DIAMOND TECH

Innovations For Creativity

POWER MAX II

™

GLASS GRINDER

OPERATIONS MANUAL

- PAGE 2

Before You Begin

Read and follow all instructions carefully.

• After unpacking all components, assemble grinder on a firm level surface to prevent grinder from tilting and rocking.

• Be sure the power switch is in the OFF position before plugging in the grinder.

• Always disconnect grinder from electrical outlet before setting up or servicing.

• Wear proper apparel. Never wear loose fitting clothes, neckties, jewelry and gloves that may

get caught in moving parts.

• Always wear safety goggles. Everyday eyeglasses have only impact resistant lenses they are not safety glasses.

• Never turn on grinder while glass or working materials are touching the bits or disks.

• Keep out of reach of children.

• Never leave grinder running unattended. Turn power OFF when not in use.

• Do not operate while under the influence of medication or alcohol.

• To ensure top performance keep grinder properly maintained and lubricated.

Contents

Your Power Max II Grinder ™ has been shipped partially assembled. Carefully remove grinder

and parts from the packaging.

1) Grinder Body

9

2) Two Work Surface Adaptors

3) 1/4" Chrome Hardened Bit

4) 1" Chrome Hardened Bit

5) Advanced Super Sponge ™ 6

6) Easy Glide ™ Work Surface

7) Hex Wrench

8) Anti-Seize Lubricant

9) Rubber Stopper

Deluxe Model Also Includes:

1) Universal Face Shield 2

8

2) Easy-On ™ Foot Switch

3) 3/4" Chrome Hardened Bit

Assembly Instructions

A. Bit Installation

3

1) Before installing the grinder bit, lubricate the top of the motor

shaft and inside the bit by applying a thin coating of anti-seize

lubricant.

2) Slide the bit onto the motor shaft, positioning the set screw over

the flat side of the motor shaft (Fig. 1). Position the bit on the

shaft so at least 1/8" of the diamond surface is exposed above

the Easy Glide ™ Work Surface.

1

3 4

2

7

5

Fig.1

PAGE 3 - POWER MAX II INSTRUCTION MANUAL

3) Secure the bit to the shaft by turning the set screw

clockwise with the hex wrench (Fig. 2).

IMPORTANT: Always secure the bit to the flat side of the motor shaft. Tightening the bit to the rounded side can scar the shaft and prevent bit removal!

B. Sponge Installation

The technologically advanced Super Sponge

™

can absorb over 10 times its weight in water. Its superior wicking ability insures a sufficient water supply to protect the bit and keep the glass cool.

1) Wet the Super Sponge™ by immersing it in water until

soft and pliable.

2) Fill the water reservoir (Fig.3) about 3/4 of the way to the

top. You may add special grinding lubricant if desired.

3) Insert the sponge between the sponge holder on the

work surface and grinder bit so that the bottom of

the sponge is in contact with the coolant/water in the

reservoir and the top of the sponge is in contact with

the diamond surface of the bit (sponge may be trimmed

to ensure proper fit).

4) The wet sponge should remain in contact with the bit

while grinding (Fig.4). Periodically rinse out the sponge

to remove grinding residue. When the sponge becomes

worn, replace it.

5) Should the sponge become dry during periods of

non use, simply immerse in water and- reinstall.

6) The Power Max II comes with two work surface adaptors

designed to allow the use of a 1" and 3/4" bit (Fig.5).

After the surface grid has been installed, place the grid

surface adaptor into the grid (Fig.6). Be sure to use the

adaptor that matches the bit you are using.

7) Soak the sponge in water, then position it into the grid

surface adaptor located behind the water reservoir.

DELUXE MODELS ONLY

1) Use the Universal Face Shield™ by simply removing

the paper covering from the shield (Fig.7), put it on the

frame, then slide the base of the frame underneath the

grinder body (Fig.8).

2) Deluxe models also come with an Easy-On™ Foot

Switch. This switch allows you to easily turn the grinder

on or off with a simple tap of the toe. To use, plug

grinder directly into the foot switch, then plug foot switch

into any outlet. Turn grinder to the ON position.

3) The 3/4" bit is useful in grinding smaller inside curves.

3/4 " adaptor

Fig.2

Fig.3

Fig.4

Fig.5

1 " adaptor

Fig.6

Fig.6

Fig.7

POWER MAX II INSTRUCTION MANUAL - PAGE 4

Grinder Use and Maintenance

A. Bit Use

Remember to wear safety glasses or install a protective face shield when grinding.

1) If you are a first time user, get the feel of the grinder by turning

on the grinder and grinding a piece of scrap glass. Begin by

pushing the glass into the grinding bit using light pressure

and moving the glass back and forth across the bit (Fig.9).

2) Slowly increase the pressure until you feel comfortable with

the grinding speed and your control. You’ll quickly learn the

optimum grinding pressure for the types of glass you use.

3) Stop periodically and check the sponge placement and water

level. Grinding without water greatly reduces the life of

your grinding bits.

4) Over time, a bit may grind less effectively causing your glass

to chip, this is a result of wearing away of the bit’s diamond

surface. When this happens, it is time to expose a new portion

of the diamond surface. Loosen the set screw using the hex

wrench and move the grinding bit up on the shaft to expose a

new 1/8" section of diamond.

5) Secure the bit back in place making sure to tighten it against

the flat side of the motor shaft. Reposition the sponge if needed.

6) The 1/4" grinder bit is useful for both drilling holes and intricate

grinding. To set up the 1/4" bit, simply install work surface,

then place the 1/4" bit directly into the top of the shaft making

sure the hex screw lines up with the flat side.

B. Care Information

1) NEVER GRIND DRY. Always make sure the sponge for the

grinder bit is wet while grinding.

2) While using the grinder bit, use only light to medium pressure

on the bit. Do not push material against bit using excessive

force. Unnecessary pressure will shorten grinder and grinder

bit life.

3) Clean water reservoir and Super Sponge™ after each use.

Remove water reservoir and flush out grinding residue

around the sides of the base. When cleaning or using large

volumes of water during grinding, remove the rubber stopper

(Fig. 10) from the grinder box and allow water to flush through

the drain (Fig. 11).

4) If the grinding bit becomes dry, add water directly to the Super

Sponge™.

5) To extend the life of the grinder, clean and lubricate the motor

shaft, inside openings of all bits and all set screws every 25

hours of use.

6) Grinder bits should be removed from the machine if they

are not in use for a week or more. This will keep them

from “cementing” to the shaft. It will also provide you with the

opportunity (and habit) of inspecting the motor shaft and bits

for proper care and maintenance.

7) DO NOT GRIND METAL. Doing so will destroy the bit and

make it unsuitable for grinding glass.

Drain

Fig.8

Fig.9

Fig.10

Fig.11

PAGE 5 -

Troubleshooting

Problem: Grinder bit has become stuck onto the motor shaft

Solution 1: Loosen set screws and push the bit as far down the shaft as possible. Most often the shaft above where the bit was mounted crusts with glass debris, coolant, hard water residue, etc.

Using a small piece of fine steel wool or scrubby, polish the end of the shaft all the way down to where the bit rests.

Solution 2: If you can push the bit down as above, but you notice that there is a burr or scar on the round side of the motor shaft caused by the set screw in the wrong position (it appears as a small ring cut into the shaft), you will need to polish it out. This can often be done by using the same steel wool mentioned above, but occasionally it requires stronger abrasives. Be very careful here! You only want to remove the scar, you do not want to make the shaft smaller. It may be necessary to use very fine grit emery cloth or sandpaper here. But again, be very careful, the motor shaft can be easily damaged. Once the scar is polished out, remove the bit. Clean both the bit and shaft and use lubricant. Never tighten the bit to the round side of the motor shaft.

Solution 3: If the bit is still stuck, use a plumbers helper or vice grip to remove the bit. If further assistance is necessary, call Diamond Tech toll free at (800) 937-9593 for tech support or to obtain a Return Authorization Number and further instructions to send your machine in for repair.

Additional Parts and Accessories

ITEM

WORK SURFACE GRID

UNIVERSAL FACE SHIELD

EASY-ON ™ FOOT SWITCH

MAX SPLASH GUARD

GRINDER MOTOR 110V/220V

GRINDER CAPACITOR 110V/220V

SUPER SPONGE REPLACEMENTS

1/4" FAST BIT

1/4" STANDARD BIT

3/4" FAST BIT

3/4" STANDARD BIT

1" FAST BIT

1" STANDARD BIT

ANGLED BIT

REDUCING BIT

1" WORK SURFACE ADAPTOR

3/4" WORK SURFACE ADAPTOR

EASY-GLIDE ™ WORK SURFACE

RUBBER DRAIN STOPPER

ITEM NUMBER

289

DM0750

FS0420

P203

P216/P216A

P221/P221A

66SUPER

GH0230

GH0600

GH0360

GH0350

GH0290

GH0410

GH0300

GH0310

P404

P224

P402

P228

Diamond Tech

Power Max II Series 6 Year Warranty

All Diamond Tech grinders and accessories are manufactured to high quality standards and are serviced by highly qualified technicians.

Power Max II ™ Grinders are warranted to the original purchaser for six full years from the original purchase date.

During the six year period, if you feel the Power Max II ™ Grinder is not performing properly and needs to be serviced, contact Diamond Tech at 800-937-9593 or email [email protected] for a Return Authorization Number. Equipment will not be accepted at Diamond Tech without a Return Authorization Number.

If returning your grinder for evaluation or repair, be sure to include your Name, Address, Daytime Phone Number with

Area Code and a letter explaining the specific problem you are encountering. You will be contacted if any necessary parts or service are not covered under the warranty.

Date of purchase ___ / ___ / ___

Mark the Return Authorization Number clearly on every package!

Do not send this product back without such prior authorization!

Return postage and insurance are the responsibility of the consumer. Diamond Tech will return your grinder postage paid and insured if it is under warranty. Any grinder no longer under warranty will be returned at the owner’s expense. Diamond Tech reserves the right to repair or replace faulty equipment at its discretion. The Power

Max II ™ Grinder is warranted against defective materials or workmanship. If the Power Max II ™ Grinder suffers damage due to customer modifications and/or is used for any application other than that for which it was designed, this warranty is void. This warranty does not include damage due to: (A) neglect (B) accident (C) unreasonable use

(D) improper maintenance (E) any other causes not attributed to defects in material or workmanship. This warranty specifically excludes the Diamond Max disclaimed.

™ Grinder bits or disks. Any implied or otherwise explicit guarantees made through merchandiser of this product are not covered in this warranty coverage agreement and are expressly

IMPORTANT NOTE: This machine was designed for certain applications only.

Diamond Tech strongly recommends that this machine NOT be modified and/or used for any application other than that for which it was designed. If you have any questions relative to its application, please contact us and we will advise as to it proper use.

5600 Airport Blvd., Suite C, Tampa, Florida 33634

Tech Support: 800-937-9593 • (U.S.A., Canada) 813-806-2923

Fax: 813-806-1988 • Email: [email protected]

www.DiamondTechGlass.com

5/2005