Diamond Tech International Power Max II User manual

POWER MAX II INSTRUCTION MANUAL
DIAMONDTECHINTERNATIONAL
InnovationsForCreativity
OPERATIONSMANUAL
POWER MAX II
™
GLASS GRINDER

POWER MAX II INSTRUCTION MANUAL
Contents
Your Power Max II Grinder™ has been shipped partially assembled. Carefully remove grinder
and parts from the packaging.
1- Grinder Body
2- Two Grind Surface Adaptors
3- 1/4” Silver Bullet™ Bit
4-1” Silver Bullet™ Bit
5- Advanced Super Sponge™
6- Easy Glide Work Surface
7- Hex Wrench
8-Anti-Seize Lubricant
Deluxe Model Also Includes:
1 - Universal Face Shield
2 - Easy-On-Footswitch
3 - Step-Up Work Surface
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
overthe flat sideof the motorshaft (Fig. 1).Position the biton the
shaft so at least 1/8” of the diamond surface is exposed above
Fig.1
2
345
6
7
8
1
2
3
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.
- PAGE 2

POWER MAX II INSTRUCTION MANUAL
Fig.2
Fig.3
Fig.4
Fig.5
Fig.6
the Easy Glide™work surface.
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)Wetthe Super Sponge™by immersingit in water untilsoft
andpliable.
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)Insertthe sponge between the sponge holder onthework
surfaceand grinder bit sothatthe bottom of thespongeis in
contactwith the coolant/water inthereservoir and thetopof
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 yourspongebecomedryduring periodsofnonuse,
simply immerse in water & 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,
thenslidethebaseoftheframeunderneaththegrinderbody
(Fig.8). 2) Deluxe models also come with an Easy-On™
Footswitch. 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 footswitch, then plug footswitch into any
outlet. Turn grinder to the ON position.
3) The Step-Up Work™Surface has pins on its bottom that
fit into the grid cover for easy installation (Fig.9).
3) The 1/4” grinder bit is useful for both drilling holes and
intricate grinding. To setup 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
PAGE 3 -
Fig.6
Fig.7

POWER MAX II INSTRUCTION MANUAL
of the shaft and tighten.
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.10).
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
grindingbits.
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 toexpose a newportion of
thediamondsurface.Loosenthe 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.
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
onthebit.Do not push material against bitusingexcessiveforce.
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. The drain hole (Fig.11) in the grinder box
allows water to flush through the drain (Fig.12) when cleaning or
if using large volumes of water when grinding.
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,insideopeningsofallbitsand 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”totheshaft. Itwillalsoprovideyouwiththeopportunity
(and habit) of inspecting the motor shaft and bits for proper care
and maintenance.
7) DO NOT GRIND METAL. It will make the surface unsuitable
for glass in seconds.
Fig.9
Fig.8
Fig.11
Fig.10
- PAGE 4
Drain
Fig.12

POWER MAX II INSTRUCTION MANUAL
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
onthe round sideofthemotorshaft causedbythesetscrew in thewrongposition(itappears
as a small ring cut into the shaft), you will need to polish it out. This can often be done by
usingthesamesteel wool mentioned above, but occasionallyitrequiresstrongerabrasives.
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.
Solution3: Ifthebitis stillstuck,useaplumbershelperor vicegriptoremove thebit.Iffurther
assistance is necessary, call DTI 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
UNIVERSALFACESHIELD DM0750
STEP-UP WORK SURFACE DM0720
EASY-ON FOOTSWITCH FS0420
MAXSPLASH GUARD P203
GRINDERMOTOR110V/220V P216/P216A
GRINDERCAPACITOR 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
ANGLEDBIT GH0300
REDUCINGBIT GH0310

POWER MAX II INSTRUCTION MANUAL
Diamond Tech International
Diamond Max Series 6 Year Warranty
All Diamond Tech International 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 International at 800-937-9593 or email [email protected] for a ReturnAuthorization Number. Equipment will
not be accepted at DTI 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. DTI 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 International 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 International 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.
DIAMOND TECH INTERNATIONAL, USA
7/2002
5600-C Airport Blvd., Tampa, Florida 33634
Tech Support: 800-937-9593 • (U.S.A., Canada) 813-806-2923
Fax: [phone] • Email: [email protected]
www.dticrafts.com