The Genie is a compact and portable cabochon grinding and polishing unit, designed for lapidaries to quickly and efficiently grind and polish stones. It comes complete with a motor, diamond wheels, and a coolant system, requiring only a standard 115-volt electrical outlet (230-volt for export models) for operation. Its clean operating nature, due to the minimal water required for grinding and polishing, makes it suitable for use in various convenient locations, including a kitchen.
Function Description:
The primary function of the Genie is to facilitate the grinding and polishing of cabochons. It is equipped with two Galaxy metal-bond diamond grinding wheels (80 grit for coarse grinding and 220 grit for fine grinding) and a set of four Nova resin-bond diamond sanding and polishing wheels (280, 600, 1200, and 3000 grit). An additional 14000 grit Nova Disc is included for an extra polishing step, allowing for a high polish on most stones within minutes without needing to change attachments or wheels.
The unit features a Spra-Mist coolant system, which uses a piston-type air pump to provide a fine mist to the underside of the grinding and polishing wheels. This system prevents rock dust formation, keeps stones cool, and maintains wheel cleanliness. The pump is designed to be trouble-free, as no water flows through it, preventing clogging or damage from grit.
Usage Features:
- Assembly: The Genie is straightforward to assemble. Users need to remove strapping and a wooden board from under the baseboard, set the pans in place, ease the hoods over their aluminum brackets, and install the splash guards. The flexible stem lamp can be attached to either button on the rear of the baseboard.
- Safety: Before operation, ensure the electrical outlet is properly grounded and protected by a Ground Fault Circuit Interrupter (GFCI). Only diamond grinding wheels should be used; silicon carbide or aluminum oxide wheels are not compatible due to safety risks. Always use sufficient water to prevent rock dust formation and wear safety glasses to protect eyes from debris. Avoid touching the motor during use as it runs hot.
- Grinding and Polishing Cabochons:
- Pre-Forming: Stones should be pre-formed by cutting them into slabs and marking the desired shape with a template. Removing excess material at this stage reduces grinding time and extends wheel life.
- Grinding on Galaxy Wheels: Start with the 80 grit wheel for coarse grinding, using light to medium pressure and working the stone over the entire wheel surface. The Cab Rest can be used to achieve a uniform 12-1½ degree bezel angle. Progress to the 220 grit wheel for fine grinding, maintaining light to medium pressure. When shaping the dome, dopp the stone for easier handling and use a circular, oscillating motion from the edge to the center to prevent flat spots.
- Sanding and Polishing with Nova Wheels: Nova Wheels require a water lubricant; running them dry can cause rapid wear. Break in new Nova Wheels by sanding a large agate cab for 2-5 minutes on each wheel. Use firm pressure to allow the rubber backing to conform to the stone, and maintain a circular, oscillating motion to eliminate flat spots and scratches. Progress through the 280, 600, 1200, and 3000 grit wheels, ensuring all scratches are removed at each stage.
- Using Nova Discs: For harder-to-polish materials like jade, the 14,000 grit Nova Disc can be attached to the right-hand shaft. Other polishing compounds can be used with canvas or leather pads. The geyser can be angled to spray water onto the Nova Disc by attaching a small white plastic base.
- Hoods and Pans: The rigid plastic hoods and pans are durable and easy to clean. The hood's top edge serves as a convenient tray for stones. To remove a hood, rotate it towards you in the direction of wheel rotation. For flat lap use, remove the hood, unscrew the end plate, and turn the pan 90 degrees parallel to the shaft for ample drip pan space.
- Flex Stem Lamp and Magnifier: The lamp and an optional magnifier are interchangeable. Adjust them using both hands at the base of the flexible stem to prevent strain.
- Optional Accessories:
- Trim Saw Attachment: Converts the Genie into an eight-inch trim saw, using water as a coolant.
- Left Hand Laps, Discs: Six-inch diameter laps with a 1/2" arbor hole can be attached to the left-hand side for grinding and polishing flat surfaces.
- Right Hand Laps, Pads: Six-inch diameter Nova Pads, Magnetic Laps, leather, canvas pads, or "No-Hole" metal bond laps can be attached to the right end.
- Jewelers Buff Kit: Includes buffs and jeweler's rouge for finishing metals, with a wheel adaptor and spacers for mounting on the right side.
- Extra Right Hand Adaptors and Spacers: Allows mounting wheels four at a time for gem carving, creating a 3" space between wheels. Also used for mounting extra grits or special shaped wheels.
- The Boxer Attachment: Holds slabs at a 45-degree angle for making miter joints, usable on either side of the Genie depending on the lap type.
Maintenance Features:
- Galaxy Wheels: Do not attempt to dress Galaxy Wheels. Use light to medium pressure, a steady rest, and coolant to prolong wheel life. Use the entire wheel surface to prevent uneven wear. Reverse wheels occasionally to renew cutting edges.
- Nova Wheels: Always use with water lubricant. Break in new wheels. Use sufficient pressure and circular, oscillating motion. Prepare stones properly on grinding wheels before sanding to extend Nova Wheel life.
- Spra-Mist Cooling System: The pump is relatively trouble-free. If a geyser becomes plugged, boil it in a vinegar and water solution or use a needle to clear obstructions. A few drops of Water Aid can improve cutting ability but avoid excess to prevent foam.
- Pump Maintenance (Oiling Leathers and Bearings):
- Unplug the machine.
- Remove the left-hand hood to expose the pump.
- To oil leathers, remove the middle red-painted screw, place one drop of 30-weight motor oil in the hole, and replace the screw.
- To oil bearings, remove the red-painted corner screw in the bottom pump block, place one drop of 30-weight motor oil in the hole, and replace the screw. Oil every forty hours of use.
- Dried Out Pump Leathers: If air output decreases, the leathers may be dried out. Disassemble the pump by removing the four head screws, cylinder head, and cylinder. Unscrew the piston screw to remove leathers and felt. Stretch and generously oil leathers and felt with 30-weight oil. Reassemble in the correct order: felt between leathers (smooth side out), piston washer (countersink side up), screw through washer and leathers, cylinder and head back over piston (air outlet tubing to rear), and finally, tighten the four head screws evenly.
- Belt Slippage: Intermittent or no air output indicates a slipping belt, often due to oil leakage. Unplug the machine, remove the left-hand hood and wheels. Rotate the pump pulley to expose two phillips head mounting screws in the pump base. Loosen these screws slightly to allow the pump to be moved to tighten the belt. Clean any oil from the pulley and belt.
- Removing and Replacing Wheels:
- Right Hand Side: Loosen the nut on the adaptor (left-hand thread), remove the wheels, and clean the shaft. Replace wheels and spacers, ensuring the adaptor is tight.
- Left Hand Side: Remove the brass lap connector (not the slotted bolt). The lap connector has left-hand threads. Turn clockwise to remove, counter-clockwise to tighten.
- Remounting and Balancing Galaxy Wheels: Ensure spacers, adaptor, and wheel hubs are clean. Mount wheels and spacers on the adaptor. Turn on the motor to check for "wobble" or "bounce." Balance wheels by loosening the lap connector, rotating the inside wheel about one-eighth of a turn, tightening, and rechecking. Once balanced, hold it in place while balancing the middle wheel, then the first wheel (80 grit). Secure all wheels tightly. A properly balanced wheel prevents premature wear.
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