MK Diamond Products MK-1590 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.
07.2018Revision 306
Manual Part No. 166110

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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.

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MK DIAMOND TRACK RAIL SAW PAGE NO.
SAFETY
Safety Message 4
Safety Warnings & Hazard Symbols 4-7
Silica Dust Warning & California Prop 65 8
Electrical Safety Requirement 9-12
Operation & Safety Decals 13
PRODUCT SPECIFICATIONS
Specications 14
SET-UP
Rail Assembly 15
Rail Assembly Connector 16
Cutting Head Assembly 17
Material Clamps & Alignment 18
Hose Set-Up 19
OPERATION
Plunge Cutting for a 90º Cut 20
Plunge Cutting for a Miter Cut 21
MAINTENANCE
Blade Replacement 22
Filter Replacement 23
Roller Wheel Replacement 24-26
Carrier Assembly 27
GENERAL PRODUCT INFORMATION
Exploded View & Parts List 28-37
Ordering Information 38
Packaging Instruction 38
Authorized Service Center 38
Contact Information and Limited Warranty 39
TRACK RAIL SAW TABLE OF CONTENTS

4
TRACK RAIL SAW SAFETY
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 warnings and
guidelines do not by themselves eliminate danger. They are not substitutes for proper accident
prevention procedures and good judgement.
SAFETY 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.
DAMAGE PREVENTION AND INFORMATION MESSAGES
NOTE: Equipment and/or property damage may result if these instructions are not followed.
GENERAL SAFETY PRECAUTIONS AND HAZARD 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.
ALWAYS read this Owner’s Manual before operating the machine. DO NOT operate or
service this equipment before reading this entire manual. Read and understand all warn-
ings, instructions and controls on the machine. Know how to stop the equipment quickly in
case of emergency. It is the operators responsibility to use this machine under safe work-
ing conditions and conform with federal, state and local codes or regulations pertaining to
safety, air, pollution, noise etc...
ALWAYS keep the Blade and Belt Guards in place. DO NOT operate this machine with any
guard or safety device removed. A Guard, or any damaged part should be repaired or
replaced immediately.
NEVER operate this equipment without proper protective clothing, shatterproof
glasses, steel-toed boots and other protective devices required by the job. Non-slip
foot wear is recommended.
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In order to prevent injury, the following safety precautions and symbols should be followed at all times!

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TRACK RAIL SAW SAFETY
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All visitors and children should be kept a safe distance from work area. Maintain a safe
operating distance to other personnel.
KEEP CHILDREN AWAY
MAKE THE WORKSHOP KID PROOF
Make the workshops kid proof by using padlocks, master switches or by removing starter keys.
ROTATING PARTS
Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never oper-
ate 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 engine or equipment can result if operated at
speeds above maximum.
ELECTRICAL SHOCK
NEVER touch electrical wires or components while the engine is running. Exposed, frayed or
worn electrical wiring and plugs can be sources of electrical shock which could cause severe
injury or burns. Do not touch the plug with wet hands.
ALWAYS avoid inhalation of and skin contact with silica dust and/or mist. Provide proper
dust removal. Use dust-collection system when applicable.
NEVER operate the machine in an explosive atmosphere or near combustible materials.
Sparks from the cutting-action of this machine can ignite flammable materials, liquids, gases
or dust.
This equipment should not be operated by persons under 18 years of age.
ALWAYS wear approved respiratory, head, ear and eye protection
when operating this machine.
Before starting the engine/motor, be sure the ON/OFF switch is in the OFF position to pre-
vent accidental starting. Place the ON/OFF switch in the OFF position before performing any
service operation. ALWAYS place the power ON/OFF switch in the OFF position when the
machine is not in use.
ACCIDENTAL STARTS!
PERSONAL PROTECTIVE EQUIPMENT
Engine components can become extremely hot from operation. To prevent severe burns,
do not touch these areas while the engine is running, or immediately after it is turned off.
Never operate the engine with heat shields removed.
HOT PARTS!
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DO NOT FORCE THE TOOL
A power tool will do a job better and safer operating at the rate for which it was designed.
DO NOT force a tool or an attachment to do a job that it was not designed to do.
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6
TRACK RAIL SAW SAFETY
Consult the owner’s manual for recommended accessories. Using improper accessories
may increase the risk of personal or by-stander injury. Unauthorized equipment
modifications will void all warranties. Manufacturer does not assume responsibility for any
accident due to equipment modifications.
ALWAYS ensure that the machine is on level ground before using.
Serious injury could occur if a power tool is tipped, or if a cutting tool is unintentionally
contacted.
When loading or unloading the machine, use caution. Remove the blade prior to hoisting,
loading and transporting the machine.
USE RECOMMENDED ACCESSORIES
NEVER STAND ON THE TOOL
TRANSPORT
Form a habit of checking to see that keys and adjusting wrenches are removed from
the power tool before it is turned on.
Cluttered work areas and benches invite accidents. Keep area around machine clear of
obstructions which could cause persons to fall.
DO NOT operate equipment in dangerous or hazardous environments. DO NOT use power
tools in damp or wet locations nor expose them to rain. Always keep the work area well
lighted.
REMOVE ADJUSTING KEYS AND WRENCHES
KEEP WORK AREA CLEAN
DO NOT USE IN DANGEROUS PLACES
MAINTAIN TOOLS WITH CARE
Keep tools clean and maintained for the best and safest performance. Always follow
maintenance instructions and examine the machine before use. If any abnormal vibrations
or noises occurs, turn off machine immediately and have the problem corrected before
further use.
DISCONNECT TOOLS
Power tools should always be disconnected before servicing, adjusting or when changing
accessories, such as blades, bits, cutters, and the like.
DO NOT OVERREACH
Keep proper footing and balance at all times by not overreaching.
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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.
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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 cover-
ing to contain long hair.
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TRACK RAIL SAW SAFETY
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. Always check the machine for loose bolts before starting.
A blade or cutter should always be installed so that rotation is in the direction of the
arrow imprinted on the side of the blade or cutter. It should correspond with the rotational
direction of the motor. Always feed work into a blade against the direction of rotation.
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.
NEVER LEAVE A TOOL UNATTENDED
CHECK FOR DAMAGED PARTS
DIRECTION OF ROTATION
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! Disconnection 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 operate this equipment under the influence of drugs or alcohol.
NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.
NEVER use this machine with any cutter designed for woodworking.
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On belt driven equipment, overtensioning of belts will result in premature crank and/or bearing
failure.
Whenever necessary, replace nameplate, operation and safety decals when they become
difcult to read.
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
DO NOT lend or rent this equipment without including the Owner's Manual and the Engine/
Motor Manufacturer's Manual.
Check the chemical properties of the material to be cut/grinded and follow all EPA/OSHA
Regulations. (cut/ground)

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TRACK RAIL SAW SAFETY
CALIFORNIA PROPOSITION 65 MESSAGE
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 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.
Use appropriate NIOSH-approved respiratory protection where dust hazard may occur. Paper masks
or surgical masks without a NIOSH approval number are not recommended because they do little to
protect the worker. For more information about respirator programs, including what respirators have
received NIOSH approval as safe and effective, please visit the NIOSH website at:
http://www.cdc.gov/niosh/topics/respirators
Observe OSHA regulations for respirator use (29 C.F.R.§1910.134).
Visit http://www.osha.gov for more information.
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/docs/96-112/
http://oehha.ca.gov/prop65/law/P65law72003.html
http://www.dir.ca.gov/Title8/sub4.html
http://www.P65warnings.ca.gov
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 dust masks that are specially designed to lter out microscopic particles. Where
use of a dust extraction device is possible, it should be used. To achieve a high level of dust collec-
tion, use an industrial HEPA vacuum cleaner. Observe OSHA 29 CFR part 1926.57 and 1926.103.

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TRACK RAIL SAW SAFETY
WARNING
In order to prevent electrical shock and injury, the following electrical safety precautions and symbols
should be followed at all times!
If permanently connected this tool should be connected to a grounded metal permanent
wiring system; or to a system having an equipment - grounding conductor.
In case of a malfunction or breakdown, grounding provides a path of least resistance for electrical
current to reduce the risk of electric shock. This tool is equipped with an electric cord which has 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 qualied 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 qualied 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.
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 qualied electri-
cian. The green-colored rigid ear, plug, and the like, extending from the adapter, must be connected
to a permanent ground, such as a properly grounded outlet box.
ELECTRICAL REQUIREMENTS AND GROUNDING INSTRUCTIONS
NOTE:
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Grounding
Means
(A)
Metal Screw
Cover of
Grounded
Outlet Box
(D)
ADAPTER
(C) Grounding
Pin
Grounding
Pin (B)
Circuit and Adapter Information
Use of a temporary adapter is not permitted in Canada.NOTE:

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WARNING
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, GFCI should be installed closest to the power
source, followed by the extension cord and lastly, the machine.
The water pump requires a GFCI. To reduce risk of electrical shock when operating the machine
with the pump plugged into the 3-pole receptacle on the motor, connect the machine to a GFCI
outlet. See the pump manual and informational tags enclosed separately for all pump information.
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CAUTION
DO NOT EXPOSE TO RAIN
For maintenance care and operation of the electric motor, refer to your electric motor instruction book-
let furnished with the electric motor. Protect the electric motor from dust as much as possible and keep
ventilating openings clean. Before plugging in the machine, make sure that the outlet voltage is within
the voltage marked on the machines's data plate.
DO NOT spray water on the electric motor. DO NOT touch the plug with wet hands. To reduce
the risk of electrocution, keep all connections dry and off the ground.
ELECTRIC MOTOR SAFETY
DO NOT operate electric motor in an explosive environment.
DO NOT expose to rain or use in damp locations.
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WARNING
If operating the equipment in damp locations is unavoidable, ALWAYS use a Ground Fault
Circuit Interrupter, ALWAYS wear rubber gloves and footwear in damp conditions.
DO NOT abuse the cord. Never use the cord to carry the equipment or to pull the plug from
the outlet. Keep the cord away from heat, sharp edges, and moving parts. Replace dam-
aged cords immediately. Damaged cords increase the risk of electric shock.
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TRACK RAIL SAW SAFETY

11
To avoid the possibility of the appliance or plug receptacle getting wet, position the machine to one
side of a wall mounted receptacle. This will prevent water from dripping into 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. Use the drip loop as a way to prevent GFCI and plug from getting
wet.
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.
Supporting
Surface
Power
Tool
Drip Loop
Power
Cord
Drip Loop Information
WARNING
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WARNING
Use only extension cords that are intended for outdoor use. These extension cords are
identied 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 dis-
connect. Keep cords away from heat and sharp edges. Always disconnect the extension cord
from the receptacle before disconnecting the product from the 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. 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. Make
certain that the correct size grounded (3-wires) extension cord is used.
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TRACK RAIL SAW SAFETY

12
MOTOR SPECS EXTENSION CORD LENGTH
Motor Voltage Amps 25' 50' 100' 200’
157801 115V 1 Ph 15 14 ga 10 ga 8 ga 4 ga
WARNING
Use of undersized 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.
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TRACK RAIL SAW SAFETY

13
TRACK RAIL 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
C
B
E
G
Part # 164202
A
BC
E
FG
Part # 154398 Part # 155587
Part # 155038
SERVICE OR
WARRANTY
FOR INFORMATION ON
PLEASE CALL
1-800-474-5594
Part # 155672
NOTICE
Most motor problems are caused by
low voltage from improper extension
cords. See owner’s manual for
extension cord selection.
!
Part # 170480
Scan for manuals
CAUTION
DO NOT
operate without
guards in place.
!
DO NOT operate
this equipment
before reading the
owner’s manual.
WARNING
!
WARNING
• Use of this equipment can expose you to chemicals
including nickel and crystalline silica which are known to
the State of California to cause cancer.
• For more information go to www.P65Warnings.ca.gov.
• Repeated and/or substantial inhalation can cause
serious or fatal respiratory diseases including silicosis.
• Employ dust controls and protection per
OSHA/NIOSH/MSHA.
!
Label Part #164202
D
Part # 155678
!CAUTION
This saw is to be used
with a Ground Fault
Circuit Interrupter.

14
TRACK RAIL SAW PRODUCT SPECIFICATIONS
• Adjustable height plunge-cutting head
• Lightweight precision extruded aluminum rails provide accurate and even tracking during all
cutting operations
• Rails have replaceable slip-on pads to protect material surface from scratches
• Precision, maintenance-free bearings provide smooth and reliable tracking of the cutting head
• Replaceable dust lter
• Valve controlled water feed
• 72” 115V standard U-ground electrical cord
• Saw comes complete with two sets of 72” track, track connector plate, 12” blade capacity cutting
head, two hold-down clamps and standard garden hose water connector
• Additional rails for extending cutting capacity sold separately
Track Rail Saw Specications
Model 166110
Motor 115V 50/60 Hz
Amps 15
Horsepower 1-3/4 HP
Blade RPM 3,500
Blade Capacity 12” (254 mm)
Arbor Size 1” (25.4 mm)
Standard Length of Cut 130” (3,202mm)
Maximum Depth of Cut 2-7/8” (73mm)
Depth of Cut at 45º 2-1/4 (57mm)
Weight 95 lbs. (43kgs.)
Dimensions (LxWxH) - inches 144” x 16” x 13”
Dimensions (LxWxH) - millimeters 3,658 x 406 x 330

15
TRACK RAIL SAW SET-UP
1. Lay Rails (A & B) on a at and leveled surface.
2. Align ends of Rails.
3. Slide Parallel Rail Support Brackets (C) from both ends of rail.
4. Tighten screws until Brackets hold Rails rmly in place (D).
5. Repeat Step 1 through 4 if a length of more than 6 feet is needed.
A
B
C
D
C
D
Rail Assembly

16
TRACK RAIL SAW SET-UP
The rail connector assembly is required to hold two Rail Assemblies together.
1. Slide the Rail Assembly (A) into the Connector Plate Assembly (B).
2. Tighten screws (C) lightly until connector plate is rmly seated.
3. Slide the other half of the Rail Assembly (D) into the Rail Connector Assembly (B).
4. Fully tighten screws.
A
B
A
D
D
C
Rail Assembly Connector

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1. Place the Rail Assembly (B) on slab.
2. Slide the Cutting Head Assembly (A) until the Carrier Wheels (C) are over Rail Assembly (B).
3. Move the Cutting Head Assembly along the Rail Assembly with a sliding motion.
A
B
WARNING
C
Cutting Head Assembly
Ensure that the power is disconnected before installing the Cutting Head Assembly to Rails.
The Cutting Head Assembly is pre-assembled and aligned at the factory.
TRACK RAIL SAW SET-UP

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1. Position Saw Assembly (A) on the slab. The inner side of the blade is approximately 6.25 inches
from the top edge of the aluminum rail.
2. Slide the Material Clamps from both ends of the Rail Assembly until the Clamp Foot (B) is
underneath the slab.
3. Tighten screws (C) until the Saw Assembly is secured to the slab without any side movement.
4. To realign the Rail Assembly, slightly loosen the Material Clamps. Realign the Rail Assembly by
tapping the ends of the Rail Assembly.
5. Repeat Steps 3 and 4 if realignment is necessary.
A
C
B
WARNING
Ensure that the electrical cord is not connected before assembling and aligning material clamps.
Material Clamps & Alignment
TRACK RAIL SAW SET-UP

19
TRACK RAIL SAW SET-UP
1. Connect Plastic Fitting (A) to Nipple (B).
2. Connect Hose Fitting (C) to Water Hose.
B
AC
Hose Set-Up

20
TRACK RAIL SAW OPERATION
A
B
CAUTION
Always use a Grounded Fault Circuit Interrupter (GFCI) with this saw.
Plunge Cutting for a 90˚ Cut
1. Loosen the Tri-Knob (A). Raise the blade to the highest position and move the Saw Assembly
to the beginning of the cut.
2. Adjust the Valve (B) for the desired amount of water ow.
3. Depress motor switch and lower the blade slowly into the material.
4. Tighten the Tri-Knob (A) once the blade cuts through the material. Follow the direction of the cut.