Diamond Tech Power Max II Operation Manual

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

2) Two Work Surface Adaptors

3) 1/4" Chrome Hardened Bit

4) 1" Chrome Hardened Bit

5) Advanced Super Sponge

™

6) Easy Glide™ Work Surface

7) Hex Wrench

8) Anti-Seize Lubricant

9) Rubber Stopper

Deluxe Model Also Includes:

1) Universal Face Shield

2) Easy-On™ Foot Switch

2

9

6

8

3

2

4

7

5

3) 3/4" Chrome Hardened Bit

Assembly Instructions

A. Bit Installation

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.

3

1

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.

3/4" adaptor

Fig.2

Fig.3

Fig.4

Fig.5

1" adaptor

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.

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.

Fig.8

Fig.9

Fig.10

Fig.11

Drain

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 [phone] 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 ITEM NUMBER

WORK SURFACE GRID 289
UNIVERSAL FACE SHIELD DM0750
EASY-ON™ FOOT SWITCH FS0420
MAX SPLASH GUARD P203
GRINDER MOTOR 110V/220V P216/P216A
GRINDER CAPACITOR 110V/220V P221/P221A
SUPER SPONGE REPLACEMENTS 66SUPER
1/4" FAST BIT GH0230
1/4" STANDARD BIT GH0600
3/4" FAST BIT GH0360
3/4" STANDARD BIT GH0350
1" FAST BIT GH0290
1" STANDARD BIT GH0410
ANGLED BIT GH0300
REDUCING BIT GH0310
1" WORK SURFACE ADAPTOR P404
3/4" WORK SURFACE ADAPTOR P224
EASY-GLIDE™ WORK SURFACE P402
RUBBER DRAIN STOPPER 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 [e-mail] 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™ 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
disclaimed.

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.

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

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

Fax: [phone] • Email: [e-mail]

www.DiamondTechGlass.com

5/2005