CYCLO 5 User manual

INSTRUCTION MANUAL
FOR
MODEL 5, 5C & 5CE CYCLO ORBITAL POLISHER/SANDER

Cyclo Toolmakers, Inc ∙ 1740 Skyway Drive ∙ Longmont, CO 80504
Phone: [phone] ∙ Fax: [phone] ∙ www.cyclotoolmakers.com
INSTRUCTION MANUAL
FOR
MODEL 5, 5C & 5CE CYCLO ORBITAL POLISHER/SANDER
This instruction manual is furnished with each Cyclo Model 5, 5C & 5CE Electric Polisher/Sander tool.
The entire manual should be read carefully before using the Cyclo Polisher/Sander tool and retained for future reference.
This manual contains separate sections to inform the purchaser of the tool on:
#1 SAFETY INSTRUCTIONS
#2 OPERATING INSTRUCTIONS
#3 POLISHERS, CLEANERS & PROTECTANTS
#4 USER MAINTENANCE & TROUBLESHOOTING
TECHNICAL SPECIFICATIONS:
Volts Cycle H.P. Amp
Model 5: 115 60 1/3 2.0 (.23kW)
Model 5C & 5CE: 230 50 1/3 1.0 (.23kW)
RPM: 2800 to 3200
Weight: 6.5 lbs (2.9 kg)
Noise Emissions - 5CE: 82.6 dBA
Vibration - 5CE (m/s2)*: Vertical Lateral Front-To-Back
Front Handle 26.3 30.2 18.4
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Rear Handle 29.9 41.9 11.2
Motor: Alternating current, Universal, Semi-Enclosed 24-bar commutator
Electric Cord: 6' long, Non-Marking, 18/3 SJT or 8' long, CEE 7/7
Housing: Heavy-duty cast aluminum
Listing/Approvals: European Community - Model 5CE
Testing Labs: TÜV, Components Reliability and Safety - Model 5CE
•Vibration testing per ISO 8662-1:1986
SAFETY INSTRUCTIONS
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:
-READ ALL INSTRUCTIONS-
1) GROUNDING INSTRUCTIONS FOR MODEL 5 & 5C
The Model 5 & 5C Polisher/Sander should be 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 conductor wire in the cord is the grounding wire. NEVER CONNECT THE GREEN WIRE TO A LIVE
TERMINAL.
If there is any doubt as to whether the wall receptacle is properly grounded, the customer should have it checked by a qualified
electrician.
DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE THIRD (GROUND) PRONG FROM THE POWER CORD
PLUG.
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2) EXTENSION CORD (Available directly from Cyclo Toolmakers)
With the Model 5 & 5C Orbital Polisher/Sander, 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.
For the 115 Volt, 2.0 Amp tool, the figures on page 3 indicate the size of wire which must be within the indicated length of
extension cord.
AMPERE 2.0
Extension Cord Length Size of Wire in Cord
25 feet 18
50 feet 18
100 feet 18
150 feet 16
200 feet 16
3) MOTOR
Your Cyclo Orbital Polisher/Sander is powered with a sturdy universal motor. Be certain your power supply agrees with that shown
on the name plate. A.C. means alternating current. Variance in your voltage by more than 10% will mean loss of power and
overheating. This tool is factory tested. If it will not operate, check electric supply for blown fuses, check plug and electrical
receptacle for proper contact.
ADDITIONAL SAFETY INSTRUCTIONS
1) Keep Work Area Clean. Cluttered areas and benches invite injuries.
2) Consider Work Area Environment. Don't use power tools in damp or wet locations. Keep work area well lit. Do not use the
tool in the presence of flammable liquids or gases.
3) Guard Against Electrical Shock. Prevent body contact with grounded surfaces. For example: pipes, radiators, ranges.
4) Keep Children Away. Do not let visitors contact tool or extension cord. All visitors should be kept away from work area.
5) Store Idle Tools. When not in use, tools should be stored in dry, and high or locked-up places - out of reach of children.
6) Do not Force Tool. It will do the job better and safer at the rate for which it was intended.
7) Use the Right Tool. Do not force small tool or attachment to do the job of a heavy-duty tool.
8) Dress Properly. Do not wear loose clothing or jewelry. They can be caught in moving parts. Rubber gloves and non-skid
footwear are recommended. Wear protective hair covering to contain long hair.
9) Use Safety Glasses. Also use face or dust masks if operation is dusty.
10) Do not Abuse Cord. Never carry tool by cord or yank it to disconnect from receptacle. Keep cord away from heat, oil and
sharp edges.
11) Secure Work. Use clamps or a vise to hold work. It is safer than using your hands and it frees both hands to operate tool.
12) Do not Overreach. Keep proper footing and balance at all times.
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13) Use Proper Hearing Protection. Prolonged exposure to tool without hearing protection could promote a loss of hearing.
14) Maintain Tool with Care. Keep tool clean for better and safer performance. Follow instructions for lubricating and changing
accessories. Inspect cord periodically and if damaged, have repaired by authorized Cyclo service facility. Inspect extension cords
periodically and replace if damaged. Keep handles dry, clean, and free from oil and grease.
15) Disconnect Tools. When not in use, before servicing, and when changing accessories, such as heads, sanding jackets, and
bonnets.
16) Remove Adjusting Keys and Wrenches. Form a habit of checking to see that keys and adjusting wrenches are removed from
tool before turning it on.
17) Avoid Unintentional Starting. Do not carry plugged-in tool with finger on switch. Be sure switch is off when plugging in.
18) Use Only Outdoor Extension Cords. Use only extension cords intended for use outdoors and so marked.
19) Stay Alert. Watch what you are doing. Use common sense. Do not operate tool while tired. Keep fingers away from moving
parts at all times.
20) 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 service center unless otherwise indicated elsewhere in
this instruction manual. Have defective switches replaced by authorized Cyclo service center. Do not use tool if switch does not turn
tool on and off.
21) Insulated Handles. Do not operate the tool without the properly insulated handles. NOTE: If shrink wrap insulation on the
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 an authorized Cyclo service center.
22) Use only Cyclo Toolmakers Recommended Products. The use of any other accessories or attachments other than those
recommended in the operating instructions or the catalogue may present a risk of personal injury, and could void any warranties.
OPERATING INSTRUCTIONS
Using the Cyclo polisher:
Your Cyclo tool has two heads rather than the single head you may be accustomed to seeing. As soon as the Cyclo tool is placed on
a working surface, orbital “hand-rubbing” action takes place. Therein lies the secret of its ability to do many different types of jobs
that could not be done with single head or rotary tools. The two heads move in a circular, overlapping motion and are
counterweighted to balance. Thus, very little centrifugal force is exerted and the vibration, heat and throwing action of a rotary tool
is eliminated.
No matter how much pressure you apply to your Cyclo tool, whether you are sanding or polishing, the machine remains steady. The
more pressure you apply the harder the heads work, although even, moderate pressure works best in most situations. The hand-like
action of the counterbalanced heads prevents surface damage, regardless of the pressure applied. It is impossible to burn, mar, or
gouge the surface, either in sanding or polishing. Move the machine slowly; you need not be afraid of burning the surface.
The polishing pads:
1) There are multiple types of Cyclo pads. Below is a list of Cyclo’s full line of pads in order of aggressiveness.
Super Fine Finishing White Foam Pad (PN 72-110; former P/N 85-085)
Light Polishing Green Foam Pad (P/N 72-120; former P/N 85-095)
Medium Compounding & Polishing Orange Foam Pad (P/N 72-12)
Heavy Compounding & Polishing Yellow Foam Pad (P/N 72-135; former P/N 85-065)
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Super Fine Cutting & Polishing White Wool Pad (P/N 72-440)
Light Cutting White Wool Pad (P/N 72-455; former P/N 85-085)
Medium Cutting Yellow Foam Pad (P/N 72-160)
Heavy Cutting White Wool Pad (P/N 72-470)
2) In order to affix the Cyclo bonnets to the twin heads, first disconnect the power cord, then simply turn the polisher upside
down and rest it in your lap. Turn the bonnet inside out and place its rubber base squarely on one of the heads. Now, grip the head
and the bonnet firmly between both hands, and with the thumbs, turn the edge of the bonnet down over the head. Rotate the head
slightly and repeat the step above until the bonnet’s edge is completely over the head.
With the velcro pads, you install the jacket with Velcro attached in the same manner as above. However, to change pads just
peel off the used pads and attach a fresh pad by pressing it firmly in place centered on the velcro jacket.
3) The pads and bonnets should be cleaned as soon as possible after use with a good industrial cleaner or detergent. For best
results, wash the foam pads out by hand, squeeze dry (do not twist or wring) and let air dry. The wool pile pads should also be
washed with a good industrial cleaner or detergent and then run through with a brush. The wool pads and can also be washed in
warm water and tumble dried in a cool dryer.
CYCLO POLISHERS, CLEANERS & PROTECTANTS
Never try to use a rotary type polish or cleaner with the Cyclo polisher and never try to use Cyclo polishes with rotary tools. The
Cyclo products are specifically formulated for use with the Cyclo and though some hand application type polishes may give
satisfactory results, we recommend that for the BEST results only the laboratory and field tested genuine Cyclo products be used
with the Cyclo tool.
1) On painted surfaces use the CTI Pro Paint Care line or the CTI One Pass Express
CTI Pro Paint Care Line:
1. Compounding Gel – Removes scratches and heavy oxidation from surface. Very aggressive compounding polish
for use on any surface.
2. Cleaner-Deoxidizer – Great for removing hair line scratches and light to medium oxidation. Mild abrasion creates a
clean and smooth surface. Does not contain any shine components.
3. Cleaner-Deoxidizer – Great for removing hair line scratches and light to medium oxidation. Mild abrasion creates a
clean and smooth surface. Does not contain any shine components.
4. Polish and Protective Sealant – High poly sealant will give your surface 12-18 months of durable protections and
brilliant gloss.
CTI One Pass Express:
1. Cleaner-Polish-Sealant – With One Pass Express you can remove light scratches and environmental contaminants. It
quickly restores showroom color and brilliance and protects finishes with a weather resistant polish and silicone film.
2) On unpainted aluminum or stainless steel use the CTI Metal Polish:
CTI Metal Polish:
1. Free FliteTM Cleaner-Polish - Aggressive rubbing compound for badly oxidized aluminum and paint. Removes
corrosion, oxidation and surface film leaving a hard polished finish. Military standard for the armed forces including the
Air Force One fleet.
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2. Mild Polish & Protectant – Mild deoxidizing agent specially formulated to bond to bare metal. Removes fine
polishing scratches only seen in direct sunlight. It also leaves a great protective coat that will prevent any further
oxidation.
Polishing:
1) After you have placed the pads or bonnets on your Cyclo tool, connect the tool to the power supply.
2) Apply a small amount (about a teaspoon) of the proper polish to each pad; small amounts repeatedly work better than large
amounts.
3) Place the twin-head Cyclo tool, pad side down on the surface and move the tool around before turning it on in order to
distribute the polish within the pad and over the surface.
4) Then, turn on the tool and move it back and forth and side to side across an area approximately 2.5 square feet in size. This
will spread the polish or deoxidizer across the surface in a latticed pattern.
5) Grip both handles of the polisher, and using moderate pressure - letting the action and the weight of the tool do the work -
move the polishing heads across the 2.5 square feet area under a comfortable speed. Deoxidize or polish the entire car in this
manner. When you have finished, rub out by hand the powdery residue left from the deoxidizer or smooth out any smudges left by
the glaze. Clean diapers are excellent for this.
6) If the residue does not wipe off easily, the surface is still not clean. Reapply a cleaning chemical to the area and rub it out.
7) Repeat steps 2-6 as necessary.
8) As the pads become badly impregnated with oxidation, they should be removed and washed. Never keep polish in pads
overnight.
Sanding:
Place two sanding jackets on your Cyclo tool and firmly press on two 4” sandpaper discs that are self-adhesive. Sanding discs can
be changed as needed.
Your Cyclo tool will handle all sanding jobs, including contour sanding. The job to be done will dictate the grade of sanding discs
to use.
Your Cyclo tool is excellent for wood and metal sanding...paint removal...orange peel removal...conditioning surfaces for
paint...floor sanding...all furniture sanding, contoured and flat...dry wall sanding. The Cyclo is a natural feather edger. It does an
exceptional job of feather edging on paint, metal or wood.
USER MAINTENANCE AND TROUBLESHOOTING
Motor:
Always be sure the Cyclo polisher/sander is disconnected from the electrical outlet before any inspection or maintenance is
performed.
The motor is only for the voltage specified on the nameplate. It is universal in that it can be used on either direct or alternating
current from 25 to 60 cycles. Voltage should not vary more than 10% over or under the voltage shown on the nameplate.
Although the Cyclo 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 the user.
If the Cyclo tool has stopped:
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1) Inspect the carbon brushes. Most likely the brushes have been worn down and need to be replaced. When replacing your
carbon brushes, keep in mind that Cyclo carbon brushes have been made specifically for the Cyclo with a pre-cut contour on
the front edge of the carbon block to match our commutator, and a nylon plug has been placed in the rear of the carbon block
(in front of the spring) to interrupt the electrical flow when the carbon block wears down to this point. This prevents the load
spring from coming in contact with the commutator and shorting out the entire armature.
CAUTION: Be sure the power cord is disconnected. Unscrew the black brush cap found on each side of the motor housing. The
carbon brush and spring can then be easily withdrawn from the motor housing. Note how the contour in the carbon block matches
the contour of the motor commutator. The carbon brush must be reinserted in this same pattern to maximize electrical contact with
the commutator. If badly worn, down to the first printed letter, call Cyclo to order new brushes. Also replace if assembly has a weak
spring. Keep brushes clean and sliding freely in their guides.
2) Check the electrical supply for blown fuses and the plug and electrical receptacle for proper contact.
How to maintain your Cyclo polisher/sander:
1) Every eight hours of use, lubricate the upper motor bearing by placing 3 drops of 3-in-1 oil in the center of the copper bushing
found at the top of the motor housing.
2) Every eight hours of use, or as conditions warrant, blow out the motor housing with an air hose 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 out the underside of the tool.
3) Never operate the polisher with chipped or otherwise damaged brush caps. Be sure the power cord is disconnected. Using a
screwdriver, remove the damaged brush 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.
ANY OTHER SERVICING SHOULD BE PERFORMED BY AN AUTHORIZED CYCLO SERVICE CENTER OR THE TOOL
SHOULD BE SENT TO CYCLO TOOLMAKERS, INC., ATTN: SERVICE DEPARTMENT, 1740 SKYWAY DR., LONGMONT,
CO 80504. ENCLOSE A $10 CHECK OR CREDIT CARD NUMBER WITH EXPIRATION DATE FOR RETURN SHIPPING.
PLEASE KEEP IN MIND SERVICE REPAIRS CAN TAKE UP TO THREE WEEKS.
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, relubricate with Texaco Multifax #2 or equivalent.
CAUTION: The secret of the operation of your Cyclo polisher/sander 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:
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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.
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Cyclo Toolmakers, Inc. 6 Plus 6 Warranty
Cyclo Toolmakers, Inc. warrants this machine to the original purchaser/user to be free from material or workmanship defects
for a period of 6 months from the date of purchase provided the machine is delivered or shipped freight prepaid to the Cyclo
Factory or a Cyclo authorized repair center. Our obligations under this warranty are expressly limited, at our option, to
replacement or repair of such parts as inspection shall disclose to have been defective and the labor required for installation at
no cost to the original purchaser – freight excluded.
Conditions resulting from misuse, negligence, alterations, accidents, damage caused by improper use of chemicals, or improper
repair by unauthorized parties, or “wear and teat” from normal usage, are not covered.
Any adjustments or replacements of defective parts made under this warranty will not void the warranty, nor will it extend the
original warranty.
For an additional 6 months, Cyclo agrees to share the cost of any necessary replacement part or parts by allowing the purchaser
a 30% discount from list prices on part or parts replaced for a period of 6 months from the date the unconditional warranty
expires.

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