-sticking backing, so be sure only to use
Sandpaper Discs with a self-sticking material. Press Sandpaper Disc firmly onto
pad. When finished, release pressure on the Brake Pin (#18).
5. When finished sanding, peel the Sandpaper Disc away from the Plate.
BRAKE PIN (#18)
RUBBER BACKING PLATE (#46)
SPINDLE (#3)
SANDPAPER DISC

SKU 46507 PAGE 9
1. Caution: Check to make sure the Switch (part #33) is in its “OFF” position before
plugging the Power Cord (part #36) into a 110-120 Volt, grounded,
electrical power outlet. (See Figures B, C, and Assy. Diagram.)
2. Make sure to use both hands to
firmly grip the Polisher/Sander by its Side
Handle (part #20) and Back Handle (part #39). (See Figures B, C, and Assy.
Diagram.)
3. To turn on the Polisher/Sander, squeeze the Switch (part #33). To turn off the
Polisher/Sander, release pressure on the Switch. NOTE: For automatic, continu-
ous running, squeeze the Switch while, at the same time, depressing the Switch
Lock. This locks the Switch in its “ON” position. To turn off the Polisher/Sander,
squeeze and quickly release pressure on the Switch. This unlocks the Switch,
and allows the Polisher/Sander to automatically turn off. (See Figures B, C, and
Assy. Diagram.)
4. Allow the Polisher/Sander to spin up to full speed before pressing it onto the
workpiece. (See Figures B, C, and Assy. Diagram.)
5. NOTE: The Polisher/Sander can be operated at different speeds (from 1,000
RPM to up to 3,000 RPM), depending on the material of the workpiece. To
change speeds, make sure the Polisher/Sander is off. Then, select the desired
speed, using the Variable Switch (part #31). (See Figures B, C, and Assy.
Diagram.)
6. Do not force the Polisher/Sander onto the workpiece. Apply moderate pressure,
allowing the Polisher/Sander to do the work without being forced. (See Figures
B, C, and Assy. Diagram.)
7. Move the Polisher/Sander along the workpiece in small, circular, patterns. (See
Figures B, C, and Assy. Diagram.)
8. When finished, turn off the Polisher/Sander and allow the Polishing Disc or the
Rubber Backing Plate to spin down and stop on their own. Do not press against
the disc to stop them. (See Figures B, C, and Assy. Diagram.)
INSPECTION, MAINTENANCE, AND CLEANING
1. Caution: Always disconnect the Polisher/Sander from its electrical power supply
source before performing any inspection, maintenance, or cleaning.
2. Before each use, inspect the general condition of the Polisher/Sander. Inspect
switch, power plug and cord assembly, and extension cord (if used) for damage.
Check for loose screws, misalignment, binding of moving parts, broken, cracked,
or improper mounting of the Polishing Disc or the Rubber Backing Plate, broken

SKU 46507 PAGE 10
parts and any other condition that may affect its safe operation. If abnormal
noise or vibration occurs, turn off the Polisher/Sander immediately and have the
problem corrected before further use. Do not use damaged equipment.
3. The Polisher/Sander features two Carbon Brushes (part #41) which, periodically,
should be examined for wear. The Carbon Brushes are located on each side of
the Plastic Housing (part #29). To inspect or replace the Carbon Brushes, use a
small standard screwdriver to remove the Brush Cap (part #40). Examine the
concave surface of the Carbon Brushes. The surface should be smooth and
clean. If there are large scratch marks in the Brushes, or parts of the Brushes
have broken off, replace both Brushes immediately with approved replacement
Brushes from Harbor Freight Tools. To reinstall the Brushes, insert them into the
two Brush Holders (part #42). Turn the Brushes vertically so they will fit into the
Brush Holders. Then, replace the Brush Caps. (See Figures B, C, and Assy.
Diagram.)
4. Do not use solvents to wipe off the Polisher/Sander, as damage may result. If
necessary, wipe with a damp cloth. You may use a mild detergent.
5. Do not introduce water, dirt, or dust into the electric motor through the motor
vents.
6. Once clean, lubricate all moving parts with a light oil.
7. When storing, keep the Polisher/Sander covered with a cloth cover.
PLEASE READTHE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCETOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR
SHE IS QUALIFIEDTO MAKE ANY REPAIRS TOTHE PRODUCT ORTHAT HE OR SHE IS QUALI-
FIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR
DISTRIBUTOREXPRESSLY STATESTHATALL REPAIRS ANDPARTSREPLACEMENTSSHOULD
BEUNDERTAKEN BY CERTIFIEDAND LICENSEDTECHNICIANS AND NOTBYTHEBUYER. THE
BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE
ORIGINAL PRODUCT OR REPLACEMENT PARTSTHERETO, OR ARISING OUT OF HIS OR HER
INSTALLATION OF REPLACEMENT PARTSTHERETO.

SKU 46507 PAGE 11
PARTS LIST
1
Adaptor
RubberBackingPlate
WoolCompounding
Bonnet
REV 09/02

PARTS LIST
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
SKU 46507 PAGE 12
45
Note: #45 includes
Arbor Nut 5/8” - 11 TPI.
For Sanding
44
REV 09/02
For Polishing
43