Milwaukee Heavy-Duty Polishers User Manual
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
Catalog No.
No de Cat.
Catálogo No.
5455
5460
5540
HEAVY -DUTY POLISHERS
POLISSEUSES EXTRA ROBUSTES
PULIDORAS EXTRA RESISTENTES
TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND OPERATOR'S MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE ET BIEN COMPRENDRE LE
MANUEL DE L'UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER Y ENTENDER EL MANUAL DEL
OPERADOR.
GENERAL SAFETY RULES FOR ALL POWER TOOLS
WARNING!
Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term "power tool" in
all of the warnings listed below refers to your mains-operated (corded) power tool or battery-opearted (cordless) power tool.
SAVE THESE INSTRUCTIONS
READ ALL INSTRUCTIONS
WORK AREA SAFETY
1. Keep work area clean and well lit. Cluttered or dark areas invite
accidents.
2. Do not operate power tools in explosive atmospheres, such
as in the presence of flammable liquids, gases, or dust.
Power tools create sparks which may ignite the dust or fumes.
3. Keep children and bystanders away while operating a power
tool. Distractions can cause you to lose control.
ELECTRICAL SAFETY
4. 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. Unmodified plugs and matching outlets
will reduce risk of electric shock.
5. 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.
6. Do not expose power tools to rain or wet conditions. Water
entering a power tool will increase the risk of electric shock.
7. 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 moving parts. Damaged or entangled
cords increase the risk of electric shock.
8. 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.
PERSONAL SAFETY
16. 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.
17. 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.
18. Disconnect the plug from the power source and/or the bat-
tery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such
preventive safety measures reduce the risk of starting the tool accidentally.
19. Store idle power tools out of the reach of children and do
not allow persons unfamiliar with the power tools or these
instructions to operate power tools. Power tools are danger-
ous in the hands of untrained users.
20. 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.
21. Keep cutting tools sharp and clean. Properly maintained cutting
tools with sharp cutting edges are less likely to bind and are easier
to control.
22. Use the power tool, accessories and tool bits etc., in accor-
dance with these instructions and in the manner intended
for the particular type of power tool, 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.
POWER TOOL USE AND CARE
SERVICE
9. 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.
10. 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.
11. Avoid accidental starting. Ensure the switch is in the off-
position before plugging in. Carrying tools with your finger on
the switch or plugging in power tools that have the switch on invites
accidents.
12. 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.
13. Do not overreach. Keep proper footing and balance at all
times. This enables better control of the power tool in unexpected
situations.
14. Dress properly. Do not wear loose clothing or jewellery.
Keep your hair, clothing and gloves away from moving parts.
Loose clothes, jewellery, or long hair can be caught in moving parts.
15. If devices are provided for the connection of dust extrac-
tion and collection facilities, ensure these are connected
and properly used. Use of these devices can reduce dust-re-
lated hazards.
page 2
23. 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.
SPECIFIC SAFETY RULES
1. Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden
wiring or its own cord. Contact with a live wire will make exposed metal parts of the tool live and shock the operator.
2. Maintain labels and nameplates. These carry important information. If unreadable or missing, contact a MILWAUKEE service facility for a free
replacement.
3. WARNING! Some dust created by 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.
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 specifically designed to filter out
microscopic particles.
1. Handle
2. Speed control dial
3. Tool rest
4. Side handle
5. Polishing pad
6. Rubber backing pad
7. Spindle lock button
8. Vents
9. Trigger
10. Cord
Symbology
Double Insulated
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
Volts Direct/Alternating Current
No Load Revolutions
per Minute (RPM)
Amperes
FUNCTIONAL DESCRIPTION
1
10
9
8
Specifications
Speed No
Cat. No.
5455
5460
5540
2
7
Volts
120 AC/DC
120 AC
120 AC
Load RPM
0 - 1750
0 - 2800
3
1750
Pad Diameter
7"/9"
7"/9"
7"
4
5
6
page 3
GROUNDING EXTENSION CORDS
WARNING!
Improperly connecting the grounding wire can result in the
risk of electric shock. Check with a qualified electrician if you
are in doubt as to whether the outlet is properly grounded.
Do not modify the plug provided 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 fit
the outlet, have a proper outlet installed by a qualified
electrician.
Grounded Tools:
Tools with 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 malfunction or break
down, grounding provides a low resistance path to carry electricity
away from the user, reducing the risk
of electric shock.
The grounding prong in the plug is connected 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 system and
must never be attached to an electrically live terminal.
Your tool must be plugged into an appropriate outlet, properly installed
and grounded in accordance with all codes and ordinances. The plug
and outlet should look like those in Figure A.
Double Insulated Tools:
Tools with Two Prong Plugs
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 Standard
Association and the National Electrical Code. Double Insulated tools may
be used in either of the 120 volt outlets shown in Figures B and C.
Fig. A
Fig. B
Fig. C
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.
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. 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 an extension cord outdoors, be sure it is marked
with the suffix W-A (W in Canada) to indicate that it is acceptable
for outdoor use.
Be sure your extension cord is properly wired and in good electrical
condition. Always replace a damaged extension cord or have it
repaired by a qualified person before using it.
Protect your extension cords from sharp objects, excessive heat
and damp or wet areas.
Recommended Minimum Wire Gauge
Nameplate
Amperes
8.1 - 12
12.1 - 15
15.1 - 20
* Based on limiting the line voltage drop to five
volts at 150% of the rated amperes.
for Extension Cords*
25'
0 - 5
5.1 - 8
16
16
14
12
10
Extension Cord Length
100'
14
12
10
10
150'
12
10
--
--
--
--
50'
16
16
14
12
10
75'
16
14
12
10
10
200'
12
--
--
--
--
READ AND SAVE ALL INSTRUCTIONS
FOR FUTURE USE.
page 4
TOOL ASSEMBLY
WARNING!
To reduce the risk of injury, always unplug tool before
attaching or removing accessories or making adjustments.
Use only specifically recommended accessories. Others
may be hazardous.
Removing and Replacing Quik-Lok® Cords (Cat. No. 5460 and 5540)
(Fig. 1)
MILWAUKEE's exclusive Quik-Lok® Cords provide instant field replace-
ment or substitution.
Fig. 1
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 the connector keyways and
push the connector in as far as it will go. Turn the cord nut 1/4 turn
to the right to lock.
Polishing Pads (Fig. 2)
MILWAUKEE polishing pads are available in two different materials.
100% lambswool pads are ideal for compounding on non-clearcoat finishes. Wool/polyester blend pads are softer, making them acceptable for
clearcoat finishes. Refer to the chart below to select the proper pad for
your application.
Backing
Pad
49-36-2500
(7")
49-36-2200
(9")
Fig. 2
Polishing Pad
49-36-1450
100% Wool
49-36-1455
100% Wool
49-36-0500
Wool/Poly.
49-36-1600
100% Wool
49-36-0700
Wool/Poly.
Pad
Size
7-1/2"
7"
7-1/2"
9"
9"
Pile
Depth
1-1/2"
2"
1-1/2"
1-1/2"
1-1/2"
Application
Compounding
Compounding
High Gloss
Finishing
Compounding
High Gloss
Finishing
Disc nut
Arbor hole
Polishing pad
Rubber backing pad
Spindle washer
Washer flange
Recommended
Surface
Paints, clearcoats
and fiberglass
Paints, clearcoats
and fiberglass
Paints and
clearcoats
Paints, clearcoats
and fiberglass
Paints and
clearcoats
1. To install polishing pads, unplug the tool and place it on its tool rest
with the spindle upright.
2. Make sure the washer flange and spindle washer are installed on
spindle. Then, slide the disc nut through the arbor hole in both the
polishing pad and the rubber backing pad, making sure to spread the
fibers 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 lock button and
turn the disc nut counterclockwise to unscrew the assembly.
Wool/Polyester Bonnets (Fig. 3)
Refer to the chart below to select the proper wool/polyester bonnet for
your application.
Backing
Pad
49-36-2500
(7")
49-36-2200
(9")
Fig. 3
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 flange 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. Securely tie bonnet
strings and tuck the strings 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.
Bonnets
48-48-0500
Wool/Poly Bonnet 7"
48-48-1000
Wool/Poly Bonnet 9"
Application
High Gloss
Finishing
High Gloss
Finishing
Disc nut
Wool/polyester bonnet
Bonnet strings
Rubber backing pad
Spindle washer
Spindle
Tool rest
Recommended
Surface
Non-clearcoat or
clearcoat
Non-clearcoat or
clearcoat
Washer flange
Spindle
Tool rest
page 5
Hook and Loop Pads (Fig. 4)
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 finishing on clearcoat
finishes. It will remove buffing swirls, hard water spots, carwash brush
swirls and 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. Refer to the chart below to select the right hook & loop pad
for your application.
Fig. 4
Foam pad with
hook and loop
Centering tool (remove
before using tool)
Backing pad with
hook and loop
Spindle washer
Washer flange
Backing
Pad
49-36-2150
Hook & Loop Pad
49-36-1500
100% Wool Pad
49-36-0600
Wool Blend Pad
49-36-1550 Foam Pad
49-36-0650 Foam Pad
Application
Compounding
High Gloss
Finishing
Compounding
High Gloss
Finishing
Recommended
Surface
Paints, clearcoats
and fiberglass
Paints or clearcoats
Clearcoat
Clearcoat
OPERATION
WARNING!
To reduce the risk of injury, wear safety goggles or glasses
with side shields. Unplug the tool before changing accessories or making adjustments.
Starting, Stopping and Controlling Speed (Fig. 5)
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 recommended for tight work areas and higher speeds are ideal for
large surface areas. Use the setting that best suits your job.
Fig. 5
Spindle
Tool rest
1. To install hook and loop pads, unplug the tool and place it on tool
rest with spindle upright.
2. Make sure washer flange 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 backing 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.
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 instructions provided with
your finishes, 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,
use very 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.
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.
page 6
WARNING!
To reduce the risk of injury, follow instructions for preventing snagging. Snagging may cuase the tool to kick back and
the operator to suddenly lose control of the tool. Always use
side handle to maintain control.
Preventing Snagging
Snagging occurs 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 trigger speed control,
release the trigger slightly so the rotation of the pad is slowed.
To prevent snagging while using Cat. No. 5455 without 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 your tool before
performing any maintenance. Never disassemble the tool or
try to do any rewiring on the tool's electrical system. Contact
a MILWAUKEE service facility for ALL repairs.
Maintaining Tools
Keep your tool in good repair by adopting a regular maintenance program. Before use, examine the general condition of your tool. Inspect
guards, switches, tool cord set and extension cord for damage. Check
for loose screws, misalignment, binding of moving parts, improper mounting, broken parts and any other condition that may affect its safe operation. If abnormal noise or vibration occurs, turn the tool off immediately
and have the problem corrected before further use. Do not use a damaged tool. Tag damaged tools DO NOT USE until repaired
(see Repairs).
Under normal conditions, relubrication is not necessary until the motor
brushes need to be replaced. After six months to one year, depending on
use, return your tool to the nearest MILWAUKEE service facility for the
following:
Lubrication
Brush inspection and replacement
Mechanical inspection and cleaning (gears, spindles, bearings,
housing, etc.)
Electrical inspection (switch, cord, armature, etc.)
Testing to assure proper mechanical and electrical operation
FIVE YEAR TOOL LIMITED WARRANTY
Every MILWAUKEE tool is tested before leaving the factory and is warranted to be free from defects in material and workmanship. MILWAUKEE
will repair or replace (at MILWAUKEEs discretion), without charge, any
tool (including battery chargers) which examination proves to be defective in material or workmanship from five (5) years after the date of
purchase. Return the tool and a copy of the purchase receipt or other
proof of purchase to a MILWAUKEE Factory Service/Sales Support
Branch location or MILWAUKEE Authorized Service Station, freight prepaid and insured. This warranty does not cover damage from repairs
made or attempted by other than MILWAUKEE authorized personnel,
abuse, normal wear and tear, lack of maintenance, or accidents.
Battery Packs, Flashlights, and Radios are warranted for one (1) year
from the date of purchase.
THE REPAIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN ARE
EXCLUSIVE. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY
INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES, INCLUDING
LOSS OF PROFITS.
THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, OR CONDITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED FOR
MERCHANTABLILITY OR FITNESS FOR PARTICULAR USE OR PURPOSE.
This warranty gives you specific legal rights. You may also have other
rights that vary from state to state and province to province. In those
states that do not allow the exclusion of implied warranties or limitation
of incidental or consequential damages, the above limitations or exclusions may not apply to you. This warranty applies to the United States,
Canada, and Mexico only.
WARNING!
To reduce the risk of injury, electric shock and damage to the
tool, never immerse your tool in liquid or allow a liquid to flow
inside the tool.
Cleaning
Clean dust and debris from vents. Keep the tool handles clean, dry and
free of oil or grease. Use only mild soap and a damp cloth to clean your
tool since certain cleaning agents and solvents are harmful to plastics
and other insulated parts. Some of these include: gasoline, turpentine,
lacquer thinner, paint thinner, chlorinated cleaning solvents, ammonia
and household detergents containing ammonia. Never use flammable or
combustible solvents around tools.
Repairs
If your tool is damaged, return the entire tool to the nearest service
center.
page 7
ACCESSORIES
WARNING!
To reduce the risk of injury, always unplug the
tool before attaching or removing accessories.
Use only specifically recommended
accessories. Others may be hazardous.
For a complete listing of accessories refer to your MILWAUKEE Electric Tool catalog or go on-line to www.milwaukeetool.com. To obtain a
catalog, contact your local distributor or a service center.
Hook and Loop Backing Pad
Cat. No. 49-36-2150
Use this pad with hook and loop pads. Includes centering tool Cat. No.
49-67-0130.
Centering Tool
Cat. No. 49-67-0130
Same as supplied with the hook and loop backing pad Cat. No. 49-36-2150.
Use the tool as a guide for centering a hook and loop pad onto the
backing pad.
Hook and Loop Pads
These pads do not require a disc nut for assembly; change pads in
seconds.
Backing
Pad
49-36-2150
Hook & Loop Pad
49-36-1500
100% Wool Pad
49-36-0600
Wool Blend Pad
49-36-1550
Foam Pad
49-36-0650
Foam Pad
Application
Compounding
High Gloss
Finishing
Compounding
High Gloss
Finishing
Recommended
Surface
Paints, clearcoats
and fiberglass
Paints or
clearcoats
Clearcoat
Clearcoat
100% Wool Yarn Polishing Pads
These pads are ideal for compounding and blending on older cars wtih
lacquer and enamel finishes.
Recommended
Compounding and
deep cleaning on
2"
paints and clearcoats
Recommended
Depth
of Pile
1-1/2"
1-1/2"
1-1/2"
1-1/2"
High gloss finish
on paints and
clearcoats
For
For
9"
7-1/2"
9"
7"
9"
Depth
of Pile
1-1/2"
1-1/2"
Cat.
No.
49-36-1450
49-36-1455
49-36-1600
Wool Blend Pads and Bonnets
These pads and bonnets are recommended for high gloss finishing on
clearcoat or non-clearcoat surfaces.
Cat.
No.
49-36-0500
49-36-0700
48-48-0500
48-48-1000
Molded Rubber Backing Pads
7" Diameter
Cat. No. 49-36-2500
8-1/2" Diameter
Cat. No. 49-36-0220
Description
Curved Wool Pad
Wool Pad
Wool Pad
Description
Curved Pad
Wool Blend Pad
Wool Blend Bonnet
Wool Blend Bonnet
Diameter
7-1/2"
7-1/2"
Diameter
Disc Nut
Cat. No. 49-40-0390
Spindle Washer
Cat. No. 45-88-8465
Quik-Lok Cord Sets
Cat. No. 48-76-5010 (10' cord)
Cat. No. 48-76-5025 (25' cord)
page 8
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