MK Diamond Products 166110 Application guide

MK DIAMOND
TRACK RAIL SAW
OPERATION & PARTS MANUAL
www.mkdiamond.com
Caution: Read all safety and operating instructions
before using this equipment. This manual MUST
accompany the equipment at all times.
03.2012Revision 302
Manual Part No. 166110

22
TRACK RAIL SAW INTRODUCTION
Congratulations on your purchase of a Track Rail Saw. We are certain that you will be pleased with
your purchase. MK Diamond takes pride in producing the nest construction power tools and dia-
mond blades in the industry.
Operated correctly, your Track Rail Saw 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 Track Rail Saw safely and correctly. Please take the time to familiarize yourself
with the Track Rail Saw by reading and reviewing this manual.
Read and follow all safety, operating and maintenance instructions.
If you should have questions concerning your Track Rail Saw, please feel free to call our friendly cus-
tomer 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.

3
MK DIAMOND TRACK RAIL SAW
SAFETY
Safety Message/Alert Symbols
Safety Warnings
Hazard Symbols
Electric Motor Safety
Rules for Safe Operation
Operation & Safety Decals
PRODUCT SPECIFICATIONS
Specications
SET-UP
Rail Assembly
Rail Assembly Connector
Cutting Head Assembly
Material Clamps & Alignment
Hose Set-Up
OPERATION
Plunge Cutting for a 90º Cut
Plunge Cutting for a Miter Cut
MAINTENANCE
Blade Replacement
Filter Replacement
Roller Wheel Replacement
GENERAL PRODUCT INFORMATION
Parts List: Final Assembly
Parts List: Main Carrier Assembly
Parts List: Cutting Head Assembly
Parts List: Blade Guard Assembly
Parts List: Parallel Rail Support Bracket
Parts List: Rail Connector Plate
Parts List: Rail Saw Material Clamp
Ordering Information
Contact Information and Limited Warranty
PAGE NO.
4
5
6
7
8-9
10
11
12
13
14
15
16
17
18
19
20
21-23
24-25
26-27
28-29
30
31
32
33
34
35
TRACK RAIL SAW TABLE OF CONTENTS

4
TRACK RAIL SAW 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 Manual has been developed to provide complete instructions for the safe and efcient
operation of the CX-3®Concrete Saw.
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.
NOTICE
You can cause PROPERTY DAMAGE to your machine if you don’t follow directions.
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.
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.
Before using this saw, ensure that the person operating the equipment has read and understands all
instructions in this manual.
DAMAGE PREVENTION AND INFORMATION MESSAGES
A Damage Prevention Message is to inform the user of important information and/or instructions that
could lead to equipment or other property damage if not followed. Information messages convey
information that pertains to the equipment being used. Each message will be preceded by the word
note, as in the example below.
NOTE: Equipment and/or property damage may result if these instructions are not followed.

5
TRACK RAIL SAW SAFETY
CALIFORNIA PROPOSITION 65 MESSAGE
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities con-
tain 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/dsg/topics/silicacrystalline/index.html
http://www.cdc.gov/niosh/consilic.html
http://oehha.ca.gov/prop65/law/P65law72003.html
http://www.dir.ca.gov/Title8/sub4.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.
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 ad-
dition, 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.
SILICA DUST WARNING

6
Potential hazards associated with the MK Diamond Track Rail Saw will be referenced with Hazard
Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Mes-
sage Alert Symbols.
ALWAYS wear a hard hat.
ALWAYS wear approved eye protection.
HAZARD SYMBOLS
ALWAYS wear approved ear protection.
ALWAYS wear approved respiratory protection.
ALWAYS read this Owner’s Manual before operating the machine.
ALWAYS avoid inhalation of and skin contact with silica dust and/or mist.
TRACK RAIL SAW SAFETY

7
WARNING
DO NOT use woodcutting, or carbide blades on this machine! Use ONLY Diamond blades on ma-
chine. Use machine only to cut tile and masonry products. DO NOT use machine to cut wood or wood
products.
ELECTRIC MOTOR SAFETY
For maintenance care and operation of the electric motor, refer to your electric motor instruction booklet
furnished with the electric motor.
Protect the electric motor from dust as much as possible and keep ventilating openings clean.
Electric Motor Connection
The table below shows the matching NEMA approved connector for the required extension cord.
ALWAYS make certain that the power source required for the electric motor is correct and always use
the correct NEMA conguration plug. Failure to supply the correct voltage to the motor can severely
damage the motor. Make certain that the correct size grounded (3-wires) extension cord is used. See
the table below.
Motors can burn out when the line voltage falls 10% below the voltage rating of the motor. Failure to
use proper voltage will cause the motor to overheat.
•
•
DO NOT spray water at any time on the electric motor.
DO NOT operate electric motor in an explosive environment.
CAUTION
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
TRACK RAIL SAW SAFETY

8
TRACK RAIL SAW SAFETY
•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 inuence of drugs or alcohol.
• Whenever necessary, replace nameplate, operation and safety decals when they become difcult
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. When using an extension cord,
be sure to use one heavy enough to carry the current your product will draw. An undersized cord
will cause a drop in line voltage that will result in a loss of power and overheating. The Table shown
on page 11 shows the correct AWG size to use depending on cord length and nameplate ampere
rating. If in doubt, use the next heaviest gage. The smaller the gage number, the heavier the cord.
• 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.
• DONOT overreach. Keep proper footing and balance at all times.
Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is
to be operated by trained and qualied personnel only! This equipment is for industrial use only.
The following safety guidelines should always be used when operating the MK-2000 Electric Saw.
GENERAL SAFETY
DANGER
RULES FOR SAFE OPERATION
ON / OFF
•DONOT operate or service this equipment before reading this entire manual.
• 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.

9
TRACK RAIL SAW SAFETY
•NEVER stand on the tool. Serious injury could occur if a power tool is tipped, or if a cutting tool is
unintentionally contacted.
•Become familiar with the controls of the machine before operating. Know how to stop the machine
quickly in case of emergency.
•ALWAYS secure work. Clamps or a vise should be used to hold work whenever practical. Keep-
ing your hands free to operate a power tool is safer.
•ALWAYS disconnect AC power plug from power source before moving, cleaning or servicing the
machine.
•NEVER leave a tool running unattended. Do not leave a tool until it comes to a complete stop.
ALWAYS turn a power tool OFF when leaving the work area, or when a cut is nished.
•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 specied 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 modications will void all warranties. Manufacturer does not assume respon-
sibility for any accident due to equipment modications.
•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.
• Replace damaged cutting blade before operating.
• NEVER try to stop a moving blade with your hand.
•NEVER lubricate components or attempt service on a running machine.
•Keep the machinery in proper running condition.
•Before using a power tool, check for damaged parts. A guard or any other part that is damage
should be carefully checked to determine if it would operate properly and perform its intended
function. Always check moving parts for proper alignment or binding. Check for broken parts and
mountings and all other conditions that may affect the operation of the power tool. A guard, or any
damaged part, should be properly repaired or replaced.
MAINTENANCE SAFETY
WARNING
NEVER use this machine with any cutter designed for wood working.
•Wear eye protection.
•Disconnect saw before servicing, when changing cutting blades and cleaning.
•Replace damaged cutting blade before operation.
•Remove adjusting keys and wrenches.
SAW SAFETY
WARNING

10
TRAIL RACK SAW SAFETY
D & F
(behind)
A
The MK Diamond Track Rail Saw is equipped with a number of safety decals. These decals are pro-
vided for operator safety and maintenance information. The illustration below also shows the location
of these decals. Should any of these operation or safety decals become unreadable, replacements
can be obtained by calling [phone].
OPERATION & SAFETY DECALS
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.
!
SERVICE OR
WARRANTY
FOR INFORMATION ON
PLEASE CALL
1-800-474-5594
DO NOT operate
this equipment
before reading
the owners’
manual!
WARNING
!
CAUTION
DO NOT
operate without
guards in place.
!
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
!
This saw is to be used
with a Ground Fault
Circuit Interrupter.
!CAUTION
Decal A Decal B
Decal C
Decal D
Decal E
Decal F
Figure 1. MK Diamond Track Rail Saw Safety Decal Sheet, Part No. 166011
C
B
E