MK Diamond MKDX User Manual
www.mkdiamond.com
MKDX
BULLNOSE & SHAPING MACHINE
OPERATION & PARTS MANUAL
Revision 105
Manual Part# 166106
Caution: Read all safety and operating instructions
before using this equipment. This manual MUST
accompany the equipment at all times.
03.2010
MK Diamond Products, Inc.
INTRODUCTION
Congratulations on your purchase of a MKDX Bullnose. We are certain that you will be pleased with
your purchase. MK Diamond takes pride in producing the nest construction power tools and
diamond blades in the industry.
Operated correctly, your MKDX Bullnose should provide you with years of service. In order to help
you, we have included this manual. This owners manual contains information necessary to operate
and maintain your MKDX Bullnose safely and correctly. Please take the time to familiarize yourself
with the MKDX Bullnose by reading and reviewing this manual.
Read and follow all safety, operating and maintenance instructions.
If you should have questions concerning your MKDX Bullnose, please feel free to call our friendly
customer service department at: 800 421-5830
Regards,
MK Diamond
NOTE:
NOTE THIS INFORMATION FOR FUTURE USE:
MODEL NUMBER:
SERIAL NUMBER:
PURCHASE PLACE:
PURCHASE DATE:
For your (1) one year warranty to be effective, complete the warranty card (including
the Serial Number) and mail it in as soon as possible.
22
MKDX TABLE OF CONTENTS
MK DIAMOND DX BULLNOSE & SHAPING MACHINE
SAFETY
Safety Message/Alert Symbols
Safety Warnings
Hazard Symbols
Rules for Safe Operation
Electrical Requirements and Grounding Instructions
Operation & Safety Decals
Safety Decal Locations
PRODUCT SPECIFICATIONS
Product Specications
Prole Wheel Specications
Basic Components
INSPECTION & START-UP
Safety Devices & Manual Handling
Unpacking and Machine Set-Up
Workstation
Installing/Changing Shaping Wheels
Water Tank Filling
PAGE NO.
4
5
6
7-8
9-11
12
13
14
15
16-17
18
19
20
21
22
OPERATION
Clamping the Material
Prole Wheel Adjustment
Shaping
MAINTENANCE
Cleaning the Machine
Adjusting the Sliding Device
GENERAL PRODUCT INFORMATION
MKDX Top Assembly Part# 165175
MKDX Material slide Assembly Part# 165170
MKDX Motor Guide Assembly Part# 165171
MKDX Switch Assembly Part# 165176
MKDX Drive Train Assembly Part# 165172
MKDX Filter Assembly Part# 165438
Accessories, Ordering and Return Information
Contact Information and Limited Warranty
23-24
25
26-27
28
29
30-31
32
33
34-35
36
37
38
39
3
MKDX SAFETY
Safety precautions should be followed at all times when operating this equipment. Failure to read and
understand the Safety Precaution and Operating Instructions could result in injury to yourself and others.
This Operation and Parts Manual has been developed to provide complete instructions for the safe
and efcient operation of the MKDX Bullnose & Shaping Machine.
Before using this machine, ensure that the person operating the machine has read and understands
all instructions in this manual.
SAFETY MESSAGE / ALERT SYMBOLS
A safety message alerts you to potential hazards that could hurt you or others. Each safety message is
preceded by a safety alert symbol ( ) and one of three words: DANGER, WARNING, or CAUTION.
DANGER
You WILL be KILLED or SERIOUSLY INJURED if you do not follow directions.
WARNING
You CAN be KILLED or SERIOUSLY INJURED if you do not follow directions.
CAUTION
You CAN be INJURED if you do not follow directions. It may also be used to
alert against unsafe practices.
Each message tells you what the hazard is, what can happen, and what you can do to avoid or reduce injury. Other important messages are preceded by the word NOTICE.
NOTICE
You can cause PROPERTY DAMAGE to your machine if you don’t follow directions.
The safety labels should be periodically inspected and cleaned by the user to maintain good legibility
at a safe viewing distance. If the label is worn, damaged or illegible, it should be replaced, contact
MK Diamond or your dealer for replacement.
4
MKDX SAFETY
SILICA DUST WARNING
Grinding/cutting/drilling of masonry, concrete, metal and other materials with silica in their composition may give off dust or mists containing crystalline silica. Silica is a basic component of sand,
quartz, brick clay, granite and numerous other minerals and rocks. Repeated and/or substantial inhalation of airborne crystalline silica can cause serious or fatal respiratory diseases, including silicosis.
In addition, California and some other authorities have listed respirable crystalline silica as a substance known to cause cancer. When cutting such materials, always follow respiratory precautions.
CALIFORNIA PROPOSITION 65 MESSAGE
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contain chemicals known (to the State of California) to cause cancer, birth defects or other reproductive
harm. Some examples of these chemicals are:
• Lead, from lead-based paints
• Crystalline silica, from bricks and cement and other masonry products
• Arsenic and chromium, from chemically treated lumber
For further information, consult the following sources:
http://www.osha.gov/SLTC/silicacrystalline/index.html
http://www.oehha.org/prop65/out_of_date/6022kLstA.html
Your risk from these exposures varies depending on how often you do this type of work. To reduce
your exposure to these chemicals, work in a well-ventilated area, and work with approved safety
equipment, such as those dust masks that are specially designed to lter out microscopic particles.
5
MKDX SAFETY
ON / OFF
Potential hazards associated with the MKDX Bullnose & Shaping Machine operation will be referenced with Hazard Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Message/Alert Symbols.
HAZARD SYMBOLS
ALWAYS read this Owner’s Manual before operating the machine.
ALWAYS avoid inhalation of and skin contact with silica dust and/or mist.
ALWAYS place the power ON/OFF switch in the OFF position when the MKDX is not in
use.
ALWAYS wear approved eye protection.
ALWAYS wear approved respiratory protection.
NEVER operate equipment with covers, or guards removed. Keep ngers, hands, hair
and clothing away from all moving parts to prevent injury.
ALWAYS use caution around gears. Keep ngers, hands, hair and clothing away from all
moving parts to prevent injury.
DO NOT touch hot engine components while the machine is running or immediately after
operating.
NEVER touch the power cord with wet hands or while standing in water when it is connected to a power source.
NEVER operate the machine in an explosive atmosphere or near combustible materials.
6
MKDX SAFETY
ON / OFF
RULES FOR SAFE OPERATION
DANGER
Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is
to be operated by trained and qualied personnel only! This equipment is for industrial use only. The fol-
lowing safety guidelines should always be used when operating the MKDX Bullnose & Shaping Machine.
GENERAL SAFETY
• DO NOT operate or service this equipment before reading this entire manual.
• This equipment should not be operated by persons under 18 years of age.
• NEVER operate this equipment without proper protective clothing, shatterproof glasses, steeltoed
boots and other protective devices required by the job.
• NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.
• NEVER operate this equipment under the inuence of drugs or alcohol.
• Whenever necessary, replace nameplate, operation and safety decals when they become
difcult to read.
• ALWAYS check the machine for loose bolts before starting.
• ALWAYS wear proper respiratory (mask) hearing and eye protection
equipment when operating this machine.
• ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean,
dry location out of the reach of children.
• NEVER leave the machine unattended. Turn off electric motor when unattended.
• CAUTION must be observed while servicing the machine. Rotating parts can cause injury if contacted.
• Ensure that any electrical extension cord is protected against damage. Always ensure that the
electrical extension cord is not trapped underneath the machine.
• DO NOT allow extension cord to come into contact with water or uids. DO NOT spray water onto electric motor.
• NEVER operate the machine in an explosive atmosphere.
• Before starting the machine, check that all guards are in position and correctly tted.
• Keep area around the machine clear of obstructions which could cause persons to fall onto moving parts.
• ALWAYS ensure that the machine is on level ground before using.
• Become familiar with the controls of the machine before operating.
7
MKDX SAFETY
• ALWAYS disconnect AC power plug from power source before moving or servicing the machine.
• Make sure the OFF/ON power switch on the electric motor is always in the OFF position before
inserting the machine’s power plug into an AC receptacle.
• Operate electric motor only at the specied voltage indicated on the nameplate.
• NEVER disconnect any “emergency or safety devices”. These devices are intended for operator
safety. Disconnection of these devices can cause severe injury, bodily harm or even death! Dis
connection of any of these devices will void all warranties.
• Unauthorized equipment modications will void all warranties. Manufacturer does not assume
responsibility for any accident due to equipment modications.
• NEVER use accessories or attachments, which are not recommended by MK Diamond for this
equipment. Damage to the equipment and/or injury to user may result.
The MKDX Bullnose and Shaping machine is designed to be used only with approved diamond
cutters. All bullnosing and shaping must be done with water as a coolant.
WARNING
MOTOR OVERLOAD SAFETY
If the machine goes off unexpectedly, the motor’s overload cutout may have been activated. In this
•
case, unplug the machine from the power supply and wait until the motor and overload cutout have
cooled down.
SHAPING SAFETY
Before starting any type of shaping operation:
•
Always check that the spray guard is in place.
Always check that the prole wheel is sharp. If necessary, sharpen using a sharpening stone.
Always check that the prole wheel shows no signs of cracking. If necessary, replace it.
Always check that nobody is in the work area except those directly involved in the operations.
WATER SAFETY
Before starting any type of proling operation, always check the level of cooling water.
•
MAINTENANCE SAFETY
•
NEVER lubricate components or attempt service on a running machine.
Never use this machine with any cutter designed for wood working.
•
Keep the machinery in proper running condition.
•
Fix damage to the machine immediately and always replace broken parts, or missing decals.
8
MKDX SAFETY
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ELECTRICAL REQUIREMENTS AND GROUNDING INSTRUCTIONS
In order to prevent potential electrical shock and injury, the following electrical safety precautions and
symbols should be followed at all times!
WARNING
In case of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet
that is properly installed and grounded in accordance with all local codes and ordinances.
• Do not modify the plug provided – if it will not t the outlet; have the proper outlet installed by a
qualied electrician.
• Improper connections of the equipment-grounding conductor can result in a risk of electric
shock. The equipment-grounding conductor is the insulated conductor that has an outer surface
that is green, with or without yellow stripes. If repair or replacement of the electric cord or plug
is necessary, do not connect the equipment-grounding conductor to a live terminal.
• Check with a qualied electrician or service personnel if the grounding instructions are not
completely understood, or if in doubt as to whether the tool is properly grounded.
• Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that
accept the tool’s plug.
• Repair or replace a damaged or worn cord immediately.
WARNING
This tool is intended for use on a circuit that has an outlet that looks like the one shown in Sketch A.
The tool has a grounding plug that looks like the plug illustrated in Sketch A. A temporary adapter,
which looks like the adapter illustrated in sketches B and C, may be used to connect this plug to a
2-pole receptacle as shown in Sketch B, if a properly grounded outlet is not available. The temporary
adapter should be used only until a properly grounded outlet can be installed by a qualied electrician. The green-colored rigid ear, lug, and the like, extending from the adapter, must be connected
to a permanent ground such as a properly grounded outlet box.
NOTE: Use of a temporary adapter is not permitted in Canada.
Fig. 1 Circuit and Adapter Information
9
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MKDX SAFETY
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WARNING
To reduce the risk of electrocution, keep all connections dry and off the ground.
A Ground Fault Circuit Interrupter (GFCI) should be provided on the circuit(s) or outlet(s) to be used
for this machine. Receptacles are available having built-in GFCI protections and may be used for this
measure of safety. When using an extension cord, the GFCI should be installed closest to the power
source, followed by the extension cord and lastly, the machine.
WARNING
The pump requires a GFCI. To reduce risk of electric shock when operating the machine with the
pump plugged into the 3-pole receptacle on the motor, connect the saw to a GFCI outlet. See the
pump manual and informational tags enclosed separately for all pump information.
CAUTION
Shock Hazard. For replacement, use only an identical MK pump, model PE-2H part #160509.
NOTE: Do not run pump dry. Also, be sure to disconnect and remove the pump when cutting dry.
When using the water pump plugged into the water pump receptacle, the machine must be plugged
into a properly installed and grounded GFCI outlet See Figure 2. If a GFCI outlet is not available,
MK Diamond has available as an accessory item, a plug-in GFCI that may be plugged into a properly
installed and grounded 3-pole outlet.
WARNING
Fig. 2 GFCI Outlet
To avoid the possibility of the appliance plug or receptacle getting wet, position the machine to one
side of a wall mounted receptacle. This will prevent water from dripping onto the receptacle or plug. A
“drip loop,” shown in Figure 3, should be arranged by the user to properly position the power cord relative
to the power source.
The “drip loop” is that part of the cord below the level of the receptacle, or the connector, if an extension cord is used. This method of positioning the cord prevents the travel of water along the power
cord and coming in contact with the receptacle.
If the plug or receptacle gets wet, DO NOT unplug the cord. Disconnect the fuse or circuit breaker
that supplies power to the tool. Then unplug and examine for presence of water in the receptacle.
Fig. 3 Drip Loop Information
10
NOTICE
Most Motor Problems are caused by improper
voltage and extension cords. Cord should be
one-piece and short as possible. Cord
selection should match the following table.
1-2 H.P.
25’
50’
75’
100’
150’
250’
Max. Cord Length
Max. Cord Length
Max. Cord Length
No. 12 Wire
No. 10 Wire
No. 8 Wire
115v 230v
MKDX SAFETY
WARNING
Use only extensions cords that are intended for outdoor use. These extension cords are identied by
a marking “Acceptable for use with outdoor appliances; store indoors while not in use.” Use only ex-
tension cords having an electrical rating not less than the rating of the product. Do not use damaged
extension cords. Examine extension cords before using and replace if damaged. Do not abuse
extension cords and do not yank on any cord to disconnect. Keep cords away from heat and sharp
edges. Always disconnect the extension cord from the receptacle before disconnection the product
form the extension cord.
WARNING
To reduce the risk of electrocution, keep all connections dry and off the ground. Do not touch the
plug with wet hands.
WARNING
Use of undersize extension cords result in low voltage to the motor that can result in motor burnout
and premature failure. MK Diamond warns that equipment returned to us showing signs of being run
in a low voltage condition, through the use of undersized extension cords will be repaired or replaced
totally at the customers expense. There will be no warranty claim.
To choose the proper extension cord
• Locate the length of extension cord needed
in table below.
• Once the proper length is found, move
down the column to obtain the correct AWG
size required for that length of extension cord.
LOCK OUT METHOD
In order to help prevent accidental starting and
to help make your work area “kidproof,” this
machine is provided with a means to deactivate
the functioning of the motor switch. The switch
is equipped with a lockout tab that can be used
with a lock to prevent movement of the switch.
With the switch unable to move the motor cannot be turned on. Removing the lock reactivates
the switch.
Fig. 4 Extension Cord Table
Fig. 5 MKDX Lock Out
11
SERVICE OR
WARRANTY
FOR INFORMATION ON
PLEASE CALL
1-800-474-5594
MKDX SAFETY
WARNING
Grinding/cutting/drilling of masonry, concrete, metal and other materials with silica in
their composition may give off dust or mists containing crystalline silica. Silica is a basic
component of sand, quartz, brick clay, granite and numerous other minerals and rocks.
Repeated and/or substantial inhalation of airborne crystalline silica can cause serious
or fatal respiratory diseases, including silicosis. In addition,California and some other
authorities have listed respirable crystalline silica as a substance known to cause cance
r.
When cutting such materials,always follow respiratory precautions.
!
Unlock locking
screw before using
NOTICE
!
CAUTION
DO NOT
operate without
guards in place.
!
NOTICE
Overtensioning of belts
will result in premature
crank and/or bearing failure.
!
DO NOT operate
this equipment
before reading
the owners’
manual!
WARNING
!
Most Motor Problems are caused by improper
voltage and extension cords. Cord should be
one-piece and short as possible. Cord
selection should match the following table.
1-2 H.P.
25’
50’
75’
100’
150’
250’
Max. Cord Length
Max. Cord Length
Max. Cord Length
No. 12 Wire
No. 10 Wire
No. 8 Wire
115v 230v
NOTICE
!
!
Loosen locking screw before
adjusting. Retighten before
operation.
AU
OPERATION & SAFETY DECALS
The MKDX is equipped with a number of safety decals provided for operator safety and maintenance
information. Should any of these decals become unreadable, replacements can be obtained by calling (800) 262-1575.
Decal A Decal B
Decal F
Decal C
Decal E
Decal D
Decal G
Fig. 6 MKDX Safety Decal Sheet, Part No. 166256
Decal H
12
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