PowerGraver OM Re-size
Contents
1. Specifications Safety Instructions The Complete PowerGraver Kit Assembly Instructions Assembly and Adjustment of Handpiece Connecting Speed Control and Foot Switch Operation Stroke Speed Adjustment Installing Accessories Changing Collets Adjusting Impact of Hammer Maintenance Routine Cleaning and Lubrication of Flexible Shaft Replacement of Worn Shaft and Sheath Replacement of Motor Brushes Handpiece Lubrication Other Service and Repair Storage For More Information Limited Warranty Specifications M PGX Motor 125 Volt DC Ball Bearing Permanent Magnet Motor Operable Speed Range 500 2 800 RPM PGX 1 is for use with 115Volt AC PGX 2 is for use with 230Volt AC C EMGX Dial Control Variable speed manually operated electronic control EMGX 1 is for use with 115Volt AC EMGX 2 is for use with 230Volt AC Safety Instructions Before using your Foredom power tool please read all these safety instructions They are for your protection and should always be followed to reduce the risk of personal injury or damage to the tool Visit Page www foredom com How To Videos 2 FOREDOM BASICS 3 4 Foredom s National Sales 4 Manager walks you through 4 5 the Basics of using and maintaining flexible shaft 5 machines Downloadable mini series of wmv files each under 5 minutes 5 Click to View 5 6 1 Introduction and 6 Proper Set up 6 2 Safety Guidelines 6 3 Handpieces and Accessories2. different shank sizes 1 16 3 32 1 8 and 3mm To use the correct collet size for the shank of the accessory you are using it is sometimes necessary to change a collet The Connecting Motor and Control 1 Connect male plug of motor to female cord of Dial Control Variable Speed Dial Control Operation Read all safety instructions on pages 2 and 3 before using your Foredom PowerGraver Wear proper eye and face protection to pro tect yourself from injuries caused by flying debris or chips from the work being done Your Foredom motor may be operated in a ver tical or horizontal position If the motor is hung up above a workbench be sure to fasten it securely Do Not Bend the Flexible Shaft at a Tight Angle Shafts and sheaths last longer when they are used without sharp bends If used at angles or loops wear will occur at the points of greatest friction 5 collet holds the accessory securely in the handpiece Unscrew the chuck nut and slip out collet Slip in new collet and screw the chuck nut back into place Chuck Nut mpact Palm Rest Niece Ring Adjusting Impact of Hammer The impact of the stroke is adjusted by rotating the knurled ring on the handpiece clockwise towards the chuck nut for a lighter impact and counterclockwise towards the back for a heavier impact 2 Connect male cord of Dial Control into wall outlet or into female cord of Optional On Off Foot Switch 3 Plug
3. 4 Maintenance of Shafts and Sheaths Grease and Replace 5 Motor Maintenance Remove Dust Replace Motor Brushes o co co Oo N N N QOQ Shaft Sheath Shaft S 93 is 39 long and 150 in diameter Flexible Neoprene Sheath S 76N is 36 4 long Optional FCGX Foot Switch On Off foot operated switching 115V or 230V AC Current Always wear proper eye and face protection Safety glasses or face shields should be worn whenever you operate a Foredom or any power tool to prevent serious eye or face injuries Always use dust collection respirator or face mask to prevent inhalation of dust particles from workpiece or abrasives e Never use or continue to use a graver or accessory which appears to be damaged or loose Inspect each graver for cracks or flaws before using it e Always insert the shank or arbor of an accessory or mandrel into the collet of the handpiece as far as possible in order to provide proper support and tighten the collet securely e Never use excessive side pressures which may tend to bend or break the shank or arbor of an accessory Let the impact of the hammer do the work e Do not stall the motor by jamming or using excessive pressure on the accesso ry This can result in damage to the motor or flexible shaft Never operate the motor with the outer sheath removed from the flexible shaft e Always disconnect the power cord before servicing the motor or removing the flexible
4. in transit or by accident misuse or ordinary wear Own Safety ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO WARRANTIES OF FITNESS AND MERCHANTABILITY ARE HEREBY LIMITED IN DURATION TO THE PERIOD MENTIONED ABOVE FROM DATE OF PURCHASE AND WE WILL NOT BE LIABLE OR RESPONSIBLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES Repair or replacement will be made at our option if the product is returned post paid to The Foredom Electric Company 16 Stony Hill Road Bethel CT 06801 All warranty repairs must be done at the factory at the above address We will not pay any shipping or transportation charges The HP76 Duplex Spring is not covered by this warranty since it is especially sensitive to the pressure and stress variables of each individual operator This warranty only covers the original purchaser of the product Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state p Please read this Assembly Operation and Service Manual before operating your Foredom power tool Always wear eye protection while using power tools FOREDOM FOREDON The Foredom Electric Company Bethel CT USA 06801 www foredom com Form 1297 n 6 08 Printed in U S A www foredom com Contents
5. Never use in an area where flammable vapors are present Replace or repair worn cord immediately 4 e e f Grounding Blade i 2 s lt Grounding 6 Means Cc A Adapter Cover of Cover of 2 prong Grounded Outet Box Outlet Box wit Adagtee The PowerGraver Kit The Foredom PowerGraver is a complete power tool used to perform a wide variety of tasks such as engraving stone setting bright cutting bead raising and other applications requiring the use of a graver or a hammering effect Foredom power tools are manufactured to high standards of precision and with proper use and regular maintenance will give you years of trouble free performance The Foredom PowerGraver Kit K 2293 consists of a permanent magnet DC motor flexible shaft with neoprene sheath dedicated handpiece with palm rest variable speed dial control and accessories listed at left The Foredom PowerGraver Kit K 2293 also includes collet changing wrenches handpiece oil flexible shaft grease 32 minute instructional DVD and booklet Locate and identify all components before discarding the packing list and materials that came with your PowerGraver Assembly Instructions Always make sure your power tool is unplugged during assembly The PowerGraver ships with the shaft and sheath assembled however please check to be sure that the tip of the shaft extends 3 4 beyond the end of the sheath If it 7 needs to be adjusted place
6. Other Service and Repair Storage Store your Foredom power tools in a dry clean All other service and repairs should only be i dust free area and out of the reach of children done by a qualified repair person or shop Your dealer can help you select one or you can send your Foredom equipment to the Bethel CT Contact Information f J factory Factory repairs are done promptly and For more information on Foredom machines wner S an lia at reasonable cost Send the equipment marked eae acne id Attention Service Department Be sure to j 34 ase i 4 include your street address email address and Eear or oi Assembly Operation and Service for the The Foredom Electric Company phone number The equipment should be 16 Stony Hill Road Bethel CT 06801 accompanied by a brief note describing the Tel 203 792 8622 Fax 203 796 7861 problem with the equipment Estimates will fs seo ee PowerGraver Kit 2 Year Warranty LIMITED WARRANTY Foredom warrants the M PGX Motor excluding flexible shaft and sheath to be free of defects in material or workmanship for a period of 2 years after purchase the C EMGX Dial Speed Control and the C FCGX Foot Switch for 1 year after purchase and the H 9D Handpiece for 90 days after purchase During the warranty period the defective product will be repaired or replaced without charge or at our option the purchase price will be refunded This warranty does not cover For Your damage caused
7. an collect making a bridge between parts causing an electrical short In high dust environments Foredom recommends cleaning the motor every 40 hours of use To remove dirt and dust buildup motor brushes should be removed cleaned and replaced and air should be blown through the motor Routine Cleaning and Lubrication of Flexible Inner Shaft The shaft should be checked wiped clean and re lubricated with grease every 50 hours of use With every 200 hours of use the shaft should be thoroughly cleaned with solvent and lubricated Use Foredom flex shaft grease p n MS10006 or high quality white lubricating grease Sheath Set Screw Motor Coupling Se a i l Shaft Motor Connector Exposing the Inner Shaft 1 Remove handpiece see page 4 2 Loosen set screw on motor P connector 3 Slide outer sheath 4 out of motor connec tor and wipe shaft clean Pa 4 Apply a very light coating of lubrication to shaft starting at the top and working downward to about one inch from the handpiece end Apply grease with your finger tip or small brush Don t overdo apply a light film of grease Once the machine is running the shaft itself will spread the grease If too much grease is applied the excess will work its way into the handpiece and eventual ly seep out between the handpiece and sheath For this reason apply a bit less near the handpiece end of the shaft Never operate the motor with the outer S
8. he shaft Both connections must be properly aligned and they move or turn independently of eachother The handpiece is easy to remove from the flexible shaft To remove simply pull the handpiece off the shaft and sheath with a firm grip 2 Install the Palm Rest Slide the larger Opening over the front of the handpiece and place it as close to the impact adjustment ring as possible Rotate the palm rest to the most comfortable position and tighten set screw with a small flat head screwdriver Use of the palm rest is a matter of personal preference You may find that the palm rest is more appropriate for some applications than others VA l S Grind corners of shank to A 1 gt dimension shown for snug fit into collet Installing Accessories The PowerGraver can take standard gravers and other accessories with 1 16 1 6mm 3 32 2 35mm 1 8 3 18mm and 3mm diameter shanks Choose the correct accessory for your particular application We recommend that you grind and trim standard graver shanks to the dimension illustrated above To install an accessory insert one wrench into the wrench flats of handpiece Insert other wrench into wrench flats of chuck nut Loosen chuck nut Insert accessory as far as possible into the collet Tighten chuck nut Test for a secure hold by pulling on accessory Remove wrenches To release an accessory follow the same steps Changing Collets The H 9D handpiece has collets to fit four
9. heath removed from the flexible Shaft 5 Replace and adjust sheath so that shaft key IMPOR TAN Tl from sheath Retighten the set screw in motor connector 6 Clean outside of sheath by wiping with a cloth 7 Hang and run the motor for about 10 minutes before attaching the handpiece to allow enough time for the grease to warm up spread and drain off Wipe off any excess grease at tip end of sheath 8 Re attach handpiece Always make sure your power tool is unplugged during maintenance Replacing Worn Shafts and Sheaths Shafts and sheaths last longer when they are not used at sharp angles or loops since wear occurs at the points of greatest friction There is no way to avoid ultimate wear and under normal condi tions a flexible shaft machine may require several replacement shafts and sheaths during its lifetime To expose the inner shaft follow steps 1 2 and 3 on the previous page Next remove motor connector a with 1 open end or adjustable wrench Motor connector has a left hand thread and must P be turned clockwise right for removal Loosen set screw on the flexible shaft motor coupling and slide shaft off the motor shaft Installation of New Shaft 1 After removing old shaft loosen set screw on the new flexible shaft motor coupling and slide coupling onto motor shaft set va 2 Tighten set screw securely onto the flat of the motor shaft motor shaft 3 Grease shaft prior
10. shaft or sheath Never operate your power tool during a perceptible power decrease Turn power tool off and do not use until power is fully restored Accessories Collets HP602 1 16 HP603 3 32 604 1 8 and HP605 3mm Gravers A G91 52 Round om A G92 3 Onglette A G93 2 Bevel A G94 40 Flat 10215 Carbide Stylus i 10177P Anvil Point _ S o gt Use proper grounding procedures This tool should be grounded while in use to protect the operator from electric shock The tool is equipped with an approved 3 conductor cord and a 3 prong grounding type plug to fit the proper grounding receptacle The green or green and yellow conductor in the cord is the grounding wire Never connect the green or green and yellow wire to a live terminal If your unit is for use on less than 150 volts it has a plug that looks like sketch A in the diagram below An adapter sketches B and C can be used for connecting plugs as shown below to 2 prong receptacles The green colored rigid ear lug etc extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box Some jurisdictions including Canada prohibit the use of 3 to 2 prong adapters Where prohibited they should not be used Use only 3 wire extension cords that have 3 prong grounding type plugs and 3 pole receptacles that accept the tool s plug Always disconnect the power cord before servicing the machine
11. the entire unit on a flat surface with shaft amp and sheath IMPORTANTI extended straight Adjust the exposed tip of the flexible shaft so that it extends 3 4 beyond the sheath as shown This is done by loosening the set screw in the motor connector and moving the sheath in or out of the motor connector When the correct adjustment is made tighten the set screw in the connector Connecting the Handpiece flattened edge of sheath _ Unlike other Foredom Handpieces the H 9D handpiece has a tab on the end where it con nects to the shaft and sheath see drawing The tab slides over the flattened edge on the sheath The H 9D will not fit other Foredom sheaths However other handpieces can be attached to the PowerGraver shaft for slow speed jobs An Owner s Registration Card and this manual should accompany each power tool Additional copies will be sent upon request or can be downloaded at www foredom com An optional on off foot switch is available Keyed Tip on handpiece End of Shaft Keyway Sheath Inside Back Oi End of Handpiete 1 In addition to aligning the outer tab the keyed tip at the end of the flexible shaft must be lined up with the keyway inside the end of the handpiece Do this by looking into the rear of the handpiece before pushing it on If it is not in line turn the key tip or the handpiece to the correct position while being sure to also align the outer tab with the flat outer edge of t
12. the Optional On Off Foot Switch into an electrical outlet outlet On Off Foot Switch Optional Plug into wall outlet or Optional Foot Switch Do Not Force the Tool Let the speed of the tool do the work Avoid using too much pressure Stroke Speed Adjustment The strokes per minute are determined by motor speed which can be varied from 500 to 2 800 strokes Set the speed desired with the knob on the Variable Speed Dial Control Both speed and impact can be adjusted while the motor is running The On Off Foot Switch will turn the motor on or off at the speed set on the speed control Maintenance Procedures Always make sure your power tool is unplugged during maintenance It is very important to routinely clean your Foredom Power Tool and lubricate the shaft NOT the motor especially in areas that generate a lot of dust Dirt and improper lubrication are the most common causes of poor operation and excessive wear Always disconnect power tool before cleaning or servicing Note The M PGX has permanently lubricated ball bearings and does not require additional lubrication Routine Cleaning of Motors Foredom Motors need air circulation through the motor housing to remove waste heat and cool the windings Inlet and outlet slots provide the means for air flow However saw dust and conductive debris like metal filings or gold dust can enter in through these slots If not cleaned regularly dust c
13. to putting on the sheath See lubrication instructions on page 6 4 Slide motor connector back up over the shaft and tighten to the left counterclockwise 5 Slide sheath over flexible shaft with plain fitting directed toward the motor and into the motor connector Each end of the sheath has a metal fitting One is plain the other fits the handpiece 6 Adjust the shaft page 6 and tighten sheath set screw in motor connector motor veoning Connector Aligning Tab Oil a ___ Duplex Spring Cover Impact Adjusting Ring 7 Palm Rest Shaft and Sheath Adjustment Place the entire unit on 7 a flat surface with shaft and sheath extended straight Adjust the exposed tip of the flexible shaft at the handpiece end so that it extends 3 4 19mm beyond the sheath as shown on page 6 This is done by moving the sheath in or out of the motor con nector When he correct adjustment is made tighten the screw in the motor connector Replacement of Motor Brushes The motor brushes MP319P should be checked for wear periodically When new they are approximately 3 4 long They should be replaced when they have worn to 1 4 To remove brushes disconnect motor power cord and unscrew the brush caps Be sure that the contour of the New Motor Brush Motor Brush that E needs replacement brushes match the contour of the armature when replacing them Be sure to replace both motor br
14. ushes even if one of them is less worn than the other To remove dirt and dust buildup when motor brushes are checked or replaced compressed air should be blown through the motor Handpiece Lubrication The H 9D Handpiece requires lubrication approximately every 40 hours of use Use oiler provided to apply two drops of oil into the oiling hole located on the barrel of the handpiece under the palm rest and into the hole on the rear of the duplex spring connection To remove palm rest loosen set screw Do not apply more than two drops of oil Set Screw Tool Holder Chuck Nut re Wrench Flats Oil Hole
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