Milwaukee 5460 User manual

Cat. No. 5455,
5460, 5540
POLISHERS
OPERATOR'S MANUAL
WARNING To reduce the risk of injury, user must read and understand operator's manual.

2
GENERAL POWER TOOL
SAFETY WARNINGS
WARNING
Read all safety warnings, instruc-
tions, illustrations and specica-
tions provided with this power tool. Failure to
follow all instructions listed below 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)powertoolorbattery-oper-
ated (cordless) power tool.
WORK AREA SAFETY
•Keep work area clean and well lit. Cluttered or dark
areas invite accidents.
•Do not operate power tools in explosive atmo-
spheres, 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 bystanders away while operat-
ing a power tool. Distractionscancauseyoutolose
control.
ELECTRICAL SAFETY
•Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power
tools. Unmodied plugs and matching outlets will
reduce risk of electric shock.
•Avoid body contact with earthed or grounded
surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
•Do not expose power tools to rain or wet condi-
tions. Water entering a power tool will increase the
risk of electric shock.
•Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or
movingparts.Damagedor entangledcordsincrease
the risk of electric shock.
•When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of
a cord suitable for outdoor use reduces the risk of
electric shock.
•If operating a power tool in a damp location is
unavoidable, use a ground fault circuit interrupter
(GFCI) protected supply. Use of an GFCI reduces
the risk of electric shock.
PERSONAL SAFETY
•Stay alert, watch what you are doing and use
common sense when operating a power tool. Do
not use a power tool while you are tired or under
the inuence of drugs, alcohol or medication. A
moment of inattention while operating power tools
may result in serious personal injury.
•Use personal protective equipment. Always wear
eye protection. Protectiveequipmentsuchasadust
mask, non-skid safety shoes, hard hat or hearing
protectionusedforappropriateconditionswillreduce
personal injuries.
•Prevent unintentional starting. Ensure the switch
is in the off-position before connecting to power
source and/or battery pack, picking up or carrying
the tool. Carrying power tools with your nger on the
switchorenergizingpowertools that have the switch
on invites accidents.
•Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key left
attachedto arotatingpart of thepower tool mayresult
in personal injury.
•Do not overreach. Keep proper footing and bal-
ance at all times. This enables better control of the
power tool in unexpected situations.
•Dress properly. Do not wear loose clothing or
jewelry. Keep your hair and clothing away from
moving parts. Loose clothes, jewelry or long hair
can be caught in moving parts.
•If devices are provided for the connection of dust
extraction and collection facilities, ensure these
are connected and properly used. Use of dust
collection can reduce dust-related hazards.
•Do not let familiarity gained from frequent use
of tools allow you to become complacent and
ignore tool safety principles. A careless action
can cause severe injury within a fraction of a second.
POWER TOOL USE AND CARE
•Do not force the power tool. Use the correct
power tool for your application. Thecorrectpower
tool will do the job better and safer at the rate for
which it was designed.
•Do not use the power tool if the switch does not
turn it on and off. Any power tool that cannot be
controlled with the switch is dangerous and must be
repaired.
•Disconnect the plug from the power source and/
or remove the battery pack, if detachable, from
the power tool before making any adjustments,
changing accessories, or storing power tools.
Such preventive safety measures reduce the risk of
starting the power tool accidentally.
•Store idle power tools out of the reach of children
and do not allow persons unfamiliar with the
power tool or these instructions to operate the
power tool. Powertoolsaredangerousinthehands
of untrained users.
•Maintain power tools and accessories. Check for
misalignment or binding of moving parts, break-
age of parts and any other condition that may
affect the power tool’s operation. If damaged,
have the power tool repaired before use. Manyac-
cidents are caused by poorly maintained power tools.
•Keep cutting tools sharp and clean. Properly
maintainedcutting tools with sharp cutting edges are
less likely to bind and are easier to control.
•Use the power tool, accessories and tool bits etc.
in accordance with these instructions, taking into
account the working conditions and the work to
be performed. Use of the power tool for operations
differentfromthose intended could resultina hazard-
ous situation.
•Keep handles and grasping surfaces dry, clean
and free from oil and grease. Slippery handles
and grasping surfaces do not allow for safe handling
and control of the tool in unexpected situations.
SERVICE
• Have your power tool serviced by a qualied
repair person using only identical replacement
parts. This will ensure that the safety of the power
tool is maintained.
SPECIFIC SAFETY RULES FOR
POLISHER
SafetyWarningsCommonforPolishingOperations:
•This power tool is intended to function as a
polisher. Read all safety warnings, instructions,
illustrations and specications provided with this
power tool. Failure to follow all instructions listed

3
below may result in electric shock, re and/or serious
injury.
•Operations such as grinding, sanding, 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.
•Do not use accessories which are not specically
designed and recommended by the tool manufac-
turer. Just because the accessory can be attached
to your power tool, it does not assure safe operation.
•The rated speed of the accessory must be at
least equal to the maximum speed marked on
the power tool.Accessoriesrunning faster than their
rated speed can break and y apart.
•The outside diameter and the thickness of your
accessory must be within the capacity rating of
your power tool. Incorrectly sized accessories can-
not be adequately guarded or controlled.
•Threaded mounting of accessories must match
the grinder spindle thread. For accessories
mounted by anges, the arbour hole of the ac-
cessory must t the locating diameter of the
ange. Accessories 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. Before each
use inspect the accessory such as abrasive
wheels for chips and cracks, backing pad 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 undam-
aged accessory. After inspecting and installing
an accessory, position yourself and bystanders
away from theplane of the rotating accessoryand
run the power tool at maximum no-load speed
for one minute. Damagedaccessorieswill normally
break apart during this test time.
•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 workpiece
fragments. The eye protection must be capable of
stopping ying debris generated by various opera-
tions. The dust mask or respirator must be capable
of ltrating particles generated by your operation.
Prolonged exposure to high intensity noise may
cause hearing loss.
•Keep bystanders a safe distance away from
work area. Anyone entering the work area must
wear personal protective equipment. Fragments
of workpiece or of a broken accessory may y away
and cause injury beyond immediate area of operation.
•Hold the power tool by insulated gripping sur-
faces only, when performing an operation where
the cutting tool may contact hidden wiring or its
own cord. Contact with a "live" wire may also make
exposedmetal parts ofthe power tool "live"and could
give the operator an electric shock.
•Position the cord clear of the spinning accessory.
If you lose control, the cord may be cut or snagged
andyour hand or arm may be pulledintothespinning
accessory.
•Never lay the power tool down until the acces-
sory 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 while 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 air vents. The
motor’s fan will draw the dust inside the housing
andexcessive accumulation of powdered metal may
cause electrical hazards.
•Do not operate the power tool near ammable
materials. Sparks could ignite these materials.
•Do not use accessories that require liquid cool-
ants. Using water or other liquid coolants may result
in electrocution or shock.
Kickback and Related Warnings
Kickbackis asuddenreaction to apinched or snagged
rotating wheel, backing pad, brush or any other ac-
cessory. 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
isentering 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 misuse and/or in-
correctoperating procedures or conditionsandcan be
avoided by taking proper precautions as given below.
•Maintain a rm grip on the power tool and posi-
tion 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 the rotating acces-
sory. Accessory may kickback over your hand.
•Do not position your body in the area where
power tool will move if kickback occurs. Kickback
willpropel the tool in direction opposite to the wheel’s
movement at the point of snagging.
•Use special care when working corners, sharp
edges etc. Avoid bouncing and snagging the ac-
cessory. 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 chain woodcarving blade or
toothed saw blade. Such blades create frequent
kickback and loss of control.
Safety Warnings Specic for Polishing Operations:
•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.
Looseandspinningattachmentstrings can entangle
your ngers or snag on the workpiece.
Additional Safety Warnings
•Maintain labels and nameplates. These carry im-
portant information. If unreadable or missing, contact
a MILWAUKEE service facility for a free replacement.
•
WARNING
Somedust createdby power sanding,
sawing, grinding, drilling, and other
construction activities contains chemicals known to
cause cancer, birth defects or other reproductive
harm. Some examples of these chemicals are:
•lead from lead-based paint
•crystalline silica from bricks and cement and other
masonry products, and
• arsenic and chromium from chemically-treated lumber.

4
SPECIFICATIONS
Cat. No............................................................5455
Volts .......................................................120 AC/DC
Rated RPM ......................................................2000
Pad Diameter...................................................7"/9"
Spindle Thread Size .................................... 5/8"-11
Cat. No............................................................5460
Volts .............................................................120 AC
Rated RPM ................................................ 0 - 2000
Pad Diameter...................................................7"/9"
Spindle Thread Size .................................... 5/8"-11
Cat. No............................................................5540
Volts .............................................................120 AC
Rated RPM ................................................ 0 - 3000
Pad Diameter....................................................... 7"
Spindle Thread Size .................................... 5/8"-11
EXTENSION CORDS
Grounded 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 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. Refer to the table shown to determine the
required minimum wire size.
Thesmaller thegauge number ofthe wire,thegreater
the capacity of the cord. For example, a 14 gauge
cord can carry a higher current than a 16 gauge cord.
When using more than one extension cord to make
up the total length, be sure each cord contains at
least the minimum wire size required. 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 wire size.
Guidelines for Using Extension Cords
•If you are using anextensioncordoutdoors, be sure
it is marked with the sufx “W-A” (“W” in Canada) to
indicate that it is acceptable for outdoor use.
•Besure your extension cord is properly wired and in
good electrical condition. Always replace a damaged
extension cord or have it repaired by a qualied
person before using it.
• Protect your extension cords from sharp objects,
excessive heat and damp or wet areas.
Recommended Minimum Wire Gauge
For Extension Cords*
Nameplate Amps Extension Cord Length
25' 50' 75' 100' 150'
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
18
18
18
18
16
14
12
18
18
18
16
14
12
10
18
18
16
14
12
10
--
18
16
14
12
10
--
--
16
14
12
12
--
--
--
* Based on limiting the line voltage drop to ve volts at 150%
of the rated amperes.
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 withapproved safety equipment, such
as those dust masks that are specially designed to
lter out microscopic particles.
SYMBOLOGY
Double Insulated
Volts
Alternating Current
Alternating Current/Direct Current
Amps
Rated Revolutions per Minute (RPM)
CUS
UL Listing Mark for Canada and U.S.
FUNCTIONAL DESCRIPTION
1234
6
7
8
5
9
1. Handle
2. Speed control dial
3. Tool rest
4. Side handle
5. Polishing pad
6. Backing pad
7. Spindle lock button
8. Trigger
9. Cord

5
GROUNDING
WARNING
Improperlyconnecting the ground-
ing wire can result in the risk of
electric shock. Check with a qualied electrician
if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug pro-
vided with the tool. Never remove the grounding
prong from the plug. Do not use the tool if the
cord or plug is damaged. If damaged, have it
repaired by a MILWAUKEE service facility before
use. If the plug will not t the outlet, have a
proper outlet installed by a qualied electrician.
Grounded Tools (Three-Prong Plugs)
Tools marked “Grounding Required” have a three
wire cord and three prong grounding plug. The plug
must be connected to a properly grounded outlet
(See Figure A). If the tool should electrically mal-
function or break down, grounding provides a low
resistance path to carry electricity away from the
user, reducing the risk of electric shock.
Thegrounding pronginthe plugisconnected through
the green wire inside the cord to the grounding
system in the tool. The green wire in the cord must
be the only wire connected to the tool's grounding
systemand must never be attached to an electrically
“live” terminal.
Yourtoolmustbepluggedintoanappro-
Fig. A
priate outlet, properly installed and
groundedin accordance with all codes
and ordinances. The plug and outlet
should look like those in Figure A.
Double Insulated Tools (Two-Prong Plugs)
Tools marked “Double Insulated” do not require
grounding. They have a special double insulation
system which satisfies OSHA requirements and
complieswith the applicable standards
Fig. B Fig. C
of Underwriters Laboratories, Inc., the
Canadian Standard Association and
the National Electrical Code. Double
Insulated tools may be used in either
ofthe120 volt outlets shown in Figures
B and C.
ASSEMBLY
WARNING
To reduce the risk of injury, always
unplug tool before changing or
removing accessories. Only use accessories
specically recommended for this tool. Others
may be hazardous.
To reduce the risk of injury, always use a side
handle when using this tool. Hold securely.
Installing Side Handle
The side handle may be installed on either side
of the gear case. Position the side handle in the
location which offers best control and protection. To
install, thread side handle into side handle socket
and tighten securely.
Removing and Replacing Quik-Lok®Cords
MILWAUKEE's exclusive Quik-Lok®Cords provide
instant eld replacement or substitution.
1. To remove the Quik-Lok®Cord, turn the cord nut
1/4 turn to the left and pull it out.
2. To replace the Quik-Lok®Cord,align theconnector
keywaysandpush the connector in as far as it will
go. Turn the cord nut 1/4 turn to the right to lock.
Polishing Pads
MILWAUKEE polishing pads are available in two
different materials. 100% lambswool pads are ideal
for compounding on non-clearcoat nishes. Wool/
polyester blend pads are softer, making them ac-
ceptable for clearcoat nishes.
Arbor hole
Disc nut
Polishing
pad
Rubber
backing pad
Spindle washer
Washer ange
Spindle
Tool rest
1. To install polishing pads, unplugthe tool andplace
it on its tool rest with the spindle upright.
2. Make sure the washer ange and spindle washer
are installed on spindle. Then, slide the disc nut
through the arbor hole in both the polishing pad
andthe rubberbacking pad, makingsure tospread
the bers in the pad so the disc nut seats on pad
backing.
3. Push in the spindle lock button (located on left side
of gear case) and simultaneously screw the disc
nut & polishing pad assembly clockwise onto the
spindle. Securely hand-tighten the disc nut and
polishing pad.
4. To remove the polishing pad, push in the spindle
lockbutton and turn the disc nut counterclockwise
to unscrew the assembly.

6
Wool/Polyester Bonnets
Wool/polyester
bonnet
Disc nut
Bonnet strings
Spindle
Tool rest
Rubber
backing pad
Spindle washer
Washer ange
1. To install wool/polyester bonnets, unplug the tool
and place it on a tool rest with the spindle upright.
2. Make sure the washer ange and spindle washer
are installed on spindle. Then, slide the rubber
backing pad onto the spindle.
3. Push in the spindle lock button and screw the disc
nut onto the spindle clockwise. Securely hand-
tighten the disc nut.
4. Cover the rubber backing pad with the bonnet.
Securelytie bonnetstringsand tuckthestrings into
the bonnet so they do not interfere with polishing.
5. To remove, untie and remove the bonnet. Push in
the spindle lock button and turn the disc nut and
rubber backing pad counterclockwise.
Hook and Loop Pads
Hook & loop pads are available in both wool/polyester
and foam. Foam pads should be used on slower/low
speed dial settings when using polisher Cat. Nos.
5540 and 5460. Foam pads are not recommended
for the inexperienced operator.
Foam pad Cat. No. 49-36-1550 is ideal for use
with clearcoat finishes and micro-fine rubbing
compounds. It will remove light surface scratches,
environmental pollutants, wet-sanding scratches
and hazy paint.
Foam pad Cat. No. 49-36-0650 is ideal for glazing
and nishing on clearcoat nishes. It will remove buff-
ingswirls, hardwater spots, carwashbrush swirlsand
mild hazing. A centering tool, Cat. No. 49-67-0130,
is supplied with hook and loop backing pads, Cat.
No. 49-36-2150, to properly align the backing pad
with the polishing pad, providing the proper balance
for your polisher.
Centering tool
(remove before
using tool)
Foam pad with
hook and loop
Backing pad with
hook and loop
Spindle washer
Washer ange
Spindle
Tool rest
1. To install hookand loop pads, unplug the tool and
place it on tool rest with spindle upright.
2. Make sure washer ange and spindle washer are
installed on spindle. Then slide hook and loop
backing pad onto spindle.
3. Push in the spindle lock button and spin the
backing pad clockwise until it is securely hand-
tightened.
4. Insert the centering tool (supplied with the back-
ing pad) into the center hole in the hook and loop
backing pad. Push desired hook and loop polishing
pad over the centering tool so that the polishing
pad fastens to the hook and loop backing pad.
Remove centering tool.
5. To remove, "peel" off the polishing pad. Push in
the spindle lock button and rotate backing pad
counterclockwise to remove.
NOTE: Use side handles for better control and safety.

OPERATION
WARNING
To reduce the risk of injury, always
unplug tool before attaching or
removing accessories or making adjustments.
Use only specically recommended accessories.
Others may be hazardous.
To reduce the risk of injury, wear safety goggles
or glasses with side shields.
Starting, Stopping and Controlling Speed
Cat. No. 5455: To start the tool, pull the trigger. To
stop the tool, release the trigger.
Cat. Nos. 5540 & 5460 feature a dial speed control,
which controls the polisher's maximum rotations per
minute. The speed will remain variable to the chosen
dial setting by use of the trigger switch. Dial settings
range from 1 through 5. Lower numbers correspond
to lower speeds and higher numbers correspond to
higher speeds. Generally, lower speeds are recom-
mended for tight work areas and higher speeds are
ideal for large surface areas. Use the setting that
best suits your job.
To control the speed, set the dial to the desired
number. Then pull the trigger. Increase or decrease
pressure on the trigger to vary the speed. To stop the
tool, release the trigger.
WARNING
To reduce the risk of injury, keep
the cord set away from the path of
the polisher. Otherwise the cord set may become
caught by the pad and wrap around the spindle;
this may cut through the cord and expose live
wires or make the gear box electrically "live."
Polishing
Always use side handle for proper control. Move the
polisher back and forth in long, sweeping strokes. Too
much pressure, the wrong angle or improper motion
may cause swirl marks or burning.
For detailed polishing instructions, read the instruc-
tions provided with your nishes, waxes and polishes.
Preventing Burning Through Paint
It is easy to burn through the paint on a surface. This
can occur if you polish at too high a speed or if you
allow the polishing pad to stay in one spot for even a
short period of time. To prevent burning through paint,
usevery light pressure and keep the polisher moving
constantly, especially when working near edges or
where there are abrupt changes in the contour of
the work surface.
Be particularly careful when using Cat. No. 5540,
which are high RPM polishers and are more likely
to burn through paint.
WARNING
To reduce the risk of injury, follow
instructions for preventing snag-
ging. Snagging may cause the tool to kick back
and the operator to suddenly lose control of the
tool.Always use side handle to maintain control.
Preventing Snagging
Snaggingoccurs when polishing pads get caught on
rough edges of a work surface. Snagging can cause
the tool to suddenly "kick back" and it may cause
the pad to burn through the paint. To reduce the risk
of snagging, use the polisher at low speeds when
polishing rough surfaces. For tricky areas such as
near trim or between a mirror and window on a car,
do not take chances with a polisher. Polish these
surfaces by hand.
When using Cat. Nos. 5460 and 5540 with the trig-
ger speed control, release the trigger slightly so the
rotation of the pad is slowed.
To prevent snagging while using Cat. No. 5455 with-
out trigger speed control, it is best to use the "coast-
down" technique to avoid snagging. To coast-down,
turn the motor ON for a few seconds, then turn it
OFF and apply the polishing pad to the surface. This
way, when the pad touches the work surface, it will
be rotating more slowly than it is when the motor is
ON. Use coast-down when working in areas where
crevices or pockets are present.
MAINTENANCE
WARNING
To reduce the risk of injury, always
unplug the tool before performing
any maintenance. Never disassemble the tool.
Contact a MILWAUKEE service facility for ALL
repairs. Maintaining Tools
Keep your tool in good repair by adopting a regular
maintenance program. Inspect your tool for issues
such as undue noise, misalignment or binding of
moving parts, breakage of parts, or any other condi-
tion that may affect the tool operation. Return the tool
to a MILWAUKEE service facility for repair. After six
months to one year, depending on use, return the
tool to a MILWAUKEE service facility for inspection.
WARNING
To reduce the risk of personal in-
jury, electric shock and damage,
never immerse your tool in liquid or allow a liquid
to ow inside it. Cleaning
Clean dust and debris from vents. Keep handles
clean, dry and free of oil or grease. Use only mild
soap and a damp cloth to clean, since certain clean-
ing agents and solvents are harmful to plastics and
other insulated parts. Some of these include gasoline,
turpentine,lacquerthinner, paint thinner,chlorinated
cleaning solvents, ammonia and household deter-
gents containing ammonia. Never use ammable or
combustible solvents around tools.
Repairs
For repairs, return the tool to the nearest service center.
Rely only on high-grade power tools on our virtual shelves.