joke jokeFlex Premium Plus User manual

Surface Technology
Oberflächentechnik
Surface Technology
Oberflächentechnik
Instruction Manual
jokeFlex Premium Plus
Motor System
Order no.: 0 016 850 and 0 016 850R

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List of contents
1 List of contents Page 02
2 Tips on using the manual Page 02
3 Safety instructions Page 02
4 Warranty/Identification Page 03
5 Device overview Page 04
6 Technical data Page 05
7 Operation/Use Page 06
8 Troubleshooting Page 09
9 Care and maintenance Page 10
10 Telefax form Page 11
Tips on using the manual
This manual has been written for the device user to ensure a problem-free operation, care and
maintenance.
Important instructions and information concerning safety and operational reliability have been
high lighted.
The symbols used in the manual have the following meanings:
Working and operating processes which must be observed to the letter to exclude any risk to
persons.
The illustrations and diagrams are numbered in sequence within each chapter. Some of these
illustrations have keys. References to illustrations within the text e. g. (5.1/2) have the following
meaning:
5.1 = Figure 5.1
2 = Position 2 in the key to the figure.
Please feel free to call our customer service department at any
time should you encounter technical problems which are not dealt
with in this manual:
Telephone [phone] / 8 39 - 0
Telefax +49 (0) 22 04 / 8 39 - 60
Internet www.joke.de
Working and operating processes which must be observed to the letter to avoid any damage to
the device.
Technical information to which the device operator must give special attention.

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Safety instructions
This device has been built according to the latest technical standards and generally accepted
safety regulations. Nevertheless, it can constitute a risk to the operator or third parties and a
hazard to the device itself or other equipment during use.
1. Only use the device if in perfect working order and for its intended purpose. You must always
pay attention to the instruction manual and safety instructions therein and be aware of the
risks! Repair any faults which could aect the device’s safety immediately by yourself or
have these repaired.
The device should only be used with tools for grinding, milling, and polishing listed and ap-
proved in the joke catalogue. Any other use will be deemed to be contrary to its intended
purpose. The manufacturer cannot be held liable for any resulting damages. The risk is
borne solely by the user. Correct use also includes compliance with the instruction manual
and an observation of the care and maintenance conditions.
2. Keep the instruction manual handy at the device’s place of use.
3. Pay attention to and observe generally applicable statutory and otherwise binding regula-
tions relating to accident prevention and environmental protection in addition to the informa-
tion provided in the instruction manual!
4. All personnel commissioned to work on or with the device must have read this instruction
manual, and particularly the safety instructions chapter, before starting work. This applies
especially for personnel who only work with the device occasionally.
5. Stop the device immediately should you notice changes to the device or its operating behav-
iour that are relevant to its safety. Have these remedied before restarting work.
6. Do not carry out any modifications, additions or conversions to the device! This also applies
to the installation and adjustment of safety equipment.
7. Spare parts must meet the technical requirements specified by the manufacturer. This can
only be guaranteed with original joke spare parts.
8. Any work on/with the device may only be carried out by qualified, appropriately trained and
authorised personnel. Pay attention to minimum statutory age limits!
9. Wear safety goggles when working with the handpiece.
10. Personnel undergoing training or in a general apprenticeship should only be allowed to work
with the machine under the constant supervision of an experienced operator!
11. Restrain from any type of work that could jeopardise your safety.
12. The device may only be used if all protective and safety equipment is in place and in proper
working order.
13. Do not leave the device unattended when switched on!
14. Stop and secure the device immediately in the event of malfunctions! Faults must remedied
at once.

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Warranty / Identification
joke warrant the correct manufacture of every joke Technology GmbH product which is delivered
in accordance with the terms of contract and delivery.
This warranty does not cover damages caused by normal wear and tear, incorrect handling,
negligent use, the fitting of non-original spare parts, inadequate care and/or a failure to comply
with this technical manual.
The device may only be used by appropriately trained personnel. If it is not, all warranty claims
will be forfeited according to the terms of delivery.
Device identification
The manufacturer’s code and type code for motor and foot control can be found on the respec-
tive type plate.
Disposal
This product shall not be treated as household waste. Instead it shall
be handed over to the applicable collection point for the recycling of
electrical and electronic equipment.

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Device overview
1 – Mains lead
2 – jokeFlex Premium Plus motor system
3 – External potentiometer
4 – Foot control
5 – Flexible shaft
6 – Motor connecting lead
7 – Plastic cap
8 – Premium Plus handpiece (not included in the scope of delivery)
Mode of operation
The jokeFlex Premium Plus motor system is electrically powered. The rotary movement is
transferred to the joke handpieces or hand-filing machines via the highly flexible shaft with ball
bearings connected to the motor system.
The flexible shaft is connected to the handpiece/hand filing machine by a quick-release spring
clip or the Rapid-Change-System.
The tools in the handpieces/hand filing machines are held by collets or clamped in a reception.
Figure 5.1 Complete overview Motor system jokeFlex Premium Plus (illustrated here: Rapid-Change Version)

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The unit is switched on and o using the foot control, simultaneously allowing continuous
adjustment of speed.
The maximum speed can be limited by the potentiometer. The potentiometer adjustment
range is 8,000 – 22,000 rpm.
The marking on the external potentiometer serves as a guide.
Figure 5.3 Section of foot control
Setting for hang-filing machines, speed up to 8,000 rpm
Setting for angle handpieces, speed up to 15,000 rpm
Setting for straight handpieces, speed up to 22,000 rpm
Figure 5.2 Foot control

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Technical data
Performance data for jokeFlex Premium Plus motor
Speed range max. 22,000 rpm
Dimensions (H x W x D) 240 x 105 x 95 mm
Weight 2,1 kg
Cable length 2,2 m
The motor is characterised by a robust construction with regard to the shaft connection and
the suspension. It can be used as a suspended and horizontal motor. It generates a low level of
noise. It is compatible with the Premium foot control.
Power supply
Supply voltage 230 V , 50/60 Hz
Connected load 1000 W
Fuse 16 A
Cyclic duration factor 100 %
Degree of protection totally insulated housing IP 20
Premium foot control performance data
Speed range 3.000 up to 22.000 rpm
Speed limit max. speed via potentiometer from 10,000 to 22,000 rpm
Connected load 230 Volt, 50/60 Hz
Weight 2,0 kg
Cable length 2,8 m
1. The foot control serves to control the motor speed by foot and is compatible with the
Premium and Premium Plus motors.
Suspension device for bench top mounting: Order no.: 0 020 100

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Figure 7.1 Rapid-Change-System
Operation / Use
Installing and connecting the device
1. Suspend motor system in a suitable sus-
pension device:
We recommend the height-adjustable suspen-
sion
devices for bench top mounting.
The motor system can also be operated
horizontally for individual applications.
2. Connecting the Quick-Change-System to
the motor system:
• Unscrew the plastic cap
• Insert the shaft in the motor connection
• then push on the plastic cap and screw it
back onto
2. the motor hand tight.
Figure 7.2 Connection of motor and shaft (here: Quick-
Change-System)

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Trial run
The first time the motor system is started
1. Let the flexible shaft hang down.
2. Press the foot control and leave the unit to run for approx. 10 min at the medium speed.
The resulting high rise in temperature of the flexible shaft is normal!
Before restarting the jokeFlex units after repairs, please pay attention to the following instruc-
tions:
1. Hang the motor in a suciently stable holder.
We recommend our suspension devices Article No. 0 020 100 , see also our catalogue „Surface
Finishing“.
2. Then screw the cap over the shaft - motor connection hand tight.
3. The flexible shaft should be run for at least 10 minutes with a slight bend at medium speed
with no load while the motor is suspended.
3. Place foot control (7.3/3) beneath the work-
ing area on the floor and connect motor
connecting lead with compact plug (7.3/2) to
the foot control.
4. Plug mains lead (7.3/1) into socket with
earthing contact - the jokeFlex Premium Plus
motor system is now ready for use.
Figure 7.3 Assembly (Symbolic drawing)
This is important so that the grease on the inner shaft is distributed evenly over the entire sur-
face. The flexible shaft may warm up slightly when running in the jokeFlex motor system. This
does not aect the functionality.
The jokeFlex Premium Plus motor system is fully ready for use after running in.
If you have any questions or encounter problems with our tools please feel free to call our ser-
vice department at any time under:
Tel: [phone] / 8 39 - 0
Fax:[phone] / 8 39 - 60

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Connecting a handpiece/hand-filing machine
Connection to the flexible shaft is the same for all handpieces and handfiling machines!
Handpieces/hand-filing machines may not be
fitted/removed whilst the shaft is rotating! Risk
of breaking the carrier!
1. Spring clip system: Push spring clip to-
gether, slide chosen handpiece/hand-filing
machine onto end of shaft and open spring
clip.
The legs of the spring clip should snap into the
corresponding grooves on the handpiece/hand-
filing machine!
2. Rapid-Change System: draw back the bush
on the coupling on the shaft side. Subse-
quently push the handpiece into the coupling
and allow the bush to snap back.
The same applies to both systems: the catch must
be corrected if necessary by rotating the collet
until it engages.
The following flexible shafts are available for the Quick Change motor system:
Figure 7.4 Spring clip system
Figure 7.5 Rapid-Change System
Motor jokeFlex Premium Plus Length Order no.:
Flexible shaft Premium Plus with spring clip 1.1 m 0 016 800
Flexible shaft Premium Plus with slip joint 1.1 m 0 016 800-3
Flexible shaft Premium Plus with rapid-change coupling 1.1 m 0 016 900

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Figure 7.6 Potentiometer
Troubleshooting
Tool does not turn
Possible cause Remedy
Foot control not pressed. Press foot control
Electric leads loose. Fix leads
Flexible shaft defective. Replace
Foot control defective. Replace
Handpiece/hand-filing machine incorrectly
connected
Check spring clip connection.
Tool reception defective. Repair/replace
Bearing defective. Repair
Carrier on shaft or handpiece defective. Repair
Speed setting for dierent applications
In order to avoid damage as a result of possibly excessively high speed settings, the maximum
rpm can be limited by the potentiometer on the foot control. The scale has three graduations
(refer to Figure 7.5):
• Working with hand-ling machines (speed up to 8,000 rpm)
• Working with angle handpieces (speed up to 15,000 rpm)
• Working with straight handpieces (speed up to 22,000 rpm)

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Servicing the motor system
The motor bearings require no maintenance. The deep groove ball bearings are sealed and have
a lifetime lubrication.
Check the carbon brushes for wear every 4 weeks to avoid damage to the armature.
If the carbon brushes have worn down to around 5 mm they should be replaced. No exact guid-
ance of the carbon brushes in the holders can be guaranteed at a length of < 5 mm.
Proceed as follows to check or replace the carbon brushes:
1. Unplug connecting lead to foot control.
2. Dismantle flexible shaft.
3. Remove the four recessed head screws at the black motor cover.
4. Pull o the lateral motor covers.
5. Remove recess head screw of carbon brush strip.
6. Replace carbon brushes.
Carbon brushes
Recessed head screw
Allow the motor to run in for approx. 1 hour after changing the carbon brushes and installing the
cover.
Regularly remove the excess grease on the shaft connection on the motor side.

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Motor system jokeFlex Premium Plus, Advantage package Order No. 0 016 850 
Motor system jokeFlex Premium Plus, Advantage package,
Rapid Change
Order No. 0 016 850R 
Motor Premium Plus Order No.. 0 016 550 
Foot control Premium Order No. 0 016 600 
Flexible shaft Premium Plus with expanding ring, 1,1 m Order No. 0 016 800 
DIPROFIL®Hand-filing machine FPB/R, FPK/RL Order No. 0 001 151 
DIPROFIL®Hand-filing machine FPK/R, FPK/RL Order No. 0 005 151, 0 005 152 
DIPROFIL®Mini hand-filing machine FMR/S 5/ S 10/ S 15 Order No. 0 001 205/ 213/ 219 
DIPROFIL®Transverse handpiece FMV/S Order No. 0 001 211 
Technical handpiece joke Premium Plus Order No. 0 030 200 
Technical handpiece THSZ/N Order No. 0 030 004 
Angle handpiece VTN-S/N Order No. 0 031 540 
Angle handpiece VTN-N 90° Order No. 0 031 341 
Angle handpiece VTN-N 135° Order No. 0 031 342 
Rotating hollow handpiece NHK-L, NHG-L Order No. 0 031 600, 0 031 400 
Telescope angle handpiece 90°, Ergo-Line Order No. 0 030 820 
Telescope angle handpiece 135°, Ergo-Line Order No. 0 030 830 
Angle handpiece 90°-R, Ergo-Line Order No. 0 030 900 
Date Signature
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To
joke Technology GmbH
Service Department
Fax: 0 22 04 / 8 39 - 60
Sender:
Company
Name/Department
Customer-No.
Street
Postcode – town/city
Please send us the spare parts drawing and
parts list for the following equipment:
as a printout (see address overleaf),
by fax,
as a pdf file to my e-mail address

Surface Technology
Oberflächentechnik
joke Technology GmbH
Asselborner Weg 14 -16
D-51429 Bergisch Gladbach
Tel. [phone] / 8 39-0
Fax [phone] / 8 39-60
Mail [email protected]
Web www.joke.de
© Copyright joke Technology GmbH • Juni 2012 • Änderungen aufgrund technischen Fortschrittes, Irrtümer und Druck-
fehler vorbehalten • This publication may not be reproduced in whole or in part in any form without the publisher‘s
permission.
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