FOREDOM K.1040 User manual

Operation and Maintenance Manual
HP4-417 Control
HP6-933
Cradle
HP6-606
Foot
Control
H.MH-140
Handpiece
K.1040
High Speed Rotary Brushless Micromotor
!For Your Safety:
Read this Manual before operating your Foredom Micromotor Power Tool.
Always wear eye protection while using the Foredom Micromotor Handpiece.
Do Not Submerge Handpiece in Liquids!

ASSEMBLY INSTRUCTIONS
Make sure the power switch on the back of the control box is turned OFF. Check to
see that the voltage selector switch on the back of the control box is set to the
voltage to be used 110 or 220 volt. Then follow steps below:
1. Connect the power cord into the back of the Control
Box and into a power outlet.
2. To use the Foot Contol, plug the Foot Control cord into
the port on the back of the control box. Align the pins
carefully and tighten the locking ring.
3. Plug the Handpiece cord into the port on the front of
the control box. Align the pins carefully and tighten
the locking ring.
4. Set the Speed Dial to '0'.
5. Make sure the handpiece collet is in the locked
position with a bur or accessory in it and that the
collet and accessory can spin freely.
Control
Box
Back
Foot
Control
Plug
T-Slot
Plugs
Power
Cord
Voltage
Selector
Switch
110 or
220 volt
On/Off
Power
Switch
Fuse
Compartment
FWD/
REV
Mode
Selector Handpiece
Connection Plug
Handpiece
Holder
Digital
speed
display
x1000rpm Speed Dial
Run
Selector
Hand or
Foot Mode
Selector
Control
Box
Front
!
SAFETY INSTRUCTIONS: A Micromotor Handpiece is a high speed
rotary power tool which can be dangerous and cause serious injury
if it is not used properly.
• ALWAYS wear proper eye and face protection.
• ONLY use accessories rated for speeds of 50,000 rpm
or higher when operating this micromotor.
• ALWAYS observe the manufacturer’s maximum
speed rating when using any accessory.
• NEVER use or continue to use any accessory which
appears to be damaged, loose, vibrating, bent, or out of
balance. Inspect each accessory for cracks or flaws
before use.
• ALWAYS insert the shank or arbor of an accessory
or mandrel into the collet or chuck of the hand
piece as far as possible in order to provide proper
support and close the collet or chuck securely.
• DO NOT use accessories with shanks that are
less than 1″long.
• NEVER use excessive side pressures 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 mounted point, buff, wheel or accessory.
This can result in damage to the motor.
• WEAR a dust protector to prevent the inhalation of
harmful dust or debris from grinding, carving or other
operations performed with this power tool.
• NEVER operate with a damaged power cord.
• USE a dust collector or filter hood to pull sawdust,
grinding dust, or other debris away from the work
area and the micromotor.
• NEVER wear open shoes or sandals. Use foot-wear that
is tough enough to protect your feet from falling tools.
• ALWAYS keep both hands and fingers away
from the cutting edge.
• NEVER cut or exert pressure, toward your hand
or any other part of your body.
• DO NOT wear loose fitting clothing or jewelry.
Loose clothing or jewelry can become entangled in the
tool. Do not wear items such as neckties, necklaces, or
bracelets when operating power tools. Secure or tie
back long hair.
• NEVER operate without wearing eye protection.
NEVER turn on or start the Handpiece while
collet is in open (unlocked) position.
This can damage the handpiece. Always operate
and store it with a bur or other accessory in the chuck
and with the chuck in the closed position. DO NOT
operate the handpiece in the presence of any flammable
liquid or gas.
UNLOCKED

Be sure the On/Off Power Switch on back lights up when you are ready to work. The switch on the
back must be in the ON position for the handpiece to run in any setting.
Always turn the Dial to ‘0’ and On/Off Switch to the Off position when not in use.
FORWARD/REVERSE MODE: With the Speed Dial at ‘0’, select the handpiece rotation /
direction by pressing the FWD/REV Mode Indicator: FWD = Forward or REV = Reverse.
•Speed Range: 500 – 50,000 RPMs
HAND/FOOT MODE: With the Speed Dial at ‘0’, select either Hand or Foot Mode for
speed control.
• When the Hand indicator lights up, the handpiece will run at the speed set by the
Speed Dial.
• Briefly press the Run Selector to activate the handpiece in Hand Mode. The RUN
light will be on. The RUN light will also light up in Foot Mode when you press the
Foot Control.
• When the Foot Mode indicator lights up, the handpiece will only operate when the Foot Control
is pressed. You can set a maximum speed with the Speed Dial, but range of speed will be
controlled by the Foot Control.
REGULATING SPEED: Use the Speed Dial to vary the speed of the handpiece from
minimum to maximum when the Hand Indicator lights up.
RUN SELECTOR:
The 1040 has two speed range choices.
• 5K: 0.5k (500rpm) - 5k (5,000rpm)
• 50K: 0.5k (500rpm) - 50k (50,000rpm)
To choose your speed range:
• When the 5K light is OFF the speed mode is 50K: 0.5k (500rpm) - 50k (50,000rpm).
• To select 5K mode PRESS AND HOLD THE RUN SELECTOR button until the 5k light turns ON.
When the light is on the unit is set to 5k: 0.5k (500rpm) - 5k (5,000rpm)
OPERATING INSTRUCTIONS
Hold To
Change
Press To Run
Hold To
Change
Press To Run
Hold To
Change
Press To Run
HANDPIECE HOLDER: The control box has T-shaped Slots
for placing the handpiece holder in a location and angle
for your convenience. The flexible vinyl covers on the
T-shaped slots can be pried out with a screwdriver with a
very thin blade.
DIGITAL SPEED DISPLAY: Displays the current rate of speed x1000rpm
For example, when the display is showing
“.5” the speed is 500rpm.
“1” the speed is 1000rpm
“25” the speed is 25,000rpm
“50” the speed is 50,000rpm

Burs and other accessories can be inserted or removed
from the handpiece collet when the collet is open. As
shown, there are 2 DOTS on the metal ring – one
will line up with the Unlock symbol and the other
dot will line up with the Lock symbol when you
twist the front of the handpiece.
TO OPEN THE COLLET:
1. Turn off the motor.
2. Twist the Front of Handpiece
by turning as shown below until it
clicks so that one of the the
dots on the metal ring lines up
with Unlock Symbol.
CAUTION Never run the handpiece when the collet
is open or in the intermediate position. The spindle
is in the locked position and will not turn. This will
damage the motor.
3. Remove the accessory and
replace with another. Insert the
accessory shank fully into the
collet for maximum support
4. To Lock: Twist
the Front of the
Handpiece by
turning as shown
above until it clicks
so that the other dot
on metal ring
lines up with the
Lock Symbol. The
accessory and collet will be able to spin freely.
Nosecone
Wrench
Collet
Wrench
Collet Wrenches
The handpiece comes with an open-end wrench, (Nosecone Wrench)
and a wrench with a triangular-shaped hole which ts over the collet,
(Collet Wrench). The Nosecone Wrench is used to tighten the nosecone,
and is also used with the collet wrench to remove the collet.
Accessory
Unlock
i
h
Dot
Dot
Lock
Unlock
i
h
Dot
Dot
Lock
Unlock
CHANGING ACCESSORIES
H.MH-140 Micromotor Handpiece
This Handpiece is intended for fine finishing and detailing work. If the handpiece is misused or abused, it
will not be covered under warranty. Avoid turning the front portion of the handpiece so far that it unscrews.
If this occurs put it in the Unlock position and tighten it.
Dot on metal ring lines up with Lock Symbol
for closed collet
Bur or Accessory
should always
be in the
collet
For maximum
speed with a foot
pedal, turn the dial
speed control to
the 'MAX' setting.
CAUTION: Never run the handpiece
when the collet is open or in the
intermediate position. The spindle is
locked and will not turn. This will damage
the motor.
Unlock Lock
Open Closed
NOTE: There are 2 DOTS on the metal ring
– one will line up with the Unlock symbol and
the other dot will line up with the Lock symbol
when you twist the front of the handpiece.
Operating the handpiece with the collet in the
open or Unlock position or with no bur or
bit in it CAN CAUSE SEVERE DAMAGE TO THE
MOTOR.

Turn off the power switch with the collet in
the Locked or closed position.
1. Rotate the bur to position the ats on the chuck
nut, so they line-up with the wrench slots in
the metal nosecone. Slide the nosecone wrench
through the slots all the way.
2. Hold the housing with one hand, and tighten
the nosecone with the Nosecone Wrench.
(Clockwise rotation)
3. Keep the Nosecone Wrench in the slots
of the nosecone. Then, open the collet by
rotating the housing so that the other dot on the
metal ring lines up with the Unlock symbol.
Be sure a bur is in the collet to avoid damaging
the collet. Next, Use the rounded triangle
hole in the Collet Wrench to un-thread the collet
(counterclockwise).
4. Once the collet is loosened, unthread it
completely by hand.
Unthread
Tighten
Collet
removed
Nosecone
Wrench
Nosecone
Wrench
Accessory
Accessory
6. Tighten with the rounded triangle hole in the
Collet Wrench to fully seat the collet while
holding the handpiece with your other hand.
When the collet is fully seated, Twist the Front of
the Handpiece by turning counterclockwise until
it clicks so that the other dot on metal ring lines up
with the Lock Symbol.
The accessory and
collet will be able to
spin freely.
5. To install the collet, rst, remove the Nose-
cone Wrench. Make sure one of the dots on
the metal ring is lined up with the Unlock
symbol, and install a bur in the collet. Screw
the collet in by hand (keeping the bur in the
collet) until it is nger tight.
Unlock
Lock
INSTALLING/CHANGING COLLETS

FUSE PROTECTION
1. To change a fuse Unplug the power cord from
the AC receptacle in the back of the control box to
expose the Fuse Compartment.
2. Use the blade of a small screwdriver in the slot
of the fuse holder and gently pry outward. The
active fuse is in the back of the holder and a
spare fuse is in the front compartment. If the
glass case of the active fuse is darkened, the fuse
is blown. From the underside of the drawer, push
out the blown fuse using a small screwdriver.
Be sure the micromotor is not being overloaded,
the line voltage is correct, matching setting and then
replace the blown fuse with the spare fuse. It is a
good idea to always keep a spare fuse in the front
compartment to avoid lost time if there is a future
blown fuse. To avoid overloading the micromotor
always use the same type and ampere rating as the
original: GDB 5 Amp, 250V, 5mm x 20mm.
If, after replacement, the fuse blows again
, the
micromotor has a fault. The unit should be analyzed by a
qualified technician, or returned to the factory for service.
See Repair Services.
Back of the control box
2- Pry with screwdriver Spare In use
Fuse Fuse
1- Remove Power Cord
Fuse Compartment
MAINTENANCE
The H.MH-140 has permanently lubricated ball bearings
that do not require lubrication. Putting even a small
amount of oil into the handpiece can damage it.
Cleaning the Handpiece
Use the Handpiece in as clean and dust free an
environment as possible.
If the Micromotor Handpiece is used for wood-
carving, it should be cleaned after every use. A
cloth with a small amount of alcohol solution can be
used to clean the outside of the handpiece if neces-
sary.
Do not use any other cleaning fluids or
immerse handpiece in any liquid.
The H.MH-140 Handpiece is
not autoclaveable.
Cleaning the Bore in the Spindle
If you are working in dusty conditions or generat-
ing a lot of dust particles you may need to remove
the collet for cleaning. With front of Handpiece in
‘Unlock’ use a Q-tip to clean out the bore in the
spindle.
The metal nose cone needs to be tight
to hold the front housing in place, to insure
that the the full stroke of the collet operating
mechanism works properly.
Nosecone
Wrench
Replacement Parts and Supplies
Part No. Description
HP6-994 Nosecone Wrench
HP6-993 Collet Wrench
HP6-933 Handpiece Cradle
HP6-610 Handpiece Holder
HP6-101 Fuse GDB 5 Amp, 250V, 5mm x 20mm
HP6-117B Collet for 1/8” diameter accessories
HP6-117 Collet for 3/32” (2.35 mm)
diameter accessories
HP6-117C Optional Collet for 3 mm diameter
accessories
CP10831 Detachable Cordset, 6’ North America
CP10834 Detachable Cordset, 6’ United Kingdom
CP10835 Detachable Cordset, 6’ Continental
Europe
CP10836 Detachable Cordset, 6’ Australia
CP10838 Detachable Cordset, 6’ Israel
Optional Collet Adapters
Great way to use smaller diameter shank accesso-
ries without changing the collet. Available from your
favorite Foredom dealer or:
www.foredom.net
Accessory
Collet Size Shank Size Part No.
3/32 ″ (2.35 mm) to 1/16 ″ 1/16 ″ HPL4-3233
1/8 ″ to 1/16 ″ 1/16 ″ HPL4-3234
3.0 mm to 3/32 ″ (2.35 mm) 3/32 ″ (2.35 mm) HPL4-3235
1/8 ″ to 3/32 ″ (2.35 mm) 3/32 ″ (2.35 mm) HPL4-3236
3.0 mm to 1.6 mm 1.6 mm HPL4-3237

Accessory more than 1
1
⁄ 2 ″ 1″ 3/4″ 1/4ʺ″ 1/8″ 3/32″ less than 3/32″
Diameter (40mm) (28– 40mm) (18 –28mm) (8– 18mm) (4 –8mm) (2 –4mm) (less than 2mm)
Rotation Speed – RPMs
RECOMMENDED APPROXIMATE BUR SPEEDS
50,000
45,000
40,000
35,000
30,000
25,000
20,000
15,000
10,000
5,000
0
ERROR CODES
Error
Code Status Cause
E 1, E5 Circuit Protection - Circuit of control is malfunctioning.
- Handpiece or foot control cords are unplugged, defective or broken.
E2 Overload Protection - Handpiece has been operated under an overload condition.
E3 Handpiece Protection - Control unit received a lower voltage than specified.
E4 Stall Protection - Collet chuck is open.
- Handpiece is mechanically stalled.
Voltage Protection - Voltage Selector switch is set for the wrong voltage.
E6 Overheating Protection - Handpiece has been operated under a high load condition or too long.
- Control unit has been exposed to an excessively
warm environment (more than 100°F)
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
below. An adapter (sketches B and C) can be used
for connecting plugs as shown in sketch A 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 type
plugs and 3-pole receptacles that accept the tool’s
plug. Always disconnect the power cord before
servicing the tool. Never use in an area where
flammable vapors are present.
Store your Foredom power tools in a DRY,
clean, dust-free area, and out of the reach
of children.
USING PROPER GROUNDING PROCEDURES.
Handpiece Maximum Torque - 11.3 oz-in / 8 N-Cm Control units Maximum Watts Output - 240 Watts

Contact Information
For more information on Foredom machines, handpieces or accessories, contact
your local dealer. When no local dealer is available, write, call, fax, or email:
Foredom Electric Company
16 Stony Hill Rd, Bethel, CT 06801
Tel: [phone] Fax: [phone]
Email [email protected]
Visit our website: www.foredom.net
F-1040 6/21 Printed in U.S.A.
Limited Warranty
Foredom warrants its product to be free of defects in material or workmanship for a period of two
years after purchase. Blackstone Industries, LLC d/b/a Foredom Electric Company warrants, to the
original purchaser only, that its products will be free from defects in material or workmanship for the
applicable period of time indicated above following the purchase date. During the warranty period, the
defective product will be repaired or replaced without charge or, at our sole 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, WITHOUT LIMITATION, IMPLIED WARRANTIES OF FITNESS FOR
A PARTICULAR PURPOSE AND MERCHANTABILITY, ARE LIMITED IN DURATION TO THE APPLICABLE
WARRANTY PERIOD. IN NO EVENT WILL WE BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES. Some states do not allow limitations on how long an implied warranty lasts or the exclu-
sion or limitation of incidental or consequential damages, so the above limitations or exclusion may
not apply to you. At our sole option, repair, replacement or refund will be made if the product is
returned postage prepaid to:
Foredom Electric Company
16 Stony Hill Road, Bethel, CT 06801
All warranty repairs must be done at the factory at the address above. We will not pay any shipping or
transportation charges. This warranty only covers the original purchaser of the product. Proof of pur-
chase may be requested. Some states do not allow limitations on how long an implied warranty lasts,
so the above imitation 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.
Repair Services
Authorized repair service is available at the
Foredom factory in Bethel, CT.
Please call 1-800-272-2885 or email
[email protected] to
request a RMA number (Return Material
Authorization Number) prior to returning.
Repairs will not be accepted without an
RMA number.
Enclose the item(s), a packing list, your address,
phone number, email address and a description
of the problem or repairs required and a RMA
number (Return Material Authorization
Number) from customer service. Estimates of
repair cost will be made upon request. If the
cost (labor plus parts) is more than fifty percent
of the price for a new replacement we will
contact you and recommend a trade-in offer.
Please retain your proof of purchase for
warranty repairs.