MK Diamond Products MK-100 SERIES User manual

www.mkdiamond.com
MK Diamond Products, Inc,
MK-100 TILE SAW
OWNER'S MANUAL
PARTS LIST &
OPERATING INSTRUCTIONS
Revision 100 08.2011
Manual Part# 158192
Caution: Read all safety and operating instructions
before using this equipment. This parts list MUST
accompany the equipment at all times.
MK Diamond Products, Inc,

Congratulations on your purchase of a MK-100 Tile Saw. We are certain that you will be pleased with
your purchase. MK Diamond takes pride in producing the finest construction power tools and dia-
mond blades in the industry.
Operated correctly, your MK-100 Tile 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 MK-100 Tile Saw safely and correctly. Please take the time to familiarize yourself
with the MK-100 Tile Saw by reading and reviewing this manual.
Read and follow all safety, operating and maintenance instructions.
If you should have questions concerning your MK-100 Tile Saw, 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.
2

SAFETY
Safety Messages
General Safety Precautions
California Proposition 65 Message
Hazard Symbols
Electrical Requirements
Safety Label Locations
Product Specifications
UNPACKING, TRANSPORT and ASSEMBLY
Unpacking
Contents
Transport
Stand
Assembly
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
Setup
Operation
Cutting Head Adjustment
Cleanup
MAINTENANCE AND TROUBLESHOOTING
Maintenance
Troubleshooting
EXPLODED VIEW AND PARTS LIST
Exploded View & Parts List
ACCESSORIES ORDERING and RETURN INSTRUCTIONS
Theory of Diamond Blades
Accessories
Ordering Information
Return Material Policy
Packaging Instructions
Authorized Service Centers
4
4-6
6
7
8-10
11
12
13
13
14
15
16-17
18-20
20-23
24-26
27
28-33
34
36-39
4O
41
42
42
42
42
3

Read and follow all safety, operating and maintenance instructions. Failure to read and follow
these instructions could result in injury or death to you or others. Failure to read and follow these
instructions could also result in damage and/or reduced equipment life.
SAFETY MESSAGES
A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preced-
ed 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.
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.
GENERAL SAFETY PRECAUTIONS AND HAZARD SYMBOLS
In order to prevent injury, the following safety precautions and symbols should be followed at all times!
SAFETY PRECAUTIONS
ALWAYS read this Owner's Manual before operating the machine.
ALWAYS keep the Blade Guards in place.
REMOVE ADJUSTING KEYS AND WRENCHES
Form a habit of checking to see that keys and adjusting wrenches are removed from
the power tool before it is turned on.
KEEP WORK AREA CLEAN
Cluttered work areas and benches invite accidents.
DO NOT USE IN DANGEROUS PLACES
DO NOT use power tools in damp or wet locations nor expose them to rain. Always
keep the work area well lighted.
KEEP CHILDREN AWAY
All visitors and children should be kept a safe distance from work area.
4

MAKE THE WORKSHOP KID PROOF
Make the workshop kid proof by using padlocks, master switches or by removing starter
keys.
DO NOT FORCE THE TOOL
A power tool will do a job better and safer operating at the rate for which it was designed.
USE THE RIGHT TOOL
DO NOT force a tool or an attachment to do a job that it was not designed to do.
USE THE PROPER EXTENSION CORD
If using an extension cord make sure it is in good condition first. 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. Table on Page 10 shows the correct AWG size to use depending on cord
length and nameplate ampere rating. If in doubt, use the next heavier gage. The smaller
the gage number, the heavier the cord.
USE PROPER APPAREL
DO NOT wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry that may
be caught in moving parts. Non-slip footwear is recommended. Wear protective hair
covering to contain long hair.
ALWAYS wear approved eye protection.
ALWAYS wear approved respiratory protection.
SECURE WORK
Clamps or a vise should be used to hold work whenever practical. Keeping your
hands free to operate a power tool is safer.
DO NOT OVERREACH
Keep proper footing and balance at all times by not overreaching.
MAINTAIN TOOLS WITH CARE
Keep tools clean for the best and safest performance. Always follow maintenance
instructions for lubricating, and when changing accessories.
DISCONNECT TOOLS
Power tools should always be disconnected before servicing or when changing
accessories, such as blades, bits, cutters, and the like.
ALWAYS place the power ON/OFF switch in the OFF position when the saw is not in use.
5

USE RECOMMENDED ACCESSORIES
Consult the owner's manual for recommended accessories.
may increase the risk of personal or by-stander injury. Using improper accessories
NEVER STAND ON THE TOOL
Serious injury could occur if a power tool is tipped, or if a cutting tool is unintentionally
contacted.
CHECK FOR DAMAGED PARTS
Before using a power tool, check for damaged parts. A guard or any other part that is
damaged 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.
DIRECTION OF FEED
ALWAYS feed work into a blade or cutter against the direction of rotation. A blade
or cutter should always be installed such that rotation is in the direction of the arrow
imprinted on the side of the blade or cutter.
NEVER LEAVE A TOOL UNATTENDED
TURN POWER OFF - 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 finished.
CALIFORNIA PROPOSITION 65 MESSAGE
,_ WARNING
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/SL TC/silicacrystalline/index. html
http://www, cdc.gov/niosh/consilic.html
http://oehha, ca.gov/prop65/law/P651aw72003, html
http ://www. dir.ca.go vFTitle8/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 filter out microscopic particles.
6

HAZARD SYMBOLS
ELECTRICAL SHOCK
NEVER touch electrical wires or components while the motor is running.
sources of electrical shock which could cause severe injury or burns. They can be
ROTATING PARTS
Keep hands, feet, hair, and clothing away from all moving parts to prevent injury.
Never operate the motor with covers, shrouds, or guards removed.
OVER SPEED
NEVER tamper with the governor components or settings to increase the maximum
speed. Severe personal injury and damage to the motor or equipment can result if
operated at speeds above maximum.
(_ DO NOT EXPOSE TO RAIN
DO NOT expose to rain or use in damp locations.
,_WARNING
Sawing and drilling generates dust. Excessive airborne particles may cause irritation to eyes, skin
and respiratory tract. To avoid breathing impairment, always employ dust controls and protection
suitable to the material being sawed or drilled; See OSHA (29 CFR Part 1910.1200). Diamond
Blades improperly used are dangerous. Comply with American National Standards Institute Safety
Code, B7.1 and, Occupational Safety and Health Act covering Speed, Safety Guards, Flanges,
Mounting Procedures, General Operating Rules, Handling, Storage and General Machine Conditions
7

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 cur-
rent to reduce the risk of electric shock. This tool is equipped with an electric cord having an equip-
ment-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 electri-
cian. 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.
Groundin
Pin
ADAPTER
Grounding
Means
(c)
Outlet Box
G roluin#ingl_k iiiiiiiiiiii _J_'_'_iiiiiiii _
(D)
Circuit and Adapter Information
8

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 the picture below, 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 exten-
sion 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.
Power Power
_/'--Tool Surface
Drip Loop
Drip Loop Information
_WARNING
Use only extension 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 disconnecting the product from the extension
cord.
9

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 under sized 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 customer's expense. There will
be no warranty claim.
To choose the proper extension cord,
• Locate the length of extension cord needed in the 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.
VOLTS TOTAL LENGTH OF CORD IN FEET
25 ft. AWG 50 ft. AWG 100 ft. AWG 150 ft. AWG
115v 14 12 Not Recommended Not Recommended
230v N/A 14 12 N/A
10

SAFETY LABEL LOCATIONS
Safety labels contain important safety information. Please read the information contained on each
safety label. These labels are considered a permanent part of your saw. If a label comes off or
becomes hard to read, contact MK Diamond or your dealer for a replacement.
D
B
C
F
G
Label A
Label C
Label B
Label E
Label F
Tile Master Label Sheet Part#166012
Decal/Label Location
A Motor-Side
B Motor- Front
C Motor- Side
D Motor- Back
E Motor- Side
F Motor- Side
G Motor- Side
H Water Pump
Label D
Description
Warning - Read and Follow Operating Instructions
Warning - Silica Warning
Notice - Receptacle is for Water Pump Only
Service/Warranty
Caution - Use with GFCI only
Caution - Receptacle for water pump
Motor Specifications
Pump Specifications
TILE SAW SPECIFIC WARNINGS
,_ WARNING
Wear eye protection.
Use splash guard for every operation for which it can be used.
Disconnect saw before servicing, when changing cutting blades, and cleaning.
Replace damaged cutting blade before operating.
11

PRODUCT SPECIFICATIONS
The MK-100 is a versatile Tile Saw. Operated and used according to this manual, the MK-100
will provide years of dependable service.
GENERAL DESCRIPTION
The MK-100 Tile Saw is engineered as a tabletop or stand mounted wet tile saw. The saw
includes a powerful 120V electric motor. The saw is capable of cutting tile up to twenty (20) inches
in length, depth of cut 3".
MOTOR SPECIFICATIONS
Motor specifications for the MK-100 are listed in below.
Voltage
Motor Only Amperage
Frequency
RPM
Horse Power
Weight
120V
14.5
60Hz
3400 rpm
1.5 hp
96 Ibs.
BLADE CAPACITY
The MK-100 uses a ten (10) inch (254 mm) diameter, wet cutting continuous rim, MK Diamond
blade with a five-eighths (5/8) inch (15.875 mm) arbor.
TILE TYPES
The MK-100 can cut a variety of tile types including stone, masonry, and lapidary products.
NOTE: The MK-100 is not designed to cut plastic or metals.
JC
H jD
F
G
E
A Motor
B Water Pump Tube
C Blade Guard
D Cutting Table
E Water Basin
F Frame
G Guide Bar
H Post
I Depth of Cut Adjustment Knob
J Belt Guard
12

UNPACKING
Your MK-100 has been shipped from the factory thoroughly inspected. Only minimal assembly is
required.
_, CAUTION Use proper lifting techniques when lifting the MK-100.
If not done, remove the MK-100, Cutting Head and accessory box from the carton.
CONTENTS
In your container, you will find one (1) MK-100 frame and water basin, one (1) MK-100 cutting head,
one (1) 10-inch wet cutting continuous rim diamond blade, one (1) adjustable cutting guide, one
(1) electric water pump, one (1) 45 ° miter, one (1) splash guard, one (1) cooling transfer tube, one
(1) flow adjusting clamp, one (1) blade wrench, one (1) drain plug, one (1) owner's manual, one (1)
pump manual and one (1) warranty card.
MK-100 Frame MK-100 Diamond Blade Adjustable
and Water Basin Cutting Head Cutting Guide Electric Water
Pump
45° Miter Splash Guard Cooling
Transfer Tube
©WN ER S MANUAL
Owner's
Manual
Flow
Adjusting Clamp
Drain Plug Pump Warranty
Manual Card
Blade Nut
Wrench
13

TRANSPORT
,_CAUTION
1. The MK-100 weighs approximately ninety-six (96) pounds; use care when transporting.
2. Never transport the MK-100 with water in the Water Pan.
The MK-100 is designed with a rigid frame and removable Cutting Head. Two people are
required to transport the MK-100 with the Cutting Head installed. The Cutting Head must be
removed first, if one person is transporting the saw (see Cutting Head Installation and Removal
in the following section).
To lift the saw using two people, each person will grasp the front and back of the frame. To lift the
saw using one person, remove the Cutting Head first, and then grasp the front and back of the
frame. Transport the Cutting Head and the Frame separately.
Cutting
Head "_
Lift Point Lift Point
14

UNIVERSAL STAND
,_ CAUTION
The MK-100 weighs ninety-six (96) pounds; follow the guidelines in the TRANSPORT
section when placing it on the stand (MK Diamond Part# 151889).
NOTE: If using the Optional MK Diamond Stand, follow these steps
(A)
Open the Universal Stand
and place on flat surface.
(B)
Remove Water Basin. (c) Orient the Saw to the Stand.
(D)
Seat Left (Post) Side of saw
onto stand between stand
Orientation Pin.
(E)
Seat Right Side of saw onto
stand between stand and
Register Angle.
(F)
Reinstall the Water Basin.
15

ASSEMBLY
Follow the assembly instructions to prepare your MK-100 for operation.
CUTTING HEAD INSTALLATION
NOTE: If the Cutting Head is installed, go to the next step.
(A)
Remove Adjusting
Knob.
DIAMOND BLADE INSTALLATION
(B)
Align Cutting Head Rear
Pivot Hole to the Post Pivot
Shaft and slide onto shaft.
(c)
Install the Cutting Head onto
the Post Pivot Shaft and
install the Adjusting Knob.
NOTE: When installing the Retaining Nut, do not "cross-thread" and DO NOT over
tighten the nut.
(A)
Position Movable Cutting
Table to the front of the saw
and raise the Blade Guard.
(D)
Install Diamond Blade onto
(B)
Locate the Shaft Lock but-
ton on the underside of the
Cutting Head.
(c)
Depress and hold the Shaft Lock
button and remove Retaining Nut
and Outer Flange using the Blade
Wrench.
(E) (F)
Check the directional arrow on Install Outer Flange and Retaining
Blade Shaft. Verify the Blade is the blade and direction of rota- Nut, depress and hold the Shaft
seated on the Blade Shaft. tion is correct. Lock button and tighten nut.
16

ADJUSTABLE CUTTING GUIDE INSTALLATION
NOTE: The Adjustable Cutting Guide can be used on either side of the Diamond Blade.
(A)
Loosen Adjustable Cutting
Guide retaining thumbscrew
and place it over the Movable
Cutting Table Ruler/Stop.
(B)
Place the Adjustable Cutting
Guide onto the Movable Cutting
Table Ruler/Stop and tighten the
retaining thumbscrew.
SPLASH GUARD INSTALLATION
(A)
Install the retaining thumbscrew
through the washer and Splash Guard
then align to the hole found on back
of the Blade Guard and tighten.
WATER PUMP PREPARATION
I
(A)
Install Water Pump
Discharge Fitting.
(B)
Press one end of the Cooling
Transfer Tube into the Water
Pump Discharge Fitting.
(c)
Slide Cooling Flow Adjust-
ing clamp on to the Cooling
Transfer Tube.
17

PRE-START INSPECTION
Prior to beginning work, a pre-start inspection of the saw should be performed.
(A)
Ensure the ON/OFF Switch
is in the OFF position.
(B)
Verify the Movable Cutting
Table moves freely.
(c)
Inspect the Diamond Blade for
damage. Verify the blade is cor-
rect for the material being cut.
(D)
Inspection the Pump Assem-
bly for damage. Ensure the
cord is free of cracks or cuts.
(E)
Inspect the MK-100 for
damage. Ensure the cord is
free of cracks or cuts.
18

CONNECTING WATER PUMP
,_WARNING To prevent the possibility of electrical shock, the MK-100 MUST be de-energized
when connecting the Water Pump.
To prevent the possibility of electrical shock, use only MK Diamond qualified
replacement parts.
NOTE: To prevent pump damage, the Water Pump must be disconnected from its power
supply if cutting with a Dry Blade.
(A)
Connect the Cooling
Transfer Tube to the inlet
connection of the Blade
Guard.
(B)
Connect the Water Pump pow-
er cord to the connection found
on the back of the motor.
WATER PUMP SETUP FOR OPERATION
The Water Pump can be setup for operation in two ways, external water source or Re-circulation.
EXTERNAL WATER SOURCE
This is the preferred method of cooling.
(A)
Remove the Drain Plug.
Place empty container under
hole for water drainage.
(B)
Place the Water Pump in an
external container and fill until
water completely covers the
Water Pump suction.
19

RE-CIRCULATION
NOTE: When using the re-circulation method, the water should be changed often for longer pump life.
(A)
Ensure the Drain Plug is in-
stalled in the Water Basin.
(B)
Place the Water Pump in the
back of the Water Basin.
NOTE: Ensure the power cord and cooling tube exit the water basin under the top rail of the frame.
MK-100 SETUP FOR OPERATION
,_CAUTION Before powering or starting, check for damage that could prevent this equipment
from proper operation or performing it's intended function. Check for binding and
alignment of moving parts. Check for damaged, broken, or missing parts.
Verify the ON/OFF switch is in the OFF position.
Before connecting the MK-100 to a power supply, be sure the voltage, cycle and phase of the job
site power source meet the requirements in the table below.
Voltage 120v
Cycle 60Hz
Phase 1-phase
If using an extension power cord, make sure the length and wire gauge correspond to he
requirements listed in the Table on Page 10. An extension power cord that is too small in wire gauge
(diameter), or too long in length, will cause the motor to overheat and could cause premature failure.
Use an approved Ground Fault Circuit Interrupter (GFCI).
Do not cover the motor vents as this could lead to motor overheating.
NOTE: In order to avoid breaker tripping, a 20 amp circuit breaker should be used.
20