MK Diamond Products MKDX Profile Milling Machine Owner's Manual

www.mkdiamond.com
MKDX
BULLNOSE & SHAPING MACHINE
OPERATION & PARTS MANUAL
Revision 105
03.2010
Manual Part# 166106
Caution: Read all safety and operating instructions
before using this equipment. This manual MUST
accompany the equipment at all times.
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 finest 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 THIS INFORMATION FOR FUTURE USE:
MODEL NUMBER:
SERIAL NUMBER:
PURCHASE PLACE:
PURCHASE DATE:
NOTE:
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.
MKDX
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 Specifications
Profile Wheel Specifications
Basic Components
TABLE OF CONTENTS
PAGE NO.
4
5
6
7-8
9-11
12
13
14
15
16-17
INSPECTION & START-UP
Safety Devices & Manual Handling
Unpacking and Machine Set-Up
Workstation
Installing/Changing Shaping Wheels
Water Tank Filling
18
19
20
21
22
OPERATION
Clamping the Material
Profile Wheel Adjustment
Shaping
23-24
25
26-27
MAINTENANCE
Cleaning the Machine
Adjusting the Sliding Device
28
29
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
30-31
32
33
34-35
36
37
38
39
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 efficient 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.
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 filter out microscopic particles.
MKDX
SAFETY
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.
ON / OFF
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 fingers, hands, hair
and clothing away from all moving parts to prevent injury.
ALWAYS use caution around gears. Keep fingers, 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.
MKDX
SAFETY
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 qualified personnel only! This equipment is for industrial use only. The following 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 influence of drugs or alcohol.
• Whenever necessary, replace nameplate, operation and safety decals when they become
difficult 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.
ON / OFF
• 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 fluids. 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 fitted.
• 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.
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 specified 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 modifications will void all warranties. Manufacturer does not assume responsibility for any accident due to equipment modifications.
• 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 Never use this machine with any cutter designed for wood working.
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 profile wheel is sharp. If necessary, sharpen using a sharpening stone.
Always check that the profile 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 profiling operation, always check the level of cooling water.
MAINTENANCE SAFETY
• NEVER lubricate components or attempt service on a running machine.
• Keep the machinery in proper running condition.
• Fix damage to the machine immediately and always replace broken parts, or missing decals.
MKDX
SAFETY
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 fit the outlet; have the proper outlet installed by a qualified 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 qualified 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 qualified 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.
-ETAL3CREW
'ROUNDING
0IN
#OVEROF
'ROUNDED
/UTLET"OX
!
"
!$!04%2
#
'ROUNDING
-EANS
'ROUNDING
0IN
$
Fig. 1 Circuit and Adapter Information
MKDX
SAFETY
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.
"
!
Fig. 2 GFCI Outlet
WARNING
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.
0OWER
#ORD
0OWER
4OOL
3UPPORTING
3URFACE
$RIP,OOP
Fig. 3 Drip Loop Information
10
MKDX
SAFETY
WARNING
Use only extensions cords that are intended for outdoor use. These extension cords are identified by
a marking “Acceptable for use with outdoor appliances; store indoors while not in use.” Use only extension 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.
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.
115v 230v
25’ 100’ Max. Cord Length No. 12 Wire
50’ 150’ Max. Cord Length No. 10 Wire
75’ 250’ Max. Cord Length No. 8 Wire
Fig. 4 Extension Cord Table
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. 5 MKDX Lock Out
11
MKDX
SAFETY
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.
! WARNING
! CAUTION
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.
DO NOT
operate without
guards in place.
Decal A
Decal B
! NOTICE
!
Overtensioning of belts
will result in premature
crank and/or bearing failure.
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.
Decal C
1-2 H.P.
115v 230v
25’ 100’ Max. Cord Length No. 12 Wire
50’ 150’ Max. Cord Length No. 10 Wire
75’ 250’ Max. Cord Length No. 8 Wire
! WARNING
DO NOT operate
this equipment
before reading
the owners’
manual!
Decal E
Decal D
!
AU
FOR INFORMATION ON
Loosen locking screw before
adjusting. Retighten before
operation.
Decal F
SERVICE OR
WARRANTY
PLEASE CALL
1-800-474-5594
! NOTICE
Unlock locking
screw before using
Decal G
Fig. 6 MKDX Safety Decal Sheet, Part No. 166256
12
Decal H
MKDX
SAFETY
SAFETY DECAL LOCATIONS
Decal C (behind)
Decal D
Decal F
Decal H
Decal E
Decal B
Decal A
Decal G
Fig. 7 MKDX Safety Decal Locations
Decal
Location
Description
A
B
C
D
E
F
G
H
Machine Front
Belt Guard
Machine Top
Belt Guard
Machine Side
Machine Front
Machine Front
Machine Front
Caution Guards in Place
Warning Silica Dust Hazard
Notice Do Not Overtension Belts
Warning Read Manual Before Operating Equipment
Notice Extension Cord Warnings
Caution Loosen Locking Screw Before Adjusting
Service or Warranty Information
Notice Unlock Locking Screw
13
MKDX
PRODUCT SPECIFICATIONS
MKDX Specifications
Model
MKDX
Weight
79 kg (146 lbs.)
Tank Capacity
3 gal. (14 liters)
4,500 min-1
Speed
Micro V
Drive Belt Type
5/8”
Arbor Size
1: 1.6
Speed Ratio of Motor to Wheel
14”
Standard Length of Bullnose
Maximum Length of
Bullnose and Shaping:
14” with optional 24”
Maximum Depth of Shaping:
15 mm
Maximum Shaping Radius:
15 mm
Maximum Cutter Diameter
120 mm
Maximum Shaping Thickness
20 mm
Maximum Shaping Length
610 mm
14
MKDX
PRODUCT SPECIFICATIONS
Type of Profile Wheel Suggested
Profile Wheel
Name
Segmented Coarse
Sintered Medium
Plated Fine
Resin Bond Polish
Resin Bond Buff
Grit
Description
Item #
30/40
10mm Radius Bullnose B-Profile
165759
30/40
15mm Radius Bullnose B-Profile
165760
30/40
45º 10T Bevel E-Profile
165762
30/40
45º 15T Bevel E-Profile
165763
30/40
90º Square Cutter
166021
60/80
10mm Radius Bullnose B-Profile
165764
60/80
15mm Radius Bullnose B-Profile
165765
60/80
45º 10T Bevel E-Profile
165767
60/80
45º 15T Bevel E-Profile
165768
140/170
10mm Radius Bullnose B-Profile
166077
140/170
15mm Radius Bullnose B-Profile
166078
140/170
45º 10T Bevel E-Profile
166079
140/170
45º 15T Bevel E-Profile
166080
400
10mm Polishing Wheel
165769
800
10mm Polishing Wheel
166082
1500
10mm Polishing Wheel
166083
1800
10mm Polishing Wheel
166084
3500
10mm Polishing Wheel
166085
400
15mm Polishing Wheel
165770
800
15mm Polishing Wheel
166087
1500
15mm Polishing Wheel
166088
1800
15mm Polishing Wheel
166089
3500
15mm Polishing Wheel
166090
Buff
10mm Polishing Wheel
166081
Buff
15mm Polishing Wheel
166086
15
MKDX
PRODUCT SPECIFICATIONS
BASIC COMPONENTS
I
K
G
J
H
C
H
A
F
B
C
D
E (inside)
Fig. 8 Basic Machine Components
A.
Spray Guard – Adjusts to protect user from flying debris and spray
B.
Material Clamp – Configures to material size for lockdown
C.
Wear Bars – Material slides along bar during shaping
D.
Material Slide – Secures material and moves along shaping wheel
E.
Water Tank – Filled for water system
F.
Material Slide Guide – Adjust to keep material slide in place
G.
Material Course Adjustment Bolt – Use for major adjustment of vertical position to material.
These have been preset at the factory for normal operations.
H.
Material Height Adjustment Bolts – Use for horizontal adjustment position to material
I.
Material Height Lock – Unlocks/locks Material Height Adjustment in place. See Page 25
Figure 36 inset photo for an idea.
J.
Belt Guard – Protects user from moving parts
K.
Material Fine Adjustment – Use for adjustment of vertical position to material
16
MKDX
PRODUCT SPECIFICATIONS
BASIC COMPONENTS
B
C
A
A.
Drain Plug
B.
Water Filter
C.
Water Pump
Fig. 9 Basic Machine Components
E
A.
Water Pump Receptacle
B.
Water Hose
C.
Lifting Handle
D.
Water Spray
E.
On/Off Switch
D
A
B
Fig. 10 Basic Machine Components
17
C
MKDX
INSPECTION & START-UP
SAFETY DEVICES
WARNING
Never run the machine if its guards and safety devices have been tampered with or removed, or are
not in working order.
C
The protection systems:
A
B
A) Power Switch
B) Spray Guard
C) Belt Guard
Fig. 11 Safety Devices
FOOT PEDAL SWITCH
A foot pedal switch has been included for easy on/off of the MKDX (Figure 12).
1.
2.
3.
4.
Place Plug/Receptacle of foot pedal switch into power source (110V).
Plug MKDX machine’s power cord into receptacle of foot pedal switch. (Figure 13).
Place foot pedal in desired location for easy on/off actuation of MKDX machine.
Turn on the MKDX machine power switch. It must be turned and left in the on position in order to
use the foot pedal switch.
5. The MKDX power switch should be turned off when machine is not being used and before unplugging the MKDX machine from the foot pedal receptacle.
WARNING
Be sure to keep the plug/receptacle
out of water.
Fig. 12 Foot Pedal Switch
18
Fig. 13 Plug Cord into Switch
MKDX
UNPACKING & MACHINE SET-UP
UNPACKING & MACHINE SET-UP
1. Remove carton top and shipping strap.
2. Remove machine from pallet and place onto flat surface. Check for broken or damaged parts.
3. Remove material slide.
4. Take the stand out of box. Remove the legs and insert into stand.
5. Place knobs in threaded portion and tighten against leg. Legs can be slid up and down and locked in place for a level profile machine.
6. Two people can now lift the MKDX machine onto the set up stand.
WARNING
Two people are recommended to move and set up this machine.
NOTICE
• Before using the machine, check for any broken, worn or damaged parts and replace them
immediately.
• ALWAYS keep the machine clean and lubricated.
• ALWAYS unwind the power supply cord completely and check for damage.
• Carefully check the “Technical Data” Label before plugging in the machine. Follow the extension cord requirements, as recommended on the machine label.
• Work on a level and clean surface.
19
MKDX
INSPECTION & START-UP
WORKSTATION
DANGER
The MKDX is designed for on-sight fabrication. Operator should be familiar with all operations of the
machine prior to use and should read this Owner’s Manual before use.
While the machine is running, NEVER reach into the shaping zone.
• During operation, the operator should stand in front of the machine.
• When shaping, one hand should be holding the back handle and the other hand should grip the front vertical handle of the material slide (Figure 14).
Fig. 14 Safety in the Workstation
20
MKDX
INSPECTION & START-UP
INSTALLING/CHANGING SHAPING WHEELS
A. Shaping Wheel
B. Spring Washer
C. Nut
Fig. 15 Shaping Wheel Components
1. Remove water filter to access shaft (Figure 16).
2. Place Shaping Wheel (A) on shaft, followed by Spring Washer (B) and Nut (C) (Figure 17).
3. Center Spring Washer (B) on shaping wheel while tightening Nut (C) (Figure 18).
4. Push Arbor Shaft Lock Button (D) to keep shaft from rotating (Figure 19).
Use wrench to tighten Nut (C)(Fig. 15).
5. Ensure shaping wheel is installed tightly.
6. Replace filter.
Fig. 16 Remove filter
Fig. 17 Place Shaping Wheel
D
Fig. 19 Arbor Shaft Lock
21
Fig. 18 Tighten Nut
MKDX
INSPECTION & START-UP
WATER TANK FILLING
1. Open water tank by pulling down handle (Figure 20).
2. Ensure drain plug is tightly in place (Figure 21).
3. Pour clean water into the machine’s tank until water line reaches the water hose fitting (Figure 22).
4. Do not let water fill past filter (Figure 23).
5. After filling tank, plug in water pump (Figure 24).
Fig. 21 Inspect Drain Plug
Fig. 20 Open Water Tank
WATER
HOSE
FITTING
FILTER
Fig. 22 Do not fill past here
Fig. 23 Add clean water
Fig. 24 Plug in water pump
22
MKDX
OPERATION
CLAMPING THE MATERIAL
DANGER
Before performing any operation, make sure that the machine is unplugged.
NOTICE
If the material is correctly positioned against the stainless steel wear bars and firmly clamped in
place, shaping will be accomplished perfectly.
WARNING
Before performing your shaping, make sure the profile wheel is sharp, correctly positioned and firmly secured in place.
Adjusting the clamps is a two step process. First the clamps must be moved to the appropriate hole
locations and then the clamps height needs to be adjusted based on the thickness of material.
ADJUSTING FOR SIZE
1. Place the material on the material slide (Figure 25).
2. Determine correct hole locations for clamps based on the size of the material (Figure 26).
3. Clamps may be rotated 90º for smaller strips. Move clamps to proper locations in order to secure material (Figure 27).
4. Clamps may be moved further apart for larger materials (Figure 28).
5. Use wrenches to remove bolts and nuts to move clamps to desired positions. (View) Bottom of the material slide (Figure 29).
6. Vertical handle may be moved for different sized pieces.
Fig. 26 Determine hole locations
Fig. 27 Determine clamp position
Fig. 25 Material Slide
Fig. 28 Top view
23
Fig. 29 Bottom view
MKDX
OPERATION
CLAMPING THE MATERIAL
ADJUSTING FOR THICKNESS
1. Lower the clamps. The material must be firmly secured in place by a minimum of two clamps
(Figure 30).
2. Adjust height of clamp by loosening the nuts. You may remove or add washers to ensure a tight
fit (Figure 31).
Fig. 31 Adjust height of clamps to ensure a tight fit
Fig. 30 Lower the clamps
24
MKDX
OPERATION
PROFILE WHEEL ADJUSTMENT
WARNING
Before performing any operation, make sure that the machine is unplugged.
The profile wheel adjustment is a two step process. There is the vertical adjustment for the width of
the material and the horizontal adjustment for the thickness.
Width of Tile
(Vertical)
Profile Wheel Adjustment
1. Remove spray guard. Unlock horizontal lock bolt (Figure 32).
2. For major vertical adjustments, loosen/tighten course vertical
adjustment bolts (Figure 33). These have been preset at the
factory for normal operation.
3. Sight down the material slide to gauge the wheel location to
material (Figure 34).
Fig. 32 Unlock lock bolt
Thickness of Tile
(Horizontal)
Fig. 33 Major vertical
(Pre-set for normal operation adjustments)
Fig. 34 Gauge wheel location
4. Profile wheel should be touching material. Only a gentle pressure should be needed when
pushing material slide through for shaping. DO NOT force the piece through or readjusting may
be needed (Figure 35).
5. Adjust horizontal bolts to material thickness (Figure 36). Be sure to tighten horizontal lock bolt when done. Second horizontal bolt is located on opposite end of motor frame.
6. Turn material fine adjustment wheel for vertical adjustment to material width (Figure 37).
7. Replace spray guard.
HEIGHT SCALE GUIDE
HORIZONTAL BOLTS
Fig. 35 Wheel touching material
Fig. 36 Adjust both horizontal bolts
25
Fig. 37 Turn adjustment wheel using
the height scale guide
MKDX
OPERATION
SHAPING
WARNING
Before starting your shaping, make sure the wheel is sharp, correctly positioned and firmly in place.
WARNING
Before shaping, make sure the handles and clamps are firmly secured to the material slide. To
prevent material dislodging and motor overloading, the forward speed during the shaping must be
proportional to the hardness and thickness of the material to be shaped. A gentle pressure should be
applied. DO NOT force the piece through.
Shaping
1. Loosen spray guard knobs (Figure 38).
2. Move spray guard down so brush is touching material slide. Tighten down by turning knobs (Figure 39).
3. Turn on machine and check water is spraying on shaping wheel. With material clamped tightly in position and all adjustments made, place hands on handles as shown (Figure 40).
Fig. 38 Loosen spray guard knobs
Fig. 39 Move spray guard down
26
Fig. 40 Place hands as shown
MKDX
OPERATION
SHAPING
4. Proceed by pushing material slide toward shaping wheel and move material completely through
and pause (Figure 41).
5. Push material slide back in opposite direction completely through shaping wheel (Figure 42).
DO NOT force through!
6. For finishing of material, change shaping wheel to finer grit and repeat material shaping process.
Fig. 41 Move material through
Fig. 42 Push in opposite direction
DANGER
While the machine is running, never reach into the shaping area. Bear in mind the instructions given in
the “Workstation” section (Page 20).
NOTICE
If you notice that the shape is of poor quality, despite having followed all the above instructions, check
the tightness of the clamps and sharpen the wheel with a sharpening stone.
DANGER
After your work and before disengaging the piece from the clamps, turn off the machine by means of
the power switch.
27
MKDX
MAINTENANCE
CLEANING THE MACHINE
DANGER
Before performing any operation, make sure that the machine is unplugged.
• Keep the material slide guide clean. Never use blasts of water, instead use a damp sponge.
• Lubricate the vertical adjustment guide.
CLEANING THE TANK & FILTER
1. Open the water tank door. Remove the plug to empty the water (Figure 43).
2. Remove filter and clean off tile chip debris. (Figure 44). Check tank for other chips and debris,
remove all.
3. Replace filter and plug.
Fig. 43 Open water tank door and remove plug
Fig. 44 Remove filter and clean off tile chip debris
ADJUSTING THE SLIDING DEVICE
1. If you notice that the material slide guides have excessive clearance, the material slide has 8
screws that may need to be adjusted (Figure 45).
2. Loosen the screws. Move the guides closer to the wear bar to take up the clearance. Tighten the
screws after adjustment (Figure 46).
GUIDE
GUIDE
Fig. 45 Adjust material slide screws
Fig. 46 Move guides closer to wear bar
28
NOTES
29
MKDX
MKDX TOP ASSEMBLY - P/N 165175
30
EXPLODED VIEW
MKDX
PARTS LIST
ITEM
DESCRIPTION
PART#
OTY.
1
NUT, 3/8-16 HEX
101188
4
2
SCREW, 3/8 - 16 X 1-1/4 HEX HEAD CAP
150774
2
3
WASHER, 3/8 SAE FLAT
150923
8
4
WASHER, 3/8 SPLIT LOCK
150925
4
5
5/16 FENDER WASHER
151053
8
6
NUT, 1/4-20 HEX
151893
14
7
WASHER, 1/4 SAE FLAT
151915
6
8
SCREW, HEX HD CAP, 3/8-16 X 1
152507
4
9
WASHER, #10 SPLIT LOCK
153684
2
10
SCREW, 10-32 X 1/2 SOCKET HEAD SET
157525
2
11
SCREW, SOC HD CAP, 1/4 - 20 X 1-1/4
159336
6
12
PLUG, 2-1/2 DIA RUBBER
159858
1
13
SCREW, 1/4 - 20 X 5/8 SOCKET HEAD CAP
161269
8
14
TRAY WELDMENT
165169
1
15
MOTOR GUIDE ASSEMBLY
165171
1
16
GUIDE “C2”
165179
1
17
GUIDE “L”
165180
1
18
FITTING, PUSH ON HOSE 1/4 X 1/4 MALE
165183
1
19
NUT, BRASS 1/4 NPTF
165184
1
20
GROMMET
165185
1
21
HANDLE, PULL
165187
3
22
DOOR
165212
1
23
PROTECTIVE STRIP
165213
1
24
PROTECTIVE STRIP
165214
1
25
FHCS #8-32 X 5/16”
165481
14
26
STAND ASSEMBLY
166304
1
27
SPACER
166565
1
28
HAND WHEEL ASSEMBLY
166635
1
31
MKDX
EXPLODED VIEW & PARTS LIST
MKDX MATERIAL SLIDE ASSEMBLY - P/N 165170
ITEM
DESCRIPTION
PART#
OTY.
1
NUT, 1/4-20 HEX
151893
2
2
WASHER, 1/4 SAE FLAT
151915
2
3
NUT, #8-32 HEX
153549
8
4
WASHER, FLAT #8
155454
16
5
SCREW, SOCKET HEAD CAP 3/8-16 X 1
156602
1
6
SCREW, SOC HD CAP, 1/4-20 X 1-1/4
159336
2
7
SCREW, 8-32 X 3/4 SOCKET HEAD CAP
164594
8
8
HANDLE, PULL
165187
1
9
MATERIAL SLIDE
165188
1
10
NUT, HEX JAM NYLON #8-32, 18-8
165227
8
11
CLAMP, TOGGLE 200#
165273
2
12
HANDLE, VERTICAL
165474
1
32
MKDX
EXPLODED VIEW & PARTS LIST
MKDX MOTOR GUIDE ASSEMBLY - P/N 165171
ITEM
DESCRIPTION
PART#
OTY.
1
NUT, 3/8 - 16 HEX
101188
4
2
WASHER, 3/8 SAE FLAT
150923
8
3
WASHER, 3/8 SPLIT LOCK
150925
4
4
SCREW, HEX HD CAP, 3/8 - 16 X 1
152507
4
5
FITTING, 1/4 - 28 GREASE
153852
1
6
MOUNTING PLATE
165190
1
7
SWIVEL MOUNT
165191
1
8
SLIDE
165193
1
9
PULL SLIDE ASS’Y
165580
1
33
MKDX
EXPLODED VIEW
MKDX SWITCH ASSEMBLY - P/N 165176
34
MKDX
PARTS LIST
ITEM
DESCRIPTION
PART#
OTY.
1
WASHER, 5/16 SAE FLAT
151754
4
2
WASHER, 1/4 SAE FLAT
151915
2
3
SHCS 5/16-18 X 3/4”
152444
2
4
WASHER, #10 SAE FLAT
154369
1
5
SCREW, FLAT HEAD 1/4-20 X 1/2
155812
2
6
SCREW, PAN HD PHIL 6-32 X 5/8
157393
4
7
WASHER, #10, INTERNAL TEETH
158336
1
8
BUSHING, SWITCH, 30 AMP
158799
1
9
SWITCH, 30 AMP MOTOR CONTROLLER
159488
1
10
PLATE, MOUNTING SWITCH
159489
2
11
LEVER, ON/OFF, 30 AMP SWITCH
159490
1
12
GASKET, COVER, 30 AMP SWITCH
159491
1
13
SEAL, LEVER, 30 AMP SWITCH
159492
1
14
SCREW, FLAT HD PHIL 6-32 X 5/16
159493
6
15
SCREW, PAN HD PHIL 10-24 X 5/16
159494
1
16
COVER, 30A SWITCH (COMP)
159539
1
17
LEVER, ACTUATOR (COMP)
159540
1
18
SCREW,HEX HD FL 10-24 X 5/16
159597
1
19
KEY, MOTOR MOUNT
159859
2
20
BOX, 30A SWITCH (COMP)
159865
1
21
MOTOR CORD
159907
1
22
POWER CORD
159908
1
23
PUMP CORD
159909
1
24
SWITCH BRACKET
165222
1
25
WIRE NUT 14/16 YELLOW
159968
1
35
MKDX
EXPLODED VIEW & PARTS LIST
MKDX DRIVE TRAIN ASSEMBLY - P/N 165172
ITEM
DESCRIPTION
PART#
OTY.
1
NUT, 5/16-18 HEX
101196
1
2
WASHER, 5/16 SAE FLAT
151754
1
3
WASHER, 1/4 SAE FLAT
151915
2
4
SCREW, HEX HEAD MACHINE 5/16-18 X 2
157938
1
5
INSERT, 3/8-16 AVK
158193
1
6
SWITCH ASSEMBLY
165176
1
7
SCREW, 1/4-28 X 1/2 SOCKET HEAD CAP
165177
6
8
DRIVE TRAIN MOUNT
165197
1
9
BELT GUARD PLATE
165202
1
10
BELT GUARD BRACKET
165203
1
11
BELT, MICRO V 32”
165210
1
12
SCREW, 1/4-20 X 1/2 SOCKET HEAD CAP
165211
4
13
ARBOR ASSEMBLY
165218
1
14
MOTOR ASSEMBLY
165219
1
15
BELT GUARD
165579
1
36
MKDX
EXPLODED VIEW & PARTS LIST
MKDX FILTER ASSEMBLY - P/N 165438
ITEM
DESCRIPTION
PART#
OTY.
1
FILTER FRAME
165439
1
2
FILTER HOLDER BAR
165440
1
3
FHCS #8-32 X 5/16
165481
6
4
FILTER COMPLETE
165919
1
37
MKDX
ACCESSORIES, ORDERING AND RETURN INFORMATION
ACCESSORIES, ORDERING AND RETURN INFORMATION
Ordering Information
You may order MK Diamond products through your local MK Diamond distributor or, you may order
direct from MK Diamond.
NOTE: There is a $25.00 minimum order when ordering direct from MK Diamond. All purchases must
be made using VISA or MasterCard.
When ordering direct from MK Diamond, please have the following information ready before calling:
• The Model Number of the machine
• The Serial Number of the machine
• Where the machine was purchased and when
• The Part Number for the part(s) being ordered
• The Part Description for the part(s) being ordered
All parts may be ordered by calling toll free to (800) 421-5830 or (310) 539-5221 and asking for
Customer Service. For technical questions, call (800) 474-5594 or (310) 257-2845.
Return Materials Policy
To expedite the service relative to the return of a product purchased through MK Diamond, please
observe the following:
NOTE: When returning items, they must have been purchased within the previous twelve (12)
months.
• Have the Model Number of the machine
• Have the Serial Number of the machine
• Have the location of where the machine was purchased and when
• Contact Customer Service for approval to return the item(s)
• Follow the packaging instructions in the following section
• Ensure your item(s) are prepaid to the destination
For returned items, call toll free to (800) 421-5830 or (310) 539-5221 and asking for Customer
Service. For technical questions, call (800) 474-5594 or (310) 257-2845.
Packaging Instructions
• Package the part in its original container or one of comparable size
• Ensure all parts are secured in the packaging to prevent moving
Authorized Service Centers
For quicker repair time, you may contact MK Diamond Customer Service, toll free at (800) 421-5830
or (310) 539-5221 for the Authorized Service Center closest to you. For technical questions, call
(800) 474-5594.
38
MKDX
CONTACT AND LIMITED WARRANTY
CONTACT
Please contact MK Diamond Products, Inc. Customer Service Department with any questions you
might have regarding distributors, parts or service.
Telephone: (800) 845-3729
Fax: (310) 539-5158
E-mail: [email protected]
Customer Service Hours: Monday through Friday, 6AM-5PM PST
MK Diamond Products, Inc.
1315 Storm Parkway
Torrance, CA 90501
MK DIAMOND PRODUCTS, INC. LIMITED WARRANTY
MK DIAMOND PRODUCTS, INC. will guarantee every machine they build, to be free from defects in
material and workmanship for (1) one year from date of purchase. The obligation of MK DIAMOND
PRODUCTS, INC. under this warranty is limited to the repair or replacement of any parts which, under
normal use, prove to be defective in material or workmanship. The parts involved or the unit in question
should be returned to MK DIAMOND PRODUCTS, INC. or to a point designated by us, transportation
prepaid.
This warranty does not obligate us to bear the cost of labor or transportation charges in connection with
replacement or repair of defective parts. Likewise, it shall NOT apply to any unit which has been subjected to misuse, neglect or accident. This warranty does NOT apply to any machine which has been
repaired or altered outside our factory.
This warranty does NOT obligate MK DIAMOND PRODUCTS, INC., with respect to items not of our
manufacture, such as engines, motors, hydraulics, etc., which are subject to their own guarantees and
warranties.
We shall in no event be liable for consequential damages or contingent liabilities arising out of failure of
any equipment or parts to operate properly.
© COPYRIGHT 2010, MK DIAMOND PRODUCTS, INC. ALL RIGHTS RESERVED.
The MK Diamond logo is a registered trademark of MK Diamond Products, Inc. and may not be used,
reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.
MK Diamond may have patents, patent applications, trade marks, copyrights of other intellectual
property right covering this product in this document.
This manual MUST accompany the equipment at all times. This manual is considered a permanent
part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for
printing.
39
MKDX Bullnose
OWNERS MANUAL, PARTS LIST, EXPLODED VIEW
& OPERATION MANUAL
MK Diamond Products, Inc.
1315 Storm Parkway
Torrance, CA 90501
Toll-Free: (800) 845-3729
Phone: (310) 539-2221
Fax: (310) 539-5158
www.mkdiamond.com