FOREDOM K Series User manual

FOREDOM
Owner's Manual
Assembly,
Operation, and
Service Manual for
Series K
Ball Bearing
Power Tool and
Handpieces
For Your Own Safety:
•Read Owner's Manual before operating your Foredom
power tool.
•Always wear eye protection while using power tools.
•Only use accessories with the same or higher speed
ratings as your power tool (18,000 RPM).
power tools
®
Contents
Safety Instructions 2
The Series K 3
Assembly Instructions 4
Assembly & Adjustment of Shaft, Sheath & Handpiece 4
Connecting Foot Speed Control 5
Attaching Accessories 5
General Accessory Recommendations 7
Operation 9
Maintenance
Routine Cleaning & Lubrication 10
Replacement of Motor Brushes 10
Replacement of Worn Shaft and Sheath 10
Handpiece Lubrication 10
Other Service and Repair 11
Recommended Spare Parts & Supplies 11
Limited Warranty 12
Owner’s Registration Card 12
For More Information 12
Safety Instructions
Before using your Foredom®power tool, please read safety instructions.
They are for your protection and should always be followed to reduce the risk of
personal injury or damage to the tool.
•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.
•Do not wear loose fitting clothing or jewelry. Loose clothing or jewelry can
become entangled in the rotating flexible shaft. Do not wear items such as neck
ties, necklaces, or bracelets when operating power tools. Be sure to tie back or
secure long hair.
•Secure power tool to motor hanger or work surface. Flexible shaft power
tools can vibrate during operation. The tool should be properly secured in order
to prevent it from vibrating off of the motor hanger or work bench.
• Never operate any accessory at speeds above it’s maximum rated speed.
When properly used, all of Foredom's accessories can be operated at the speed
ratings listed in the Foredom Accessory Catalog or on the accessory kits and
packages. Always find out the manufacturer's speed rating before using
accessories other than Foredom accessories.
Page
2

• Never use or continue to use any accessory which appears to be damaged,
loose, vibrating, or out of balance. Inspect each accessory for cracks or flaws
before using it.
• Always insert the shank or arbor of an accessory or mandrel into the collet or
chuck of the handpiece as far as possible in order to provide proper support and
tighten the collet or chuck securely.
• Never use excessive side pressure which may tend to bend or break the
shank or arbor of an accessory. Let the speed of the accessory do the work.
• Do not stall the motor by jamming or using excessive pressure on the
accessory. This can result in damage to the motor or flexible shaft.
• Never operate the motor with the outer sheath removed from the flexible shaft.
• Always disconnect the power cord before servicing the motor or removing the
flexible 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.
• 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 plug to fit the proper grounding receptacle.
The Series K
You have purchased a quality power tool
which will perform a wide variety of tasks
difficult to do with any other kind of power
tool. Foredom power tools are manufactured
to high standards of precision and performance
and, with proper use and regular maintenance,
will give you years of trouble-free performance.
A complete Foredom flexible shaft power tool
consists of a motor, flexible shaft and sheath,
speed control (foot or manual), and a handpiece.
Locate and identify all components, parts, and
accessories you purchased before discarding the
packing list and packing materials that came with
your power tool.
This instruction manual contains instructions
for the assembly, operation, and servicing of
the Foredom power tools shown at right.
3
FCT2-CE Foot Speed Control
Series K Motor
Assembly Instructions
Always make sure your power tool is unplugged during assembly!
After identifying all the components of your power tool, it should be assembled in
the following manner:
Assembly and Adjustment of Flexible Shaft, Sheath & Handpiece
Proper assembly and adjustment of the flexible shaft and sheath are critical for
the correct operation of your Foredom power tool.
Important Note: The shaft and sheath should be checked and adjusted if
necessary even if you received them assembled and attached to the motor!
Please follow the directions below to assemble and adjust the shaft and sheath
and attach the handpiece.
Assembly:
1.Remove the motor connector (see figure 1). This has a left hand thread and
must be turned to the right to remove.
2.Loosen the set screw on the flexible shaft motor coupling and slide the shaft
coupling onto the motor shaft. Tighten the set screw onto the flat in the
motor shaft.
3.Put the motor connector back on the motor by sliding it up the flexible shaft and
tightening. Grease shaft (see page 12).
4.Now slide the sheath over the flexible shaft with the plain sheath fitting (not the
grooved fitting) going toward the motor and into the motor connection.
4
Adjustment:
5.Before attaching handpiece, shaft and sheath adjustment must be carefully
checked. Place the entire unit on a flat surface with shaft and sheath extended
straight. Adjust the exposed tip of the flexible shaft so that it extends 19mm
beyond the sheath, as shown in diagram above. This is done by moving the
sheath in or out of the motor connector. When the correct adjustment is made,
tighten the screw in the motor connector.
19mm

5
Attaching Handpiece:
6. Finally, attach the handpiece by pushing it on the grooved QD (quick disconnect)
fitting on the sheath. Be sure that the keyed tip of the flexible shaft is properly
lined up with the slot in the handpiece shaft connector by looking into the rear of
the handpiece before pushing it on. If it is not in line, turn the shaft tip or the
handpiece to the correct position.
Connecting Foot Speed Control
Connect the foot control to the motor by inserting the 3-prong plug on the end of
the motor power cord into the socket connector on the shorter power cord on the
foot control. Insert the plug on the longer power cord from the foot control into a
proper 3-wire power outlet.
7A
7AD
8
18D
18
15D
15
10D
10
8D
52D
53
52
44T
35
30®
25C
28
25
Foredom
Handpieces
6
Attaching Accessories to Handpieces
Directions for attaching accessories to handpieces vary according to the type of
handpiece being used. Locate the model number of your Foredom handpiece
from the illustrations on page 5. Attach the accessory according to the
following directions:
Collet Types
General Directions: Be sure to use the correct shank size. The correct shank
will fit snugly inside the collet.
Caution: Never tighten a collet unless an accessory has been inserted. Tighten
an empty collet or inserting an accessory which is too small or too large may
damage the collet.
Nos. 8, 8D Handpieces:
Pull back chuck guard sleeve to uncover the lower portion of the spindle hole.
Insert pin or wrench provided into the spindle hole or grip lower spindle with
wrench. Loosen chuck nut. Insert accessory shank as far as possible into the
collet. Tighten chuck nut. Test for a secure hold by pulling on accessory. Pull out
pin or release grip on spindle. To release an accessory, follow the same steps.
Accessories can be released when chuck nut is ready to be loosened. If acces-
sory does not run true, loosen chuck nut, rotate accessory, and retighten.
To change the collet, simply unscrew the chuck nut and slip out collet. Slip in
new collet and screw chuck nut back in place.
No. 28 Handpiece:
The No.28 comes with a pin and wrench for opening and closing the collet. To
open the collet, insert the pin through the hole in the handpiece and the spindle
and loosen the chuck nut with the wrench. Insert the shank of the accessory as
far as it will go into the chuck nut and collet, then tighten the chuck nut securely
with the wrench. Remove the pin from housing before starting the flexible shaft
machine.
Nos. 25, 35, and 44T Handpieces:
To insert or exchange accessories, insert pin provided into the pilot hole and
through the spindle hole (turn spindle to align holes). Loosen chuck nut slightly
with wrench provided. Insert shank of accessory into collet. Tighten chuck nut
with wrench, keeping pin in pilot hole. Test for a secure hold by pulling on acces-
sory. Remove pin.
Chuck Type — Nos. 25C, 30®Handpieces:
These handpieces have Jacob's type chucks. Open chuck jaws as far as neces-
sary with key provided. Insert shank of accessory into the chuck as far as possi-
ble. Tighten jaws with chuck key until accessory is secure and centered. If
accessory does not run true, reopen jaws, rotate accessory and retighten. To
release accessory, simply reopen chuck jaws with key and pull out accessory.
Hammer Type — Nos. 15, 15D Handpieces:
These handpieces have a threaded spindle. Thread anvil or stylus into threaded
spindle as far as it will go with clockwise motion. Insert pin provided into cross
hole in anvil or stylus. Tighten and remove pin. To release accessory, insert pin
into the cross hole and unthread
Latch Type — Nos. 55A, 55D, 56A, 56D Handpieces:
These handpieces have simple finger latches. Slide the latch over and insert the
shank of the accessory as far as possible. Slide the latch back into place.

7
Test for a secure hold by pulling on the accessory. To release the accessory,
slide latch out again and pull out accessory.
Quick Change Type
Nos. 7A and 7AD Handpieces:
These handpieces have a push-pull collet closer. Pull the handpiece grip back
as far as it will go. Insert accessory shank (size 2.35mm only) as far as it will go.
Push front portion of the handpiece forward firmly. Test for a secure hold by
pulling on the accessory. To release accessory, pull handpiece grip back with
firm pull. Pull out accessory.
Nos. 10 and 10D Handpieces:
These handpieces operate only when a 2.35mm shank bur is inserted. It will
lock if bur is not inserted. To insert bur, move lever 180º clockwise towards the
back (shaft connection end) of handpiece. Insert or change a 2.35mm shank bur
and move lever 180º forward. Make sure lever is completely locked into the
forward position.
Nos. 18 and 18D Handpieces:
These handpieces have a lever on side of handpiece. Push the spring loaded
lever in to open collet and release the shank of accessory (2.35mm only). Insert
accessory while holding the lever down with thumb or finger. Never push lever
down while handpiece or flexible shaft are rotating.
Nos. 52, 52D, and 53 Handpieces:
These quick change handpieces have a unique push/pull collet chuck release
mechanism for rapid accessory changing (2.35mm only). Wait for the motor, flex-
ible shaft, and accessory to come to a full stop before opening the chuck. After
accessory has stopped rotating, pull the outer grip forward with one hand while
holding the back of the handpiece with the other. Remove the accessory and
insert the shank of the new one at least 1″(25mm) into the chuck. Pull the grip
all the way back until the chuck snaps closed.
Be sure to read the following accessory recommendations before using
your Foredom Power Tool.
General Accessory Recommendations
The wide assortment of Foredom accessories makes your flexible shaft power
tool very versatile. Grinding, sanding, brushing, cutting, buffing and polishing can
all be easily accomplished. Choose the right accessory for your special needs
by referring to the Foredom Accessory Catalog No. 350. Accessories may be
purchased through your local dealer or by contacting: The Foredom Electric
Company, 16 Stony Hill Road, Bethel, CT 06801, [phone].
Always let the speed of the power tool do the work. Avoid forcing the tool or
applying too much pressure. Experience will help you choose the right speed for
the work you are doing. It's always a good idea to practice on a scrap piece of
the same material you plan to work on to determine the best accessories and
speeds to use.
Always follow the manufacturer’s RPM or speed recommendations when
selecting accessories.
Your Series K motor is supplied with a variable speed control so that you can
operate it at the most suitable speed for each job. The motor has a maximum
speed rating of 18,000 RPM. Always use an accessory which has the same
or a higher rating than your tool. Using an accessory with a lesser rating
can result in serious injury.
1. Abrasive Points, Wheels and Discs:
Use Silicon Carbide (green color) for low-tensile, brittle or “smeary” types of
metals such as aluminum or brass. Use Aluminum Oxide (red color) for fast
cutting on high-tensile, tough materials such as steel and malleable iron. Also
use on glass and porcelain, etc. Aluminum Oxide (white color) points have an
extremely fine grit for producing a fine, high finish on high-tensile materials
including gem stones, stainless steel, and glass. Rubber Bonded Abrasive
Wheels are used for removing rust and for polishing with various grits. For best
results, use finer grits for finishing at high speeds and coarser grits for stock
removal at lower speeds. NewCeramCut BlueTM Stones are made from a mixture
of special man-made ceramic grain and aluminum oxide bonded together. The
ceramic grain provides a faster cutting action and is more durable so that shapes
are maintained longer than pure aluminum oxide stones.
2. Burs and Cutters:
Vanadium Steel Cutters are suitable for all materials except hardened steel and
glass. Use Carbide Burs on such materials as wood, plastic and tough alloys
(Carbide is generally referred to as the “hardest man-made metal”). Engraving
Burs are used for fine detailed work on metal and other hard materials. Generally,
use medium speeds for stock removal. Higher speeds are required for finishing
work and for the smaller points.TyphoonTM Carbide Burs are specifically made for
use on soft and hard woods and plastics.
3. Sanding Drums, Bands and Discs:
These accessories are used for removing rust, smoothing rough surfaces and for
sanding jobs on wood, plastic and metal. (Avoid using too much pressure which
will cause clogging or a build-up on the work surface.) For best results, use medi-
um speeds for coarser grits and larger diameters. Use higher speeds for
finishing work or with smaller sizes.
4. Cotton or Felt Bobs and Buffs:
Solid Felt Buffs or Bobs are used in combination with gritty or smooth compounds
for a variety of buffing and polishing operations on plastic, wood, and metal. They
vary in shape and come in three hardnesses — medium, hard, and rock hard.
Loosely-stitched Soft Cotton Buffs are used for delicate work; especially work
with precious metal and during polishing operations. Generally, use high speeds
for cutting down and buffing. Medium speeds are used for delicate, precise work
and for polishing.
5. Brushes:
Miniature power brushes are generally used on metal surfaces and hard-to-reach
areas. They are ideal for deburring, surface finishing, edge blending, roughening
to create a good bonding surface, and general cleaning. Use high speeds for
cleaning and deburring. Medium speeds are needed when cleaning hard-to-reach
areas and edge blending.
6. Diamond Burs:
Diamond Burs are used to remove stock from extremely hard materials such as
tungsten and tantalum carbide cutting tools, dies and molds, broaches, and for
lapping and polishing synthetic jewels and precious metals, fiberglass and
reinforced plastics, PVC and ceramics.
8

9
Minimum
Operating
Radius
Do Not
Do This!
4″radius
4″radius
Operation
Read all the safety instructions in this manual before operating any
Foredom Power Tool. Proper eye and face protection must be worn to
protect you from injuries caused by flying debris, chips, or sparks which
might result from the work being done.
Your Foredom motor may be operated in a vertical or horizontal position, but it
should not be enclosed or confined so as to restrict air circulation. If the motor is
hung up above a workbench, be sure it is fastened securely to the wall or motor
hanger. The motor may develop a high operating temperature (up to 100oF +
ambient) after prolonged use, and it will be too hot to hold. This will not harm the
motor which is designed to operate at this temperature for pro-
longed periods.
Do not bend at 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. When operating your power tools be
careful not to bend the flexible shaft too much
at either the handpiece or motor shaft connec-
tions. Excessive heat and wear will occur if the
bend is too great.
Follow these guidelines for trouble-free use:
a 4″or larger radius, as shown to the right, should
be maintained for shafts on all motors. In its normal
curved position, the Series H can withstand 28 lbs. of
torque before breaking. All other Series can tolerate up to
12 lbs. of torque. There is no way to avoid ultimate wear
and under normal conditions a flexible shaft machine may
require several replacement shafts and sheaths during its
lifetime. (Follow shaft and sheath assembly instruction in the
Assembly section of this manual.)
Do not force the tool
Let the speed of the tool do the work. Avoid using too much
pressure. Generally, slower speeds are used for rougher,
heavier work or when greater control over the accessory is
required for precise, delicate work. Higher speeds are used for
buffing, cutting and polishing. Read Accessory Recommendations on page 7 of
this manual.
Voltage Decreases
Never operate a power tool during a perceptible power decrease. Turn off tool
and unplug until full power is restored.
Always wear proper eye and face protection when operating
10
Maintenance
It is very important to routinely clean and lubricate your Foredom Power
Tool, 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: Ball Bearing Motors do Not Require Lubrication.
1. Routine Cleaning of Universal Motors
Universal 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, dust and conductive debris (like metal filings and gold dust) can
enter in through these slots. If not cleaned regularly, dust could collect, making a
bridge between parts, causing an electrical short. Therefore, in high dust
environments, Foredom recommends cleaning the motor every 40 hours
of use. To remove dirt/dust buildup, brushes should be removed, cleaned and
replaced, and air should be blown through the motor.
2. Routine Cleaning and Lubrication of Flexible Shaft
The flexible shaft should be cleaned and lubricated once every 50 hours of use.
Expose the shaft by removing the handpiece and then the sheath. Apply a light
film of Foredom flexible shaft grease (Part No. 10006) along the entire length of
the shaft. Replace the sheath according to instructions in the Assembly and
Installation section of this manual. Once every 200 hours, the shaft should be
thoroughly cleaned with a solvent and lubricated.
3. Replacement of Motor Brushes
The motor brushes should be check for wear periodically. When new, they are
approximately 19mm long. They should be replaced when they have worn to
6mm. To remove brushes, disconnect motor power cord and unscrew the brush
caps. Be sure that the contour of the brush matches the armature when
replacing them.
4. Replacement of Worn Shafts and Sheaths
Be sure to disconnect your power cord before servicing. Shafts and sheaths last
longer when they are used at a straight angle. If used at sharp angles or loops,
wear will occur at the points of greatest friction. There is no way to avoid ulti-
mate wear, and under normal conditions a flexible shaft machine may require
several replacement shafts and sheaths during its lifetime. Follow replacement
instructions in Assembly section of this manual.
5. Handpiece Lubrication (See page 5 for handpiece photos.)
Numbers 7A and 7AD*: Unscrew the front housing which exposes the spindle.
Clean the spindle thoroughly with solvent. Apply several drops of Foredom oil
(part nos. 10005 or 10010) to the spindle and spread it over the spindle uniform-
ly. This should be done each 20 hours of operation.
Numbers 8, 8D*, 18, 18D*, 25, 25C, 30®, 35, and 44T: These handpieces have
been permanently lubricated with greased-shielded ball bearings and should
absolutely not be lubricated.

Owner's Registration Card
Send your Owner's Registration Card to Foredom right away. We will keep your
card in our Registration and Serial Number File.
Repair Services
Authorized repair service is available at the Foredom factory in Bethel, CT. Send
items for repair to the factory marked “Attention: Repair Department”. Enclose
the item(s), a packing list, and information regarding the problem or repairs
required. Estimates of repair cost will be made upon request. It is our policy not
to proceed with a repair without your approval if the cost (labor plus parts) is
more than fifty percent of the cost for a new replacement. You will be notified by
mail and advised of the cost to repair and to purchase a new replacement.
Please allow three business days for an estimate to be done and five to seven
business days for repair work to be completed after we receive your approval
to proceed.
Series K Ball Bearing Motor
LIMITED WARRANTY
Foredom warrants the Series K Motor to be free of defects in material or workman-
ship for a period of 1 year 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 damage caused in transit or by
accident, misuse, or ordinary wear.
ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO WARRANTIES
OF FITNESS AND MERCHANTABILITY, ARE HEREBY LIMITED IN DURATION
TO A PERIOD ENDING 1 YEAR 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 #76 Duplex Spring is not covered
by this warranty since it is especially sensitive to the pressure and stress variables
of the 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.
For More Information
For more information on Foredom machines, handpieces or accessories,
contact your local dealer. When no local dealer is available, write, call or fax:
The Foredom Electric Company, 16 Stony Hill Road, Bethel, CT 06801
[phone], Fax: [phone]. Visit on line at: www.foredom.com
FOREDOM
Form 1267 2/03 b Printed in U.S.A.
THE FOREDOM ELECTRIC CO.
Bethel, CT 06801
®
11
Number 10: Lubrication should not be required for the first 2-3 months of contin-
uous use. Then, approximately every two weeks, remove the sheath connector
(it has a standard right hand thread) to expose the slotted shaft connector and
back of handpiece spindle. Clean off any dirt or old lubricant. Apply 1 or 2 drops
only of Foredom oil to the spindle where it attaches to the slotted shaft. Now
replace sheath connector.
Number 10D* Handpiece with Duplex Spring Connection: Approximately
every 20 hours of operation apply 1 or 2 drops of Foredom oil into the hole in
the duplex spring collar next to the sheath connector. This will provide sufficient
lubrication for both the duplex spring connection and the handpiece spindle.
Numbers 15 and 15D*: Before disassembling, clean off any dirt to prevent
foreign matter from falling inside the handpiece. Remove the threaded
nosepiece assembly carefully with wrench supplied by turning counterclockwise
(right-hand thread). Put two drops of Foredom oil into the bottom of the threaded
hole of the housing and one drop into the nosepiece assembly. Replace the
nosepiece assembly, hold the handpiece upright and run it slowly to distribute
the oil. Lubricate every 100 hours of use.
Handpieces 52, 52D, 53: These handpieces do not require any
lubrication. Putting oil or grease into the front or back of these handpieces will
damage their prelubricated ball bearings.
*Note: All handpieces marked with asterisk have duplex spring connections
(flexible springs in middle). These connections must be lubricated once every 20
hours of operation. Apply about two drops of oil into the hole on the rear of the
connection collar. This should be done with Foredom Hypodermic type oiler
(Part No. 10005).
Other Service and Repair
All other service and repairs should only be done by a professional repair person
or shop. Your dealer can help you select one or can arrange to have your
Foredom equipment returned to the Bethel, CT factory. (See Repair Service
section in this manual.)
Storage
Store your Foredom power tools in a DRY, clean, dust-free area. Store out of the
reach of children.
Recommended Spare Parts and Supplies for Series K
The following parts and supplies are recommended as spares to keep on hand
to insure continuous operation of your Foredom power tool.
1 flexible shaft (Part No. 93)
1 pair motor brushes (Part No. 2019)
1 Foredom flexible shaft grease (Part No. 10006)
1 Neoprene Sheath (Part No. 77N)