CYCLO 6CE, 5, 5C Instruction Manual

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CYCLO DUAL HEAD ORBITAL POLISHER

MODEL 5, 5C AND 6CE

INSTRUCTION MANUAL

Cyclo Toolmakers, Inc., 1740 Skyway Drive, Bldg. C, Longmont, CO 80504-5556 USA

Phone: +1-303-485-1990, Fax: +1-303-723-8680, www.cyclotoolmakers.com

1 Rev 2010.08.23

This instruction manual is furnished with each Cyclo® Model 5, 5C & 6CE Electric Dual Head Orbital Polisher. The entire manual should be read carefully before using the Cyclo Dual Head Orbital Polisher and retained for future reference.

CONTENTS

SAFETY INSTRUCTIONS .................................................................................................... 1

DETAILING BASICS ........................................................................................................... 4

CYCLO POLISHER SET-UP................................................................................................. 5

GUIDE TO GENUINE CYCLO ACCESSORIES ...................................................................... 6

MACHINE OPERATING INSTRUCTIONS ............................................................................. 9

USER MAINTENANCE & TROUBLESHOOTING ................................................................. 10

TECHNICAL SPECIFICATIONS ........................................................................................ 12

PARTS DIAGRAMS AND LISTING ..................................................................................... 13

APPLICATION AND ACCESSORIES QUICK GUIDE ........................................................... 15

SAFETY INSTRUCTIONS

GENERAL SAFETY RULES

WARNING: Read all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term “power tool” in all

the warnings listed below refers to your mains-operated (corded) power tool or battery–operated (cordless) power tool.

SAVE THESE INSTRUCTIONS

1) Work Area

a) Keep work area clean and well lit. Cluttered and dark areas invite accidents. b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gasses or dust. Power tools create

sparks which may ignite the dust or fumes.

c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2) Electrical Safety

a) 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.

b) 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.

c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d) 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.

e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the

risk of electric shock.

f) Guard against electrical shock. It is recommended to use this tool on a GFI (Ground Fault Interrupter) or RCD (Residual Current Device)

protected circuit with a rated residual current of 30 mA or less.

3) Personal Safety a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired

or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal

injury.

b) Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing

protection used for appropriate conditions will reduce personal injuries.

c) Avoid accidental starting. Ensure the switch is in the off-position before plugging in. Carrying power tools with your finger on the switch or

plugging in power tools that have the switch on invites accidents.

d) Remove any adjusting key or wrench before turning the power tool on. A wrench or key left attached to a rotating part of the power tool may

result in personal injury.

e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. f) Dress properly. Do not wear loose 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.

g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used.

Use of these devices can reduce dust-related hazards.

4) Power Tool Use and Care a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the

rate for which it was designed.

b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and

must be repaired.

c) Disconnect the plug from the power source and/or the battery 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 power tool accidentally.

d) Store idle power tools out of the reach of children, and do not allow persons unfamiliar with the power tool or these instructions to

operate the power tool. Power tools are dangerous in the hands of untrained users.

e) Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the

power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.

f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

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g) Use the power tool, accessories and tool bits etc. in accordance 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.

5) Service

a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the

power tool is maintained.

6) Safety Warnings Common for Polishing Operations. a) This power tool is intended to function as a polisher only. Read all safety warnings, instructions, illustrations and specifications

provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

b) Operations such as sanding, grinding, wire brushing, or cutting off are not recommended to be performed with this power tool.

Operations for which the power tool was not designed may create a hazard and cause personal injury.

c) Do not use accessories which are not designed and recommended by the tool manufacturer. Just because the accessory can be attached

to your power tool, it does not assure safe operation.

d) The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster

than their rated speed can break and fly apart.

e) The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized

accessories cannot be adequately guarded or controlled.

f) The arbor size of wheels, flanges, backing pads or any other accessory must properly fit the spindle of the power tool. Accessories with

arbor holes that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.

g) Do not use a damaged accessory. Before each use inspect the accessory such as backing pad for cracks, tear or excess wear. If

power tool or accessory is dropped, inspect for damage to 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.

h) Wear personal protective equipment. Depending on application, use a 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 flying debris generated by various operations. The dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.

i) 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 fly away and cause injury beyond immediate area of operation.

j) Hold power tool by insulated gripping surfaces only when performing an operation where the cutting accessory may contact hidden

wiring or its own cord. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and shock the operator.

k) Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged and your hand or arm may be pulled

into the spinning accessory.

l) Never lay the power tool down until the accessory has come to a complete stop. The spinning accessory may grab the surface and pull the

power tool out of your control.

m) 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.

n) Regularly clean the power tool’s air vents. The motor’s fan will draw the dust inside the housing and excessive accumulation of powdered

metal may cause electrical hazards.

o) Do not operate the power tool near flammable materials. Sparks could ignite these materials. p) Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.

7) 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 misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.

a) Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary

handle, if provided, for maximum control over kickback or torque reaction during start up. The operator can control torque reactions or

kickback forces, if proper precautions are taken.

b) Never place your hand near the rotating accessory. Accessory may kickback over your hand. c) Do not position your body in the area where power tool will move if kickback occurs. Kickback will propel the tool in a direction opposite to

the wheel’s movement at the point of snagging.

d) Use special care when working corners, sharp edges etc. Avoid bounding and snagging the accessory. Corners, sharp edges or

bounding have a tendency to snag the rotating accessory and cause loss of control or kickback.

e) Do not attach a saw chain, woodcarving blade, or toothed saw blade. Such blades create frequent kickback and loss of control. f) Safety Warnings Specific for Polishing Operations: g) Do not allow any loose portion of the polishing bonnet or its attachment strings to spin freely. Tuck away or trim any loose attachment

strings. Loose and spinning attachment strings can entangle your fingers or snag on the workpiece.

WARNING: When using electric tools, basic safety precautions should always be followed to reduce the risk of fire, electric shock, and personal injury, including

but not limited to the following:

3 Rev 2010.08.23

8) Grounding Instructions

a) The Cyclo Polisher should alw a ys be electrically grounded while in use to protect the operator from electric shock. This tool is equipped

with an approved three-conductor cord and three-prong grounding type plug to fit the proper grounding type receptacle. The green or green/yellow conductor wire in the cord is the grounding wire. NEVER CONNECT THE GREEN OR GREEN/YELLOW WIRE TO A LIVE TERMINAL. If there is any doubt as to whether the wall receptacle is properly grounded, you should have it checked by a qualified electrician.

WARNING: DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE THIRD (GROUND) PRONG FROM THE POWER CORD PLUG.

9) Extension Cord a) With the Cyclo Polisher, use only three-wire extension cords that have three-prong grounding type plugs and three-pole receptacles

that accept the tool's plug. Replace or repair damaged cords. When using this tool at a distance from the power source, a three conductor

grounding type extension cord of ADEQUATE SIZE must be used for safety and to prevent the loss of power and overheating.

Extension Cord Length Size of Wire in Cord 0-100 feet (0-30 m) 18 AWG (0.75mm2) 101-250 feet (30–76 m) 16 AWG (1.0 mm2)

10) Motor a) Your Cyclo Polisher is powered by a sturdy motor. Be certain your power supply agrees with that shown on the name plate (a.c. means

alternating current). Variance in your power supply’s voltage may result in loss of power and overheating. This tool is factory tested. Built into the motor of the Model 6CE is a thermal circuit interrupt. This device will open the power circuit if the motor windings exceed 120 – 130 C. It is not resettable, and if it the protector is activated, the motor field (stator) may have to be replaced. If it will not operate, check electric supply for blown fuses; check plug and electrical receptacle for proper contact.

11) Additional Safety Instructions: a) Do not Abuse Cord. Do not force sharp bend in cord, especially where it exits the handle and particularly when curling cord for storage. b) Maintain Tool with Care. Keep the tool clean for better and safer performance. Follow instructions for lubricating and changing accessories.

Inspect cord periodically and, if damaged, have repaired by a Cyclo Toolmakers service facility. Inspect extension cords periodically and replace if damaged. Keep handles dry, clean, and free from oil and grease. Using compressed air, blow dry the bearings under the heads or pads, and blow away dirt or lint inside the motor case. This should only be performed with the power cord disconnected and with proper eye protection.

c) Keep Work Area Clean. Cluttered areas and benches invite injuries. d) Use the Right Tool. Do not force a small tool or attachment to do the job of a heavy-duty tool. e) Use Proper Support. Ensure that you have provided proper support for the work piece. A loose work piece may be propelled by the tool if not

supported or fixed in place.

f) Check Damaged Parts. Before further use of tool, a guard or other part that is damaged should be carefully checked to determine whether it will

operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other condition which may affect the tools operation. A guard or other part that is damaged should be properly repaired or replaced by an authorized Cyclo Toolmakers service center unless otherwise indicated elsewhere in this instruction manual. Have defective switches replaced by a Cyclo Toolmakers service center. Do not use tool if switch does not turn tool on and off.

g) Handles Should Remain Insulated. Do not operate the tool without the properly insulated handles. NOTE: If shrink wrap insulation on the rear

metal handle is damaged or is removed at the time of repair, it must be replaced before the tool is put back into service. The proper precut length is available from Cyclo Toolmakers or your dealer. When re-installing, be sure not to cover any part of the “1” or “0” (on/off) indicators embossed in the aluminum handle.

h) Use only Cyclo Toolmakers Recommended Products. The use of accessories or attachments other than those recommended in these

operating instructions may present a risk of personal injury.

i) Use of Residual Current Device is Recommended. The use of residual current device with a rated residual current of 30 mA or less is

recommended. In the United States and Canada, a residual current device is also known as a ground fault circuit interrupter (GF CI), ground fault interrupter (GFI) or an appliance leakage current interrupter (ALCI). In Australia they are sometimes known as "safety switches" or simply "RCD" and in the United Kingdom they can be referred to as "trips" or "trip switches."

j) k)

4 Rev 2010.08.23

Profile image of paint with scratches in the clear coat and oxidation and pollutants on the clear coat.

Profile image of paint with various scratches.

DETAILING BASICS

This section presents the basic steps involved in vehicle detailing, much of which is accomplished without your Cyclo polisher. More instructions on polisher operation are provided later in this manual.

1) Washing

a) Soap. To wash the vehicle and remove old wax or polish, use cold or warm water and a dishwashing detergent. A standard detergent usually

requires 1-2 ounces per gallon of water. If you do not w ish to remove existing wax, then use a car washing soap that has a neutral pH, making it “wax-friendly.” This describes most “car wash” soap products.

b) Sponges, mitts and more. It is important to use an appropriate washing device. This includes wash mitts and sponges made from foams, wool

and other materials. Advancements in detailing tools include specific types of products designed for easy wheel cleaning, safe, yet aggressive bug removal, and a gentle wash while providing a comfortable fit. They need to be easy to use and assuredly not scratch the surface.

c) Application tips. Use a mitt or sponge that holds the car wash solution. The more solution the mitt or sponge can hold, the more lubricating

soapy water you can get onto the surface to be cleaned. Lubrication created by soapy water helps prevent dirt from scratching the surface while being cleaned. Start up high -- away from most of the grit and grime. Rinse your mitt or sponge out frequently. You do not want to rub grit into the paint and cause swirls or scratches. Prepare two 5 gallon buckets by filling one half-full with the soap-and-water wash solution and the other bucket three-quarters full with clear rinse water.

d) Rinse before and after you wash. Rinse the vehicle thoroughly, starting at the top and working your way down. Pre-rinsing is an important step

and should not be skipped. Then wash the vehicle, then rinse again.

e) Do it in the shade. Washing and most other detailing work should be preformed out of direct sunlight. A v oid rapid evaporation which can create

hard water spots. Do not allow chemicals to dry on painted surfaces or trim pieces.

f) Environment. Make sure that you are practicing good environmental stewardship. Use appropriate cleaners on paints, wheels and metals. Follow

all applicable guidelines for water containment. Utilize as little water as necessary and never leave a water hose running when not in use.

2) Claying

a) Clay bars and optional use. Clay bars are used to remove paint over spray, tree sap, airborne contaminants and industrial fallout from the cars

painted surfaces. Clay also works well on glass, plastics and many metals. Claying is an optional step performed before polishing. When hard paint contaminants are present, claying first then polishing can save time over polishing only.

b) Paint surface check. Use a plastic sandwich bag or any type of thin plastic bag as a tool to inspect the painted surface. Using a clean plastic bag

with your fingers or hand inside, run your finger tips across the painted sur face. Be careful not to drag any loos e debris. The plastic increases the sensitivity of your fingertips to contaminants. Your paint may feel clean and smooth to the bare hand’s touch, but with a plastic bag over your hand, it is a different story! The bumps and roughness you may feel are contaminants and pollutants that need removed for a show car finish. After using detailing clay, the surface will be as smooth as glass and ready for polishing.

c) Application tips. Thoroughly wash and dry the vehicle. Cut a large clay bar into smaller, more manageable pieces. Begin by spraying a clay bar

lubricant over a 2’ x 2' area. Hold the clay bar so that your hand and finger nails do not touch the painted surface. Glide the clay bar across the area. We recommend that you work in a consistent direction – not cross hatching. Move the clay bar back and forth, and you will begin to feel it cleaning the surface. When claying entire vehicles, it is best to begin at the top and then work your way to the lower areas. Inspect the clay bar often and remove large contaminants that could scratch. When the clay bar becomes dirty you can switch to the clean side or knead the clay to extend its use. Continue the process around the entire vehicle until all painted surfaces, glass, chrome, metal pieces and coated wheels have been clayed. Then the painted surface will be smooth and ready for polishing and waxing.

d) Special tips and guidelines. You can save time by using the clay bar after the final wash rinse, while the surface is still wet. Never allow a clay

bar to drop on the ground. It would be nearly certain to pick up a scratching hazard; if so contaminated, it should be discarded. It is important that you work on the vehicle in a shaded area, away from direct sunlight.

e) Re-rinse. Re-rinse or re-wash the vehicle if necessary to clean up after claying.

3) D r y i n g

a) D r y thoroughly. The vehicle should be completely dry before polishing and waxing. Scratches can easily be imparted when substandard towels

are used for drying. Discarded household towels should never be used to dry a vehicle. They can scratch the surface and produce lint. There are several professional quality tools including microfiber towels, drying air blowers, water blades, chamois and available to reduce drying time.

4) What Is Polishing - It Is Important That You Do Not Just Wax

a) Your paint’s appearance is dependent on being well polished to a highly reflective,

smooth finish. Polishing removes oxidation, old wax buildup and other contaminants while cleaning, leveling and shining your paint. Polishing can smooth the edges of larger imperfections and even remove light scratches. Polishing is important to prepare the surface for protecting with a sealant or wax.

b) It is important to remove all of the oxidation, wax buildup and contaminants before

applying a wax or sealant. You do not want to seal in the contaminants.

5) Swirls, Scratches and Other Defects Removal

a) Swirls and holograms are imperfections in paint appearance caused by thousands of

microscopic scratches in the clear coat. These scratches can be the result of polishing with a high speed buffer, dirt and sand in the air, rough drying towels and car wash and snow removal brushes. The removal of swirls and holograms is ac compl ished by removing the fine scratches. Your Cyclo polisher does this with the right combination of liquid compounds, polishes and p ads and the correct technique.

i. If a scratch catches your fingernail then it’s likely too deep to remove. Polishing the scratched area is still recommended. However, do

so with the idea that you are attempting to make the defect less noticeable but not to remove it entirely.

ii. Some scratches and swirl marks are too deep to safely remove. Attempting to do so may result in buffing through the top layer of paint

or clear coat and permanent damage. Always test in an inconspicuous area.

iii. Severe scratch and defect removal requires advanced training and the correct combination of detailing liquid compounds and polishes,

pad selection and high speed rotary buffer application. We do not recommend cutting or compounding paint with a high speed rotary buffer without prior experience.

Specific instructions on compounding, polishing and swirl removal are provided in the later section, Machine Operating Instructions.

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CYCLO POLISHER SET-UP

1) Determine the Intended Application and Appropriate Attachment System Configuration for Your Application. a) Polishing/Waxing/Buffing/Deoxidation/Cutting/Compounding/Swirl Removal

i. Automotive paints, gel coats, boats, RV’s, Aircraft, and more.

ii. ProGuard™ Orbital Backing Plates, heads with Rubber Pad Holders, DoublePrecision™ 2-sided pads

b) Metal Polishing

i. Aluminum, stainless steel.

ii. ProGuard Orbital Backing Plates, heads with Rubber Pad Holders, DoublePrecision 2-sided pads

c) Scrubbing Carpets/Upholstery/Fabrics

i. Interior and exterior applications.

ii. Scrub brushes, ProGuard Orbital Backing Plates with foam pads and pad covers, heads with Rubber Pad Holders with foam pads and

pad covers, DoublePrecision 2-sided pads with pad covers

d) Other Miscellaneous Applications.

i. Hockey arena boards

Fa s tCut ™ Discs on ProGuard Orbital Backing Plates, heads with Rubber Pad Holders

ii. Tile and grout cleaning

Scrub brushes

iii. Headlight restoration

ProShine™ Discs on ProGuard Orbital Backing Plates, heads with Rubber Pad Holders, DoublePrecision 2-sided pads

e) Refer to the application chart (on the back cover) for additional information and product application suggestions.

2) Backing Plates and Attachment Alternatives a) ProGuard Orbital Backing Plates

Featuring a low profile for improved control and a non-marking bumper for safe operation. The advanced design ensures against delamination with the plate-integrated hook field, provides faster pad centering and is perfect for quick and easy pad changes (79-112-5/16). For use with 72- series foam and wool pads.

b) Rubber Pad Holders

Durable, long-lasting Pad Holders fit directly over the Cyclo Polisher Head Assemblies to hold 72- Series pads via Velcro hook face (79-101).

c) Quick Connect Adapters

Center pads easily and save time by simply snapping the pads in place. System replaces Cyclo Polisher heads to hold 77- Series Double-Precision, two-sided pads (79-725-5/16).

d) Head Assemblies

The original backing plate for Rubber Pad Holders or foam and wool bonnets (71- series foam and wool pads permanently attached to a rubber backing). Alternately, you can use Rubber Pad Holders which fit directly over the Head Assemblies (60-055).

e) Scrubbing Brushes

Genuine Cyclo scrubbing brushes have integral connectors which screw directly into the Cyclo Polisher replacing the heads. By simply attaching two Cyclo Brushes you can clean carpet, upholstery, tile, grout and more.

f) ProShine Interface Pad

Cushion backing plate for ProShine abrasive discs. Interface pads improve performance by allowing the sanding discs

3) Configure the VES™ Counterweights on Your Polisher. a) When new, your polisher will have Cyclo’s exclusive VES counterweight system but wi t h no VES weighted insert installed. You

will need to install the appropriate weighted insert then install whichever attachment you will be usi n g – Heads with Rubber Pad Holders, Brushes, DoublePrecision Adapters, or other attachment.

b) Lay the polisher with heads facing up on your lap, a bench or other flat surface. You can use the cardboard insert removed fr om

inside he polisher box to support polisher and hold it in place.

c) Determine the attachment system configuration that you intend to use – head assemblies with rubber pad holders or bonnets,

carpet and scrub brushes, Quick Connect adapters with DoublePrecision™ pads, or other Genuine Cyclo attachments.

d) Select the appropriate VES weighted insert from TABLE 1: ADJUSTABLE COUNTERWEIGHT APPLICATION TABLE below. e) Thread the weighted insert into the counterweight and hand tighten using the 7/32” L hex key (included). f) IMPORTANT! Tighten VES weighted insert firmly by attaching the 5/8” flat wrench (included) to the counterweight’s threaded nut

style adapter and turn counterclockwise until you make contact with the L hex key. Use the flat wrench pivoting on hex wrench to prevent counterweight from turning while tightening the weighted insert. Turn the L hex key clockwise to tighten VES weighted insert firmly, but not too tight

g) Configuration complete. You may now install the attachment system you have chosen.

Table 1: Adjustable VES Counterweight Application Table

WEIGHTED INSERT

(top and side views)

PART NO.& DESCRIPTION

A P P L I C A T I O N

20-072

PROGUARD™ ORBITAL BACKING PLATE

6.5g WEIGHT, Blue

OR OTHER AFTER MARKET HEAD ASSEMBLIES

20-076

DOUBLEPRECISION ADAPTER AND PADS

18.75g WEIGHT, SILVER, 1 STRIPE

CARPET AND SCRUB BRUSHES

20-078

HEAD ASSEMBLY WITH BONNETS

32.0g WEIGHT, YELLOW WITH 2 STRIPES

OR RUBBER PAD HOLDER WITH PADS

Why Low Vibration Is Important: Operators face significant risk of muscle, joint and nerve damage caused by the hand-arm vibration of many power tools. By reducing the amount of vibration you can reduce muscle and joint fatigue as well as the potential risk for permanent damage, as described in ISO 5349-1:2001. Mechanical vibration -- Measurement and evaluation of human exposure to hand-transmitted vibration. Cyclo machines are designed to minimize vibration.

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4) Attaching Head Assemblies, Quick Connect Adapters, Scrub Brushes, ProGuard Orbital Backing Plates and Other Accessories.

a) Lay the polisher facing up on your lap, a bench or flat surface. You can use the insert removed from inside the polisher box to

support polisher/hold it in place or use towels.

b) Attach the flat wrench to the nut attached to the counterweight. c) Hold the flat wrench on the counterweight nut with your left hand and take the attachment and screw it into the counterweight

nut, turning clockwise.

d) Use the flat wrench to hold the counterweight in place. Do not over tighten but use a firm grip for a hand tightening. e) Complete the installation procedure for both sides, left and right.

5) Detailing Polishes and Products Selection – CTI Pro Paint Care™ Line and Other Leading Professional Products

a) Cyclo products are specifically formulated for speed, action, and weight of the Cyclo Polisher. While many other professional

grade machine-application polishes may give satisfactory results, the company’s rec ommend ation for superior results are the field-proven Genuine Cyclo CTI products for use with the Cyclo Polisher and Genuine Cyclo Accessories. For additional information on use and application of other leading professional quality polishes and products, please visit our website’s support section at www.cyclotoolmakers.com.

b) Selection of the appropriate detailing chemical is essential for proper results. Many polishes can remove light

scratches, and there are products specifically designed to remove swirl-marks and holograms. There are more aggressive products and it is important to understand the difference between a polish, wax and sealant. When using these products, read all instructions carefully and we recommend that you always use the least aggressive product and pad combination necessary for your finish condition.

c) CTI Pro Paint Care Heavy Compounding Gel – Removes scratches, heavy oxidation, orange peel, acid rain damage

and other defects. Very aggressive cutting and compounding polish for use on any surface.

d) CTI Pro Paint Care Light Compounding Liquid – Eliminates hairline scratches and oxidation. Leaves a smooth

sruface ready for polishing. Follow with our Polish & Swirl Remover (CTI 1 Pass Express™), then our Protective Sealant (Pro Paint Care Polish and Protective Sealant).

e) CTI Pro Paint Care Polish and Swirl Remover – CTI 1 Pass Express™ safely removes swirls, haze, light scratches,

mild oxidation and surface contaminants while restoring depth and brilliance. Use in a one-pass application for express polish and seal. Follow with CTI Protective Sealant or CTI Finishing Wax to lock-in the new car shine. Excellent on all painted surfaces, gel coats and clear coats.

f) CTI Pro Paint Care Protective Sealant – Our Polish and Protective Sealant is a high poly sealant will give your surface up to 6

months of durable protection and brilliant gloss. Shows your paint’s original new car shine. Use on all painted surfaces.

g) CTI Pro Paint Care Finishing Wax: This easy to apply creme wax will give your surface up to 6 months of durable protection and

brilliant gloss. Shows your paint’s original new car shine. Use on all painted surfaces.

6) Met al Polishes and Sealants – CTI Metal Polishes and Sealants Line and Other Leading Professional Products

a) Cyclo products are specifically formulated for use with the Cyclo Polisher and though some machine application type polishes may give

satisfactory results, we recommend that for the BEST results only the laboratory and field tested Genuine Cyclo Accessories and products be used with the Cyclo Polisher. For additional information on use and application of other leading professional quality polishes and products, please visit our website’s support section, www.cyclotoolmakers.com.

b) Free FliteTM Cleaner-Polish – With one easy step this aggressive rubbing compound removes corrosion, oxidation and

surface film while also leaving a polished finish that is absolutely stunning. For quality that meets high government standards for its aircraft, insist on Free Flite Cleaner-Polish. Stainless steel, aluminum, billet parts, virtually every metal.

c) Free FliteTM Protective Sealant – Specially formulated to bond to bare metal, allowing you to deoxidize the surface and

effortlessly remove finishing scratches. Plus, its protective coat helps prevent further oxidation. Great for chrome.

Guide to Genuine Cyclo Accessories

The following information will assist you in selecting the appropriate accessory for use with the Cyclo Polisher. For additional tips and application guides, please refer to the application chart included with this manual.

1) Pad Selection Guide – Genuine Cyclo Pads

a) Detailing pads made of either wool blends or high tech foams, these pads can be used for restoration and defect removal, polishing, applying

waxes and sealants as well as final buffing. Each pad type serves a specific function in the detailing process. You will want to match the appropriate pad with the type of detailing liquid compound, polish, wax or sealant.

b) Foam pads are made from specially designed synthetic foams with small, uniformly shaped cells that may be either open or closed. The smaller,

more densely constructed cells are less aggressive finishing pads. As the cell size increases so does the pads ability to carry detailing liquids and therefore the level of aggressiveness. Foam pads containing larger cells (higher part numbers in our system, i.e. 72-145 versus 72-110) are more aggressive and they hold more liquid compound.

c) Wool pads can be made from a variety of natural wools and synthetic fibers. The yarn blend may also be twisted or not, and the fiber may be

treated to have more or fewer barbs. For an aggressive action, our non-twisted 50/50 poly/wool pad is best. Twisted wool can transport more compound and that increases aggressive when used with an aggressive compound. For final finishing or non-aggressive polishing, our blue and yellow wool blend pads utilize a greater portion of soft synthetics like Rayon.

Pad Type Bonnets Velcro DoublePrecision™

White Foam Finishing Pad 71-110 72-110 77-110 Blue Foam Polishing Pad 71-115 72-115 77-115 Green Foam Polishing Pad 71-120 72-120 77-120 White Finishing/Green Polishing Combination F oam Pad Not available Not available 77-110/120 Yellow Foam Cutting Pad 71-135 72-135 77-135 Orange Foam Polishing & Compounding Pad 71-145 72-145 77-145 Yellow Cutting/Orange Polishing & C omp. Comb.Foam Pad Not available Not available 77-135/145 Yellow Foam Scrubbing Pad 71-160 72-160 77-160 The Original Cyclo Cutting White Wool Pad 71-455 72-455 Not available Yellow Medium Cutting Wool Pad Not available 72-435 77-435 Blue Polishing Wool Pad Not available 72-415 77-415

7 Rev 2010.08.23

d) Scrubbing/Bug& Tar Removal

i. Yellow Cutting Foam Pad

1. Open cell, premium quality – Foam Bonnet (71-160), Velcro Pad (72-160), DoublePrecision (n/a)

2. Recommended applications a. Bug Removal • Paint Deox • Paint Compound • Paint Scratch Removal • Metal

Polish/Cleaner

b. Scrubs away hard to remove materials such as bugs, tar, and sap. Also used as a more

aggressive deoxidizer.

e) Cutting/Compounding/Deoxidation/Swirl Removal

i. Original Cyclo Cutting Wool – Foam Bonnet (71-455), Velcro Pad (72-455), DoublePrecision (n/a)

1. Natural wool and polyester blend

2. Recommended applications a. Metal Polish/Cleaner • Paint Deox • Paint Com pound • Paint Swirl Removal b. The preferred multipurpose wool/poly pad, used for metal polishing and aggressive paint

compounding. This pad is excellent for removing swirl marks and scratches.

ii. Orange Compounding & Polishing Pad – Foam Bonnet (71-145), Velcro Pad (72-145), DoublePrecision (77-145)

1. Closed cell, premium quality

2. Recommended applications a. Paint Polish/Cleaner • P aint Deox • Paint Compound • Metal/Chrome Polish b. An exceptional, all-in-one cleaning and polishing pad. This high density pad has the

power to remove lights scratches and polish the surface.

iii. Yellow Cutting Foam Pad – Foam Bonnet (71-135), Velcro Pad (72-135), DoublePrecision (77-135)

1. Closed cell, premium quality

2. Recommended applications a. Paint Polish/Cleaner • P aint Deox • Paint Compound • Paint Scratch Remover b. A firm, versatile pad that can be used on everything from compounding and scratch

removal to applying paint cleaners and polishes.

iv. Yellow Cutting Wool Pad – Foam Bonnet (n/a), Velcro Pad (72-435), DoublePrecision (77-435)

1. 50% wool, 50% acrylic

2. Recommended applications a. Paint Polish/Cleaner • P aint Deox • Paint Compound • Metal/Chrome Polish b. An exceptional, all-in-one cleaning and polishing pad. This pad has the power to remove

light scratches and polish the surface.

f) Cleaning/Polishing/Deoxidation

i. Green Polishing Foam Pad– Foam Bonnet (71-120), Velcro Pad (72-120), DoublePrecision (77-120)

1. Open cell, 60 pores per inch

2. Recommended applications a. Sealant • Paint Polish • Paint Cleaner • Metal Sealant b. A more aggressive pad than our white or blue pads. The pore density makes it perfect

for polishing and removing light oxidation for a stunning shine.

ii. Blue Polishing Foam Pad – Foam Bonnet (n/a), Velcro Pad (72-115), DoublePrecision (77-115)

1. Open cell, 80 pores per inch

2. Recommended applications a. Paint/Metal Sealant • Paint Polish • Paint Cleaner • Final Wax Buf f • Wax Application b. The perfect pad for light polishing on any surface. Use with wax and polish for a fine

gloss finish or to remove swirl marks.

iii. Blue Polishing Wool Pad – Foam Bonnet (n/a), Velcro Pad (72-415), DoublePrecision (77-415)

1. 70% acrylic, 30% wool

2. Recommended applications a. Paint Polishing • Paint Cleaner • Finishing Touch b. Used for applying the finishing touches on most automobiles. A blend of 70% acrylic and

30% wool, this wool pad is perfect for creating a fine luster on nearly any finish.

g) Wax/Sealant Application

i. White Finishing Foam Pad – Foam Bonnet (71-110), Velcro Pad (72-110), DoublePrecision (77-110)

1. Open Cell, 100 pores per inch

2. Recommended applications a. E x t reme Shine • Final Wax Buff • Wax Application • Sealant • Metal Sealant b. This superfine pad is used in final buffing, after polishing with other pads.

h) Final Wax Buff

i. White Finishing Foam Pad – Foam Bonnet (71-110), Velcro Pad (72-110), DoublePrecision (77-110)

ii. Microfiber Suede Pad Cover

1. Ultra soft microfiber

2. Recommended applications a. Extreme Shine b. An ultra-soft cover used for final touches. Removes all surface residue.

2) Genuine Cyclo Scrub Brush Selection Guide

The Cyclo Dual Head Orbital Polisher is one of the most versatile machines available for polishing, buffing and compounding vehicles, planes and RV’s and more. By simply attaching two Cyclo Brushes to the heads you can clean carpet, upholstery, tile, grout and more. The rotating motion of the Cyclo polisher heads combined with the high quality brushes safely cleans leather, fabric, upholstery and carpets. Brushes are available in four varieties and each brush is made of durable nylon bristles modified for specific applications. Use your favorite carpet or upholstery shampoo with the Cyclo brush to remove tough stains from your vehicle, RV or your home. For additional tips and application guides, please refer to the application chart included with this manual.

Brush Type Product Number

Gray Ultra Soft Upholstery Brush 76-810 Aqua Soft Carpet Brush 76-830 White Standard Carpet Brush 76-840 Black Scrub Brush 76-870

8 Rev 2010.08.23

a) Upholstery, Fine Carpets, Fine Interiors

i. Gray Ultra Soft Upholstery Brush – 76-810

ii. Recommended applications

1. Ideal for use on headliners, leather, and other fragile upholstery

2. Natural fiber fine carpets

b) Fine Carpets, Durable Carpets, Auto & RV Carpets & Upholstery

i. Aqua Soft Carpet Brush – 76-830

ii. Recommended applications

1. Each brush kneads and vibrates loose any soil or debris

2. Perfect for most carpets

c) Auto & RV Carpets & Interiors, Tile & Grout, Durable Carpets

i. White Standard Carpet Brush – 76-840

ii. Recommended applications

1. The white brush is designed for more vigorous cleaning for floor pads

2. More durable carpets

d) Tile & Grout, Truck Bed Liners, Heavy Scrubbing

i. Black Scrub Brush – 76-870

ii. Recommended applications

1. Cleaning tile and stone floors

2. Pick-up truck bed liners

3) Genuine Cyclo Pad Covers

Each pad cover has a specific function in the detailing process. Whether you are applying polish, cleaning interior surfaces, buffing wax, or adding that final touch to bring paint and interiors to a gorgeous shine. The pad covers fit snugly over foam pads with a durable elastic cuff. They will not fly off, bunch, or tear as you buff your paint. For additional tips and application guides, please refer to the application chart included with this manual.

Type Product Number

Microfiber Suede Pad Cover 73-515 Microfiber Terry Pad Cover 73-530 Cotton Terry Pad Cover 73-550

a) Extreme Shine

i. Microfiber Suede Pad Cover – 73-515

ii. Recommended applications

1. Ultra-soft and ideal for removing surface residue

2. Buff out for extreme shine

b) Final Wax Buff

i. Microfiber Terry Pad Cover – 73-530

ii. Recommended applications

1. The preferred cover for applying polish and buffing wax

2. Its hooked fibers remove surface residue.

c) Upholstery

i. Cotton Terry Pad Cover – 73-550

ii. Recommended applications

1. Perfect for cleaning interior surfaces and for buffing, polishing

2. Drying exterior surfaces

4) Genuine Cyclo Abrasive Discs

Genuine Cyclo Abrasive Discs, when used in conjunction with the ProShine™ Interface Pad, can make easy work of the even the most unshapely of contours and surfaces from Plexiglass to paint scratch removal.

Type Product Numbers

ProShine Abrasive Discs in grades of 1500, 2400, 4000, 6000, 8000, 12000 72-701, 72-702, 72-704, 72-706, 72-708 & 72-712

Fastcut 600 Grit Disc 74-660

a) Deep Scratch Removal

i. Proshine Discs 1500-4000

ii. Recommended applications

1. Requires interface pad such as 77-920 or 72-920.

2. Discs are ideal for removing scratches and use water as a lubricant for discs. Start with 1500 or 2400 and you should be able to switch over to light compounding after 4000.

b) Light Scratch Removal

i. Proshine Discs 2400-8000

1. Recommended applications

a. Requires interface pad such as 77-920 or 72-920. Discs are ideal for removing light scratches and use water as a

lubricant for discs. Start with 2400 or 4000 grade disc on one head of the polisher and just use a Green Foam Polishing Pad or Blue Foam Light Polishing Pad on the opposite head to minimize amount of sanding area and impact.

b. Once sanded, you should be able to switch over to light compounding, swirl remover or polish after application of

6000 grade discs.

c) Aggressive Surface Scrubbing and Cleaning

i. Fastcut 600 Grit Disc

ii. Recommended applications

1. Requires interface pad such as 77-920 or 72-920.

2. Use Fastcut discs for scrubbing floors, tile, showers, hockey arena boards bugs on bumpers and more.

9 Rev 2010.08.23

Machine Operating Instructions

Your Cyclo Polisher has two heads rather than the single head you may be accustomed to seeing. As soon as the Cyclo Polisher is placed on a working surface, and switched on, orbital “hand-rubbing” action takes place. Therein lies the secret of the tool’s ability to do many different types of jobs that could not be done with a single head or rotary tools. The two heads move in a circular mot ion, nearly overlapping pattern without forced spinning and are timed and weighted to balance away vibration forces. Thus, very little centrifugal force is exerted and the vibration, heat and throwing/pulling action of a rotary tool is eliminated.

IMPORTANT POLISHER OPERATION INFORMATION:–EXCESSIVE PRESSURE DOES NOT IMPROVE PERFORMANCE AND MAY DAMAGE THE

POLISHER’S TRANSMISSION. The hand-like action of the polisher’s heads prevents surface damage regardless of the pressure applied. Move the machine slowly. You need not be afraid of burning, gouging, or swirling the surface.

1) General Polishing Instructions

a) After you have placed the pads or bonnets on your Cyclo Polisher, connect the tool to the power supply. b) Apply a small amount (about a teaspoon, or a spot the size of a dime) of the proper polish or compound to each pad. c) Place the Cyclo Polisher, pad side down on the surface, move the tool around before turning it on in order to distribute the polish within the pad

over the surface .

d) Turn on the tool and move it back and forth and side to side in a latticed pattern across an area approximately 2’ x 2’ in size. Use the first 20-30

seconds to further evenly spread the liquid detailing product. Then slow down.

e) Grip both handles of the polisher, and using only light or moderate pressure - letting the action and the weight of the tool do the work - move the

polishing heads across the area at a very slow comfortable speed. Deoxidize or polish the entire car in this manner. When you have finished, you can remove any powdery or lubricant residue left by your liquid products using a microfiber towel. You may also use white foam pads or bonnets, or microfibre or terry pad covers to removing any remaining residue.

f) If the residue does not wipe off easily, the surface is still not clean, repeat steps 2-5 as necessary. g) As the pads become fully impregnated with polish or oxidized paint, they should be removed and washed. Never keep polish in pads overnight.

Additional pad care information is included below.

IMPORTANT PAD CARE INFORMATION: – DO NOT WASH P A D S IN GASOLINE OR SOLVENTS. Instead, use Cyclo’s CTI Pad Cleaner or another mild

detergent and water. For maximum life, be sure to clean pads, bonnets, and pad covers after each use. To clean, spray CTI Pad Cleaner on the pad face, work in, and let soak in a container of water diluted Pad Cleaner (or clean warm soapy water). After soaking, rinse out, and if clean, place the items back on Cyclo Toolmakers Polisher and run for a few seconds. Allow the action of the machine to shake excess water from the pad. You may also just squeeze dry (do not twist or wring). Then allow to air dry. The pads and bonnets should be cleaned as soon as possible after use, and do not allow compounds to dry in pads. The wool fiber pads should also be washed with CTI Pad Cleaner and then run through with a brush. Pads and other accessories c an al s o be machine washed in warm water and tumble dried in a cool dryer.

2) General Scrubbing Instructions

a) Begin by vacuuming the loose debris and materials from the area to be scrubbed. b) Pre-treat the area with Cyclo CTI Pad Cleaner or an alternative cleaning agent or enzyme c) After you have installed the appropriate style of scrub brush to your Cyclo Polisher, connect the tool to the power supply.

For additional information on the installation of scrub brushes, please refer to the MACHINE SET-UP section of this document.

d) Place the Cyclo Polisher, brush side down on the surface. e) Turn on the tool and move it back and forth and side to side in a latticed pattern. f) Grip both handles of the polisher, and using only light or moderate pressure - letting the action and the weight of the tool do

the work - move the polishing brushes across the area at a comfortable speed.

g) When you have finished, you can wipe down the treated areas by hand to remove residue. If you have an extractor or wet

vacuum, lightly wet the area and extract the water.

h) If the residue does not wipe off easily, the surface is still not clean, repeat steps b-f as necessary. i) As the brushes become impregnated with loose fibers, they should be removed, combed out and cleaned.

3) General Pad Cover Instructions

a) Lay the polisher with heads facing up on your lap, a bench or flat surface. You can use the insert removed from inside the polisher box to support

polisher/hold it in place or use towels.

b) Attach foam pads or bonnets onto the Cyclo Polisher. It is common to use the Green Polishing, Yellow Cutting or Orange

Compounding and Polishing Foam Pads or a wool pad.

c) Stretch the pad cover’s elastic ring over the foam. Make sure that you have completely covered the foam pad. The elastic band should never

come in contact with each other and the Pad Cover will completely cover the foam.

d) Rotate each head to ensure that the Pad Covers do not contact each other. If the Pad Covers contact each other continue to smooth out the

covers over the pads to remove any wrinkles in the material and to ensure that elastic bands are not making contact.

e) Connect the tool to the power supply. f) For use in final buff and exterior detailing, follow the General Polishing Instructions. g) For use on interiors and upholstery, please refer to the General Scrubbing Instructions

ADDITIONAL TIPS AND INSIGHTS:

1) Attaching Rubber Pad Holders and Bonnets to Head Assemblies:

a) Lay the polisher with heads facing up on your lap, a bench or flat surface. b) Take pad holder or bonnet and turn it completely inside-out. c) Center the inside-out pad holder or bonnet onto the head assembly. d) Flip one edge of pad holder or bonnet over the head assembly using your thumbs to stretch it over the

head.

e) Rotate pad and stretch the other half of the pad holder or bonnet over the head assembly. f) Use your thumbs to center the pad holder or bonnet over the head for an even fit. g) Complete for both head assembl ies.

10 Rev 2010.08.23 Good Brus h Holder Cap

Bad Brush Holder Cap

USER MAINTENANCE AND TROUBLESHOOTING

Below are instructions on care and maintenance of your polisher. You can also visit our website at www.cyclotoolmakers.com for tutorials and video instructions

on proper tool care and maintenance.

How To Maintain Your Cyclo Polisher

1) Lubricate the upper motor bearing

After every eight hours of use, lubricate the upper motor bearing by placing 3 drops of light machine oil (e.g. 3-in-1 oil) in the center of the bronze bushing found at the top of the mot or housing.

2) Clean your tool of dirt, fiber, and other debris by blowing it out with compressed air. a) Every eight hours of use, or as conditions warrant, blow out the motor housing with

compressed air to clean out any accumulated dust or dirt. If the tool is being used to clean carpets, be sure to blow out the motor housing after every use. If tool should get wet, be sure to blow dry the underside of the tool.

If Your Cyclo Polisher Fails to Run

Be sure the polisher is disconnected from the electrical supply before any inspection or maintenance is performed. The motor is only for the voltage specified on the nameplate. Voltage should not vary more than 10% over or under the voltage shown on the nameplate. Although the Cyclo Polisher is built to last a lifetime, it can encounter problems from heavy wear and tear. All problems are repairable, and can most often be repaired by a mechanically inclined technician or user

2) If your polisher fails to run, unplug it from the outlet or power source. a) Check your power cord plug for bent prongs that could be preventing proper contact with the outlet. b) Check your power cord for areas of worn or cracked insulation. If any of these are noted, DO NOT CONTINUE TO OPERATE the tool.

IMMEDIATELY contact Cyclo Toolmakers or your dealer to have your tool repaired and serviced.

c) Check your source of power for blown fuses or open circuit breakers in the line. Also verify that your power source is providing adequate voltage

and current to safely operate your polisher. Use a volt meter if able.

3) If your polisher starts to arc, experiences a loss in torque, seems to be running hotter than normal or has stopped during operation: a) Turn off your polisher and DO NOT CONTINUE TO OPERATE the tool. Continuing to use your tool may cause further damage by creating a

short circuit in the motor windings. Unplug your polisher from the outlet or power source, and proceed through the following steps or contact Cyclo Toolmakers or your dealer to have your tool repaired and serviced:

4) Clean your tool of dirt, fiber, and other debris by blowing it out with compressed air. a) This is recommended maintenance for every 8 hours of operation or as conditions warrant. Pay particular attention to the area around the carbon

brushes’ contact with the motor, just inside the top of the motor cover. If tool is being used on carpets or with wool pads/bonnets, it is recommended to blow out your tool after every use. If the tool should get wet, also blow out the underside of the tool. If the tool has gotten wet, you may need to allow the tool to completely dry before you are able to completely blow out all the fibers and other debris.

5) Check the carbon brushes, brush holder and brush holder caps. a) The carbon brushes in your polisher are wear items and periodically will need to be replaced (after 50 to 150 hour of use). The carbon brushes

that are used in your polisher will shut off the polisher when they need to be replaced. Never operate your polisher with chipped or cracked brush holder caps. Refer to the images to the right for examples of good and worn parts. You may also refer to the “Instructions for Inspecting and Replacing the Brushes and Brush Holders” at www.cyclotoolmakers.com for instructions on removing, inspecting and replacing the brushes and brush holders in your polisher as well as inspecting and cleaning your brush holder caps. Since brushes are wear items, we recommend that you keep a spare set of brushes. Please note that some specialty tools are required for replacing the brush holders. It is recommended that you have Cyclo Toolmakers or your dealer perform this service.

6) Inspection of the brush holder caps. a) WARNING: Never operate the polisher with chipped or otherwise damaged brush holder caps. b) Be sure the power cord is disconnected. Using a screwdriver, remove the damaged brush holder cap and the

carbon brush and spring, with a cotton Q-tip wipe the threads on the inside of the brush holder clean of any foreign matter, replace the carbon brush and spring and screw on a new brush cap.

TABLE 2: VISUAL INSPECTION OF THE CARBON BRUSH HOLDERS AND CARBON BRUSHES

Good Brush Holder Bad Brush Holder (photos and illustration) – Look for New Carbon Brush Worn /Bad Brush – scarring or marking on the surface of the carbon brush too short to use holder. These may be electrical shorts.

7) If the previous steps have not enabled you to determine the problem, please return your polisher to Cyclo Toolmakers or your dealer for a complete

diagnosis. Follow the return instructions on the next page!

ANY OTHER SERVICING SHOULD BE PERFORMED BY THE FACTORY OR AN AUTHORIZED CYCLO SERVICE CENTER.

Oil here

Compressed Air

11 Rev 2010.08.23

Additional Maintenance and Service Information Lubrication:

This tool was properly lubricated at the factory and is ready to use. The gears should be inspected after approximately 400 hours of use. If necessary, re-lubricate wi t h Texaco Multifax #2 or equivalent.

Timing:

The secret of the operation of your Cyclo Polisher lies in the fact that the two heads are timed exactly 1/2 turn apart. This is necessary for the balanced operation of the tool. If the machine is disassembled, use the following procedures to insure proper timing of the heads.

1) Turn the tools main case upside down, with the motor case, cover plate, and idler gear removed. Move the two heads together as close as possible. Then, put a heavy rubber band around the side of the two heads to keep them together.

2) Turn the tool right side up and carefully replace the idler gear without moving the drive gears. Now, pack the recessed well in back of the idler gear with lubricant. Also, lubricate the metal shafts in the center of each gear.

3) Reassemble the cover plate and motor case and remove the rubber band.

Bearings:

The bearings in the counterweights will loosen slightly with continued long use. This actually improves the action of the tool by allowing the heads to tilt slightly and follow a contoured surface better. These bearings should not be considered defective until they become objectionably noisy at which time the entire polisher should be sent to an authorized Cyclo service center for repair.

Heads:

The twin heads of the polisher will wear out gradually with use and should be replaced when they no longer hold the polishing bonnets firmly in position. Simply turn the polisher upside down (so the twin heads are facing up), rest the polisher on a counter or on your lap. Slide a flat 5/8” wrench between the head and the counterweight. With the wrench in one hand and the head in the other, twist the head counterclockwise until the threaded shaft is completely clear of the nut. Oil the nut threads slightly and reverse the above procedure to attach new heads or brushes. Be sure to screw the head of brush straight into the counterweight nut. If the shaft seems to be screwing into the nut with difficulty, back it out and start over again. Be sure to tighten the heads or brushes snugly into the nut or the polisher will vibrate badly when in use.

Sending Your Cyclo Polisher In For Repair:

 Please attach a note answering the following questions:

o Is your tool under warranty? (Enclose proof of purchase in order to be covered) o Would you like an estimate, or a repair?

 If you would like your tool immediately repaired, please indicate that Cyclo Toolmakers, Inc. has permission to make repairs costing up

to $100. We can only repair your tool if you have provided us with your credit card information. For all repairs costing over $100, Cyclo will contact you to confirm the price before making any repairs.

o What is wrong with your tool? Please include a complete description of the problem, the conditions under which the polisher failed or is

operating incorrectly

o Please also include all your contact information, $10 for US domestic return shipping address and phone numbers, and your email address

so that you can be contacted with a resolution or estimate to repair your polisher. There will be no charge for product failures covered by our warranty.

 If your tool is not claimed within 30 days after repair quotation (when not in warranty), your tool will be disposed of. If $10 was included for return

shipping, we will return the polisher to the address given.

 Repair labor is $50/hour.  It can take up to 2 weeks or longer after receipt to provide an estimate or repair.  Send repairs to: Cyclo Toolmakers, Inc. ATTN: Service Dept. 1740 Skyway Drive Bldg. C Longmont, CO 80504 U.S.A.

CYCLO TOOLMAKERS, INC. ONE-YEAR LIMITED WARRANTY

This written warranty protects your investment.

CYCLO TOOLMAKERS, INC. WARRANTS this machine to the original purchaser to be free from material or workmanship defects for a period of ONEYEAR from the date of purchase but no longer than two-years from date of manufacture. Our obligations under this warranty are expressly limited to replacement or repair of such parts as we determine to be defective and the labor required for installations. Our obligation is limited to performing repairs in our U.S. factory location (address below). Your Cyclo dealer may provide local services at its own option. If you ship your product to us for repair and your claim for service is covered by this warranty, we will pay the return freight cost to places within the 48 contiguous United States, but not to other locations.

Conditions resulting from misuse, negligence, alterations, accidents, damage caused by improper use of chemicals, repair by unauthorized parties, or “wear and tear” from normal usage, are not covered. Disassembly of the tool may also void this warranty.

This warranty does not cover damage to machine occurring in shipment, nor damage caused by alterations, fire, accidents, force majeure, misuse or abuse. To invoke coverage under this warranty you, the (end user purchaser), must register within 15 days of purchase and provide proof of purchase (sales

receipt) when requesting warranty service. We recommend that only Genuine Cyclo accessories be used with this machine. Our products are specifically designed, formulated and tested for product

capability. This warranty is in lieu of all other warranties, expressed or implied, and we do not assume any other liability in connection with the sale of this product. No

claim for consequential damage shall be allowed.

12 Rev 2010.08.23

JOIN ORBIT CLUB TODAY

Join the Cyclo Toolmakers’ Orbit Club and you’ll receive preferred customer discounts, special news, usage tips, and exclusive membe rs-only offers.

Simply go online and provide us with your email address. Just visit the Cyclo website at www.cyclotoolmakers.com and click the Orbit Club link to sign up.

Then, you’ll be the first to receive:

• Perform ance tips to i ncrease productivity

• News and events to improve your business

• Special offers and product news

We look forward to seeing you there!

Disposal and Recycling information:

EU countries only Do not dispose of electric power tools in the household waste! In accordance with the European Directive

2002/96/EG on Waste Electrical and Electronic Equipment and transposition into national law, used electric power tools must be collected separately and recycled in an environmentally friendly manner.

USA and other non-EU countries Do not dispose of electric power tools in the household waste! You may return your used polisher to

Cyclo Toolmakers, Inc to be recycled in an environmentally friendly manner.

Technical Specifications Model 5, 5C and 6CE

Power Supply Nominal Current Output

Model 5: 115 V a.c., 60 Hz, 2.0A .35 h.p. (.23kW) Model 5C: 230 V a.c., 50 Hz 1.0A .35 h.p. (.23kW) Model 6CE: 230 V a.c., 50 Hz 1.0A .35 h.p. (.23kW)

Speed 5 & 5C: 2800 to 3200 RPM Speed 6CE n0 = 3200/min Weight: 6.5 lbs (2.9 kg) Pad or Bonnet Capacity 2 x 4” (2 x 100 mm) diameter Motor: Alternating current, Universal, Semi-Enclosed 24-bar commutator Electric Cord: Model 5 - 9.5' long, Non-Marking 16 AWG/3 SJTOW

Model 5C - 2.5 m long, Non-Marking 1mm2 Model 6CE - 2.5 m long, Non-Marking, 1mm2 Housing: Heavy-duty cast aluminum Orbital Stroke Length 5/16 in. (8 mm)

Testing Labs: Intertek ETL SEMKO, Sun Microsystems Advance Product Testing Laboratory * - Vibration testing and weighting per EN ISO 5349-1:2001, Vibration testing per ISO 8662-1:1986

Vibration – (m/s2)*: Vertical Lateral Front-To-Back

Velcro Pads on Rubber Pad Holders Front Handle 0.00013 0.11208 0.00024 Rear Handle 0.00415 0.81142 0.00001 Pads on DoublePrecision Quick Connect Adapters Front Handle 0.00017 0.06622 0.00001 Rear Handle 0.00067 0.59596 0.00000

THE APPEARANCE OF YOUR CYCLO POLISHER

Each of our Cyclo Polishers are hand crafted with the same superior level of quality and workmanship. As all handmade items will vary slightly, we cannot guarantee that each polisher will be identical with every other one of our polishers. You may notice light sanding or buffing marks in the hand-finished aluminum castings. These are all marks of an authentic Cyclo Toolmakers tool. Naturally, Cyclo Toolmakers, Inc. will replace or repair material or workmanship defects. Refer to the Cyclo Toolmakers Warranty for further information.

13 Rev 2010.08.23

CYCLO POLISHER PARTS DIAGRAMS

14 Rev 2010.08.23

CYCLO TOOLMAKERS, INC. DUAL HEAD ORBITAL

POLISHER PARTS LIST

Indicator Part Number Number Description

12-560

Handle, Plastic Front, Polisher

50-010

Needle Bearing

11-080

Short Shoulder Bolt for Retaining Cover Plate

10-020

Metal Cover Plate

20-190

Screw, Handle Retaining

60-010

Nylon Drive Gear, Connects to Counterweight

60-020

Nylon Idler Gear (Center Gear)

10-01

Main Gear Case

22-160

Washer, Lock, Star

20-500

Screw, Metal Housing Retaining

22-520

Nut For Front Shoulder Bolt

50-040

Bearing, Main Drive Gear

20-180

Screw, Main Bearing Retaining

60-035

VES™ Counterweight Assembly (with bearing)

60-055

Head Assembly (connects to 60-035-a Counterweight Assembly)

10-040

Motor Case, Models 5 or 5C

51-705

Oiler Felt for Bronze Bearing

50-020

Bronze Bushing

30-525

Brush Holder Caps

30-500

Carbon Brush, Contoured Spring, and Dead Stop

30-515

Carbon Brush Holder

21-020

Screw, Brush Holder Retaining

30-300

Field 115V, 60Hz

20-020

Screw, Rear Handle

22-010

Split Lock Washer For Field Retaining Screw

20-100

Screw, Field Retaining

30-200

Armature, 115V, 60Hz

20-080

Screw, Motor Bearing Hold

50-030

Bearing, Lower Motor

51-710

Lock Ring for Pinion Gear

30-010

Switch, Single Pole, Single Throw, 230V, Model 5 and 5C

31-800

Crimp-on Wire Connector

20-060

Screw, Grounding

31-00

Power Cord Assembly, U.S.A. Standard.

30-020

Switch, Double Pole, Single Throw, 230V, Model 5CE

30-030

Noise Suppression Capacitor

30-040

RFI Power Line Filter

31-815

Terminal, Nylon Female Quick Disconnect

31-820

Male Connector

31-825

Female Connector

30-320-GR

Field, 230V - 50Hz,

30-220-GR

Armature, 230V - 50Hz

10-045

Motor Case, Model 6C E

31-025

Power Cord Assembly, European CE Standard

99-900

Shrink Wrap, Rear Handle (Unit of Measure = 6 inches)

20-072, -076, -078

VES Weighted Inserts (Unit of Measure = each) Please refer to pages 6 or 12 for additional information

IMPORTANT INFORMATION: –GR armatures work with –GR fields only, and standard armatures work with standard fields only. Do not mix types.

When ordering par t s please specify Polisher Model Number, Part Number and Part Description; provide serial number if not sure which version of part is required.

Send orders to your Cyclo Toolmakers dealer. If you need information on a dealer in your area, please visit our website at www.cyclotoolmakers.com.

Entire contents ©2005-2010 Cyclo Toolmakers, Inc. All rights reserved. CYCLO, ORBIT CLUB, PROGUARD, VES, FASTCUT, CTI PRO PAINT CARE, CTI 1 PASS EXPRESS, FREE FLITE and Cyclo Toolmakers, Inc logo are registered and unregistered trademarks of Cyclo Toolmakers, Inc. VELCRO is a registered trademark of Velcro USA and its affiliated

companies.

LOOK FOR THE SPACE-AGE BODY WITH THE ORBITING HEADS. Polisher configuration, including tapered conical motor housing, dual heads, and t-grip handle, is a registered design trademark of Cyclo Toolmakers, Inc.

15 Rev 2010.08.23

CYCLO 6CE, 5, 5C Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual