Caberet Lapidary Grinder/Polisher Graves Company 1800 North Andrews Avenue Pompano Beach, FL 33069 USA Telephone: 800-327-9103 Website: www.gravescompany.com INSTRUCTION MANUAL FOR THE GRAVES CABERET GEM CUTTER Congratulations on your purchase of the Graves Caberet gem cutter. This machine has been engineered and built with the finest materials and designed to provide you with trouble free cutting for many years.Your Caberet is small (22x16x12 inches) and weighs only 34 lbs., yet it is powerful enough to cut stones up to 30x40mm. Everything is included with the machine to begin cutting immediately. All you need is to provide the stones! Before using your Caberet, read this instruction booklet and pay particular attention to WARNINGS and CARE of your machine. We urge you to become familiar with the features of the machine and follow some basic rules to ensure safe operation of the machine. Please observe the following safety do’s and don’ts. DO 1. Set up your machine on a stable flat surface. Otherwise, it may tend to walk and fall off the surface due to vibration and/or pressure exerted against the wheels while cutting. 2. Prior to plug-in, make sure the motor switch is in the off position. In the USA, always connect the power cord to a standard 110V/60 Hz three wire grounded circuit. Foreign customers should use 220V/50Hz after attaching a compatible plug to the motor cord. Because gem cutting requires the use of water sprayed onto the surface of the wheels failure to use a grounded circuit could cause a short circuit and damage to the machine or yourself. 3. Always wear safety glasses or goggles when grinding, sanding or polishing gemstones. Keep loose clothing or jewelry away from the wheels. 3. Keep your machine clean and clear of obstructions or materials that might become caught in the wheels. 4. Keep the wheel retaining nuts tight to preclude free wheeling that could damage the wheels or shaft. A quarter turn with a wrench after hand tightening is enough. 5. Always wear a dust mask when cutting sea shells, metal ore or stones that contain toxic materials; such as malachite and calcite or rocks containing arsenic or asbestos. Use ample coolant and ventilation to guard against airborne particles. 6. Clean the machine regularly with a mild cleanser and sponge to maintain its surface and always empty the water pans after each cutting session; otherwise the pans and surfaces may become stained from minerals inherent in the gemstones being cut. 7. Always ensure there is sufficient water in the pans while cutting and that the sprayers are supplying water to the wheel surfaces. Failure to do so will cause the wheels and/or stone to overheat and clog with swarf causing damage to both. Remember to move the water sprayer each time you change wheels. Graves Company accepts no responsibility for damage caused by cutting with dry wheels. DON’T 1. Never connect your Caberet to an ungrounded circuit. 2. Never run your wheels dry while cutting as this can produce dust or fumes dangerous to your health. 3. Never allow anything to become entangled in the wheels such as a necklace, glove, hair or lose clothing. 4. Do not wear ANY hand jewelry while cutting. The wheels are coated with diamond, the hardest material known to man, and WILL damage any metal or stones (including diamonds) in your rings. 5. Never use excessive pressure against the wheels as this can damage the wheels or the gemstone. Be patient! 6. Never reach under the wheels to retrieve a stone while the machine is running. 7. Never try to change the end/back-plate while the machine is running. 8. Do not use your wheels for any operation for which they are not intended. 9. Do not overload the wheel cover/tray. The load capacity in the front two compartments is rated at 1lb. Any load above this could damage the cover. ASSEMBLY If your Caberet is shipped without the wheels attached, assemble them as follows: Cutting is performed from inside the wheel to outside the wheel with three wheels on each side. On the left side, slide on one 1x3/4 washer and then the COARSE GRIND STEEL wheel and a narrow spacer. Slide on the FINE GRIND steel wheel followed by a wide spacer and the COARSE SAND NOVA/FLEX steel wheel and another 1x3/4 washer and the retaining nut. Do not tighten at this time. The wheels should be separated by approximately ½ inch and the nut should be flush with the end of the wheel. On the right side, slide on one 1x3/4 washer, the FINE SAND Nova/Flex wheel followed by a wide spacer, the PRE-POLISH Nova/Flex wheel, a wide spacer, the POLISH Nova/Flex wheel and another 1x3/4 washer and the nut. Spacing between the wheels should be approximately 1/2 inch. The different spacing between wheels and size of the spacers results from some wheels having wheel hubs of different widths. You may need to experiment a bit to get the wheels spaced correctly. After all wheels are on, hand - tighten the retaining nuts using a rubber pad for a good grip; or use slip pliers. Do not over tighten! Should there be vibration when you first start the machine the wheels may be out of balance, similar to tires on a car. On one side at a time, loosen the nut until the wheels spin freely. By hand, spin each wheel, allowing it to stop by itself and mark the bottom of the wheel with a Sharpie pen. When all wheels are marked, position them so the marks are juxta-opposed; this will insure the weight from any heavy spots will be equally distributed. One last thing, gently spin the 6 polishing back-plate into the 1/4x20 hole on the right end of the shaft. MOTOR AND DRIVE SYSTEM The Caberet is equipped with a high speed continuously variable speed (approx 0-2000 rpm) permanent magnet DC motor that is lubricated for the life of the machine. The motor is controlled by a variable speed controller located on the front of the machine which is also the on/off switch. The motor drives the 19.5x 3/4 inch stainless steel shaft by a heavy duty V- belt. The shaft bearings are permanently sealed and lubricated. COOLANT SYSTEM All lapidary grinders should be used with proper grinding coolant. It is essential to keep the point of contact between the abrasive surface and the stone clean and cool. Graves believes water alone is not an adequate coolant. Instead, Graves Dia- Cut grinding and cutting concentrate (or an equivalent) is recommended for use with water. It contains a dispersing agent that breaks the surface tension of the water and gets more coolant onto the surface; it contains a mild detergent for good cleaning/cooling action and Dia-Cut also has rust and corrosion inhibitors to protect your grinding wheels. Simply mix a capful per tray of water. Fill each water tray until the water covers the ‘button’ in the center of the tray. Remember to periodically add water as needed. This will provide enough water to cover the intake holes on the sides of your brass spray head. Too much water will cause excessive spray. You may want to remove the spritzer from the tray you are not using and lay it in the middle of the machine out of the way until it is needed - this will reduce water spray. KEY FEATURES OF YOUR CABERET 1. Shroud 2. Wheel cover and tray 3. Six wheels (from left to right) • coarse sanding • fine grinding • coarse grinding • fine sanding • pre-polish • polish 4. End plate for polishing with various powders and carriers 5. Power cord (rear of the machine) 6. Fuse holder 7. Water pans 8. Power on/off and speed controller 9. Water pump switch - The water pump switch is handy when you want the machine to be on, such as when polishing on the end plate, but do not want the water sprayers to be on. Simply turn the switch clockwise to turn it on or off. ABOUT YOUR NOVA/FLEX WHEELS The diamonds in Nova/Flex wheels are embedded in a tough, flexible plastic resin on a cloth material backed by a soft sponge rubber. This construction allows the wheels to conform to the shape of the stone and eliminate flat spots and scratches. Nova/Flex wheels must be used with water to lubricate them. We recommend you add DiaCut (Graves Item No. 08-081) to provide increased lubrication of the wheel’s surface. If the wheels are run dry for more than a few seconds while cutting they may be damaged. Make certain the sprayer supplies adequate water to the wheels surface before using it and remember to move the sprayer when changing wheels. Nova/Flex wheels should be broken in by sanding and polishing a large smooth piece of junk agate or jasper (hardness 7) prior to cutting a gemstone. This removes excess resin coating and exposes the diamond grit. Spend two to five minutes on each wheel working across the entire surface with a generous water supply. Finer grit wheels (3000 grit and up) will take longer to remove the excess resin and will continue to improve as more stones are worked. When smoothing, use light pressure against the diamond surface to remove more material more quickly; but this will also produce some flat areas or ridges on the stone. Slightly heavier pressure will cause the surface of the wheel to depress and conform to the stone’s surface eliminating flat spots left by the grinding wheels.