Instruction Manual for Power Hand 2X controllers and handpieces combine to create the most versatile finishing system in the industry, offering rotary, profiling and belt sanding action. 15,000PM otary Handpiece Model: New Z-15X #510-2270 Power Hand 2X component selection: Three controllers Six straight (four standard, two slimline) and two angle rotaries Two reciprocating profilers One side-to-side profiler One belt sander One 4:1 reduction gear Separate motors and handpiece heads 255 Hancock Ave., Bridgeport, CT 06605, USA 1-203-366-5400 FAX 1-203-366-3953 Order toll-free 1-800-243-4466 Web site: gesswein.com E-mail: info@gesswein.com #890-2034/0311
Introduction Notes The Gesswein Power Hand 2X New Z-15X otary Handpiece is engineered and manufactured to a high degree of precision and will give you many years of trouble-free service. Backed by a limited warranty that covers wear parts for 90 days and overall balance of parts for six months. This DC electrically driven rotary handpiece is designed to be used with Gesswein Power Hand 2X Single, Standard, Dual, Jewelers Micromotor, Power Carver II and Bright-Cutting Controllers. These controllers convert the Alternating Current (AC) power supply to a variable Direct Current (DC) by means of an I.C. transistorized automatically controlled circuit. The Gesswein Power Hand 2X handpiece series consists of nine models and eleven head assemblies with maximum operating speeds ranging from 8,000 to 55,000rpm and 0 to 117 strokes per second. All models are identified by their names, which are engraved on the motor housings. Specifications Speed ange (PM) Dual or Single Controller* 0-15,000 Standard Controller 1,500-15,000 Input Voltage 3-30V DC Max. Shaft Output (W/sec.) Dual Controller 49 Standard Controller 44 Single Controller 33.8 Max. Stoppage Torque (ft.-lbs./n-m**) Dual Controller 0.065/0.088 Standard Controller 0.058/0.078 Single Controller 0.053/0.072 Net Wt. (without power cord) 9.5 oz. *Or Standard Controller with variable-speed foot rheostat **Foot-pounds/Newton-meters 2 15
Notes 1. Accessories Included Accessories A. One 3 32" (2.35mm) Collet (reorder #501-0100) B. One 1 8" (3.2mm) Collet (reorder #501-0105) C. Two Carbon Brushes (reorder #510-0168) D. One Collet Wrench (reorder #510-0180) Optional Accessories A. Handpiece Extension Cord (#510-1120): adds 6 feet, or almost 2 meters, to the 1.7-meter rotary handpiece cord B. Handpiece Cradle est (#510-1130): provides a safe holding place for the rotary handpiece when not in use C. Variable-Speed Foot heostat (#510-3100) D. On/Off Foot Switch (#510-3105) E. 3mm Collet (#501-0106) F. educing Collets: 1 8" to 3 32" (#816-1501), 1 8" to 1 16" (#816-1502), 3 32" to 1 16" (#816-1503), 3mm to 3 32" (#816-1504), 3mm to 1 16" (#816-1505) 2. Parts Nomenclature 1. Test od 1 3 4 6 7 2. Collet 3. Head Cover 4. Collet elease ing 5. Motor Connecting ing 2 Fig. 1 5 8 6. Motor Housin g 7. Motor Cover 8. Power Cord with 3-pin plug 14 3
3. General Description of Use Tool Changing The Gesswein Power Hand 2X otary Handpiece uses a quick-tool-release mechanism that allows for rapid tool changes. To operate, turn the Collet elease ing toward the arrow pointing to the or release position (see fig. 2). When in full position, the Collet elease ing will make a click sound; the collet is then fully open and ready to accept a tool. Collet elease ing S S To secure the tool, rotate the Collet elease ing toward the S or secure position. Again, a click sound will be heard, indicating the collet is fully closed and the tool is secure. When changing tools, be sure that the handpiece motor is not running. If you attempt a tool change under this condition, the motor will be stalled and damage will occur. Fig. 2 Collet emoval The Gesswein Power Hand 2X otary Handpiece can be fitted with three different size collets. Standard sizes are 3 32" (2.35mm) and 1 8" (3.2mm). Bright Cutting Package supplied with a 3.0mm collet. Loosen Tighten Collet Wrench To change collets, rotate the Collet elease ing to the full position and remove the tool in the collet. Hold the collet between thumb and forefinger and turn in a counterclockwise direction until the collet is removed. Insert the new collet and reverse the procedure. It is best to tighten a replaced collet by hand with the collet wrench (#510-0180), securing until just tight. S Fig. 3 4 13
New Z-15X Parts List, continued When ordering spare parts, always specify part# (or item# if applicable) and description. Part# Item# Description New Z-15X-101 Motor Case New Z-15X-102 New Z-15X-103 New Z-15X-104 New Z-15X-105 New Z-15X-106 Head Screw ubber O-ing New Z-15X-200 510-2316 Armature Complete New Z-15X-201 New Z-15X-202 New Z-15X-203 Ball Bearing New Z-15X-204 510-2317 Armature New Z-15X-205 New Z-15X-301 New Z-15X-302 New Z-15X-303 Ball Bearing ubber O-ing ear Lid New Z-15X-304 510-0163 Carbon Brushes (one set) New Z-15X-305 New Z-15X-306 New Z-15X-307 New Z-15X-308 (+) Terminal Plate Brush Side Lid ( ) Terminal Plate Pan Head Screw New Z-15X-309 510-0167 Motor Cord with Plug New Z-15X-310 Motor Cover If the collet cannot be loosened by hand using the Collet Wrench, additional torque may be required. To use the Collet Wrench, place the triangular cutout in the wrench over the collet (see fig. 3), and turn counterclockwise to loosen and clockwise to tighten the collet. If more torque is required, hold the handpiece with the Collet Wrench secure on the collet, and tap the wrench with a solid tool (see fig. 3a) in a counterclockwise direction. This procedure will loosen the collet, which can then be removed by hand. If the handpiece collet is so tight that the above procedure will not loosen it, then remove the Head Assembly from the Motor Assembly. This can be done by grasping the Motor Connecting ing (see fig. 1) and pulling upward. Insert the Chuck Joint Wrench (see Fig. 3b) into the Nylon Coupler (#510-0151), hold the Head Assembly and Chuck Joint Wrench securely in one hand, and with the Collet Wrench in place on the collet, loosen in a counterclockwise direction (for parts drawing, refer to page 11.) Blank Bar Loosen Tighten Fig. 3a Collet Wrench Collet elease ing Chuck Wrench After a collet is replaced, be sure that the Collet elease ing is rotated to its full S position and that the collet rotates freely when turned by hand. If the collet does not rotate freely, it is not fully seated in the Head Assembly, and you must repeat the removal-replacement procedure. S Chuck Joint Wrench Fig. 3b 12 5
4. Operating Procedure with Standard Controller With your rotary handpiece fitted with a selected tool, connect the Gesswein Power Controller to an electrical supply and the handpiece to one of the two output sockets provided. Set the Slide heostat on the Controller to Low or the 0 position. Put the Controller Main Switch to the ON position, which lights up a pilot light that indicates your rotary handpiece is ready to use. To increase the speed of the rotary handpiece, move the Slide heostat toward High or 10. You can then begin working. When work is completed, put the Main Switch to OFF. To operate your rotary handpiece using the optional Variable-Speed Foot heostat or optional On/Off Foot Switch, please refer to the Power Hand 2X Controller Instruction Manual for proper connection. The handpiece will not rotate until the foot rheostat/switch is depressed. The rheostat provides infinitely variable speed control; the switch only turns handpiece on and off (operates at speed selected on control unit). 6 11
New Z-15X Parts List When ordering spare parts, always specify part# (or item# if applicable) and description. Part# Item# Description Z-STX-101 Top Cover Z-STX-102 Z-STX-103 Z-STX-104 Z-STX-105 Z-STX-106 Z-STX-201 Z-STX-202 Z-STX-203 Z-STX-204 Z-STX-205 Z-STX-206 Z-STX-207 Z-STX-208 Z-STX-209 Z-STX-210 10 Teflon ubber O-ing Dust ing Clip ing Clip ing Dust Seal B Dust Seal A Ball Bearing Bearing Ball Bearing Coil Spring Cover Coil Spring Z-STX-214 501-0100 Collet, 3 32" (2.35mm) Z-STX-215 501-0106 Collet, 3.0mm Z-STX-216 501-0105 Collet, 1 8" (3.175mm) Z-STX-217 Z-STX-218 Z-STX-219 Z-STX-220 Chuck Case Coil Spring Joint Shaft Z-STX-221 510-0151 Nylon Coupler (Joint) Z-STX-222 Z-STX-301 Z-STX-302 Z-STX-303 Z-STX-304 Z-STX-305 Z-STX-306 Z-STX-307 Z-STX-308 Z-STX-309 Z-STX-310 Z-STX-311 Z-STX-312 Z-STX-313 Z-STX-314 Dust Seal Coil Spring oller ing oller Set Set ing Thrust ing etainer Clip ing Washer Coil Spring Lock ing Coupler Stainless Steel Ball Z-STX-001 510-0180 Collet Wrench 510-0179 Chuck Joint Wrench 5. Precautions A. Before operating your handpiece, be sure that the Collet elease ing is in the S or secure position. Failure to do so (referred to as locked rotor condition ) will cause the motor to stall and could possibly cause motor damage. B. Do not attempt to change tools or rotate the Collet elease ing while the handpiece is running. This action will stop the motor abruptly, cause parts damage, and could also possibly cause motor damage. C. During use, avoid stalling the motor by pushing too hard on the work tool or by exceeding the torque capacity of the handpiece motor. D. The Gesswein Power Hand 2X otary Handpiece is designed not to overheat with normal use. It can be used continuously and will provide efficient, longlife performance if you apply just enough machining and polishing pressure to maintain full motor speed. E. The 3 32" (2.35mm), 1 8" (3.2mm) and 3.0mm collets are manufactured to accept 3 32", 1 8" and 3.0mm ± 0.0008" shank tools respectively. Use only tools that correspond to the collet size being used. F. Do not use your handpiece in water or oil, and never allow any oil, water or other fluids, dirt, or wood dust to enter the inner casing. Failure to keep foreign matter out of the inner casing will cause damage to the ball bearing assemblies. G. Do not subject the power cord on the handpiece to sharp bending or rough treatment. Such treatment could break the cord wires or damage the male connecting pins and female cord connectors. H. To disconnect the power cord, unscrew the motor cover to expose the male connector, then pull the cord straight back. Do not wiggle it back and forth. I. Be careful not to point the handpiece at any part of the body while it is running, particularly during startups. J. Be careful when using Wire Burnishing Tools. Do not use these tools at speeds faster than 14,000-15,000rpm. Each tool is made of individual piano wire. Operating a Wire Burnishing Tool at higher than recommended speed could cause the wire to come free from the hub. 7
6. Maintenance eplacement of Carbon Brushes The motors in the Gesswein Power Hand 2X otary Handpieces use a spring tension-type carbon brush assembly. The approximate life of these brushes is 800-1,000 hours. Use the set of two replacement carbon Brushes supplied with your handpiece when it becomes necessary to replace worn brushes. (Brushes should be changed when handpiece is not running at maximum speed, or if it sounds as though it s running out of gas.) Please note that in the event you must change the brushes, it is important that both be replaced at the same time. eplacement of only one carbon brush will cause motor damage. To replace worn carbon brushes, shut off main power supply. Disconnect the Motor Cover by unscrewing it in a counterclockwise direction. The motor brushes are now exposed. The worn brush assemblies can be removed by using a small Phillips head screwdriver on the screws that secure the assemblies (see fig. 4). The brush spring mount will push the assembly out of the well so that it can then be lifted clear. The two new carbon brushes should be installed by gently pushing them into the brush well. When each assembly has been screwed in securely, replace the Motor Cover and Power Cord. Dust emoval From time to time, it will be necessary to clean excessive dust that accumulates in the motor cover. To remove this dust, unfasten the handpiece Motor Cover by turning it in a counterclockwise direction. If compressed air is available, use it inside the cover and the motor armature air cooling vent. If air is not available, remove excessive dust with a dry brush. If necessary, use a cloth moistened with detergent to clean the cover, and blow into the air cooling vents to clean around the armature. Do not use any volatile liquid as a cleaner (i.e. paint thinner or alcohol). Periodically cleaning the inner threads on handpiece collets will ensure their easy collet removal when changing sizes. Twist a clean rolled-up piece of tissue paper in and out of the threaded area. Lubrication Lubrication of your Gesswein Power Hand 2X otary Handpiece is not necessary, and you should not let oil or other fluids enter the Head Assembly (see Precautions, 5F). Carbon Brush Screw Loosen Tighten Motor Cover Fig. 4 8 9