MK Diamond Products MK-377 User manual

05.2010
MK-377 TILE SAW
OWNERS MANUAL
PARTS LIST &
OPERATING INSTRUCTIONS
www.mkdiamond.com
Caution: Read all safety and operating instructions
before using this equipment. This parts list MUST
accompany the equipment at all times.
Revision 100
Manual Part# 160030

2
INTRODUCTION
Congratulations on your purchase of a MK-377 Saw. We are certain that you will be pleased
with your purchase. MK Diamond takes pride in producing the nest construction power tools
and diamond blades in the industry.
Operated correctly, your MK-377 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-377 Saw safely and correctly. Please take the time to familiarize
yourself with the MK-377 Saw by reading and reviewing this manual.
Read and follow all safety, operating and maintenance instructions.
If you should have questions concerning your MK-377 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.

3
TABLE OF CONTENTS
SAFETY
Safety Messages 4
Damage Prevention Message 4
General Safety Precautions 4
Rules for Safe Operation 4
California Proposition 65 Message 6
Hazard Symbols 7
Maintenance Safety 8
Electrical Requirements 8-10
Safety Label Locations 11
Product Specications 12
UNPACKING, TRANSPORT
Unpacking 13
Contents 13
Transport 13
STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
Cutting Head Installation 14
Diamond Blade Installation 14-15
Adjustable Cutting Guide Installation 16
Splash Guard Installation 16
Pre-Start Inspection 16
Water Pump Preparation 17
Setup for Operation 18
Adjustment & Operation 19
Cleanup 20
Lockout 21
MAINTENANCE AND TROUBLESHOOTING
Maintenance 21-22
Blade Dressing 22
Motor Brush Change Out 23
Troubleshooting 24-26
EXPLODED VIEW AND PARTS LIST
Exploded View & Parts List 27-29
ACCESSORIES ORDERING and RETURN INSTRUCTIONS
Accessories 30
Ordering Information 31
Return Material Policy 31
Packaging Instructions 31
Authorized Service Centers 31

4
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 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.
In order to prevent injury, the following safety precautions and symbols should be followed at all times!
GENERAL SAFETY PRECAUTIONS AND HAZARD SYMBOLS
SAFETY PRECAUTIONS
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.
DO NOT use power tools in damp or wet locations nor expose them to rain. Always
keep the work area well lighted.
All visitors and children should be kept a safe distance from work area.
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.
ALWAYS read this Owner’s Manual before operating the machine.
ALWAYS keep the Blade Guards in place.
REMOVE ADJUSTING KEYS AND WRENCHES
KEEP WORK AREA CLEAN
KEEP CHILDREN AWAY
DO NOT USE IN DANGEROUS PLACES
MK-377 SAW SAFETY

5
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 1, 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.
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.
Keep proper footing and balance at all times by not overreaching.
Clamps or a vise should be used to hold work whenever practical. Keeping your
hands free to operate a power tool is safer.
Keep tools clean for the best and safest performance. Always follow maintenance
instructions for lubricating, and when changing accessories.
Power tools should always be disconnected before servicing or when changing
accessories, such as blades, bits, cutters, and the like.
Make the workshops kid proof by using padlocks, master switches or by removing starter
keys.
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.
MAKE THE WORKSHOP KID PROOF
DO NOT FORCE THE TOOL
USE THE RIGHT TOOL
USE THE PROPER EXTENSION CORD
USE PROPER APPAREL
ALWAYS wear approved eye protection.
ALWAYS wear approved respiratory protection.
ALWAYS place the power ON/OFF switch in the OFF position when the saw is not in use.
ON / OFF
SECURE WORK
DO NOT OVERREACH
MAINTAIN TOOLS WITH CARE
DISCONNECT TOOLS
MK-377 SAW SAFETY

6
MK-377 SAW SAFETY
Consult the owner’s manual for recommended accessories. Using improper accessories
may increase the risk of personal or by-stander injury.
Serious injury could occur if a power tool is tipped, or if a cutting tool is unintentionally
contacted.
Before using a power tool, check for damaged part. A guard or any other part that is
damaged should be carefully checked to determine if 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 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.
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
USE RECOMMENDED ACCESSORIES
NEVER LEAVE A TOOL UNATTENDED
NEVER STAND ON THE TOOL
CHECK FOR DAMAGED PARTS
DIRECTION OF FEED
WARNING
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 and
• 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.

7
MK-377 SAW SAFETY
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
HAZARD SYMBOLS
NEVER touch electrical wires or components while the engine is running. They can be
sources of electrical shock which could cause severe injury or burns.
Keep hands, feet, hair, and clothing away from all moving parts to prevent injury.
Never operate the motor with covers, shrouds, or guards removed.
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.
((
)
)
on
DO NOT expose to rain or use in damp locations.
WARNING
ROTATING PARTS
ELECTRICAL SHOCK
OVER SPEED
DO NOT EXPOSE TO RAIN

8
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!
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.
WARNING
• 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
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 qualied 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.
'ROUNDING
-EANS
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Circuit and Adapter Information
MK-377 SAW SAFETY

9
Supporting
Surface
Power
Tool
Drip Loop
Power
Cord
Drip Loop Information
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.
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.
WARNING
MK-377 SAW SAFETY

10
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.
To reduce the risk of electrocution, keep all connections dry and off the ground. Do
not touch the plug with wet hands.
WARNING
WARNING
EXTENSION CORD MINIMUM GAGE FOR LENGTH
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
MK-377 SAW SAFETY

11
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.
Decal/Label Location Description
A Motor - Back Caution - Receptacle is for Water Pump Only
B Motor - Side Caution - Use with GFCI only
CMotor - Top Service/ Warranty
D Motor Post Warning - Silica Warning
E Cutting Head – Top Warning - Read Owners Manual
F Table Notice - Voltage/extension cords
TILE SAW SPECIFIC WARNINGS
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.
WARNING
Tile Saws
Receptacle is for
water pump only.
125V, .6 amps max.
!CAUTION
This saw is to be used
with a Ground Fault
Circuit Interrupter.
!CAUTION
Tile Master Label Sheet Part#166012
Label B
Label A
Label C
Label D
Label E
Label F
SERVICE OR
WARRANTY
FOR INFORMATION ON
PLEASE CALL
1-800-474-5594
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.
For Your Own Safety Read Instruction Manual
Before Operating Saw.
Wear Eye Protection.
Disconnect Saw Before Servicing, when Changing
Cutting Wheels and Cleaning.
Use Tool Only with Smooth Edge Cutting Wheels
Free of Openings and Grooves.
Replace Damaged Cutting Wheel Before Operating.
Do Not Fill Water Bath Above Water Fill Line.
See Manual for Pump Replacement.
!
WARNING
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
!
WARNING
!
F
E
C
A
B
D

12
PRODUCT SPECIFICATIONS
The MK-377 is a versatile Tile Saw. Operated and used according to this manual, the MK-377 will
provide years of dependable service.
General Description
Motor Specifications
Blade Capacity
Tile Types
The MK-377 Tile Saw is engineered as a tabletop wet tile saw. The saw includes a powerful 120V
electric motor. The saw is capable of cutting tile up to fourteen (14) inches in length. The saw can
cut an object two (2) inches thick in one pass.
Motor specifications for the MK-377 are listed in the table below.
Voltage 120v
Overall Amperage 7.4 A
Frequency 50/60Hz
RPM 6000 rpm
Horse Power 1-1/4 hp
The MK-377 uses a seven (7) inch (178mm) diameter, wet cutting continuous rim, MK Diamond
blade with a five-eighths (5/8) inch (15.875 mm) arbor.
The MK-377 can cut a variety of tile types including stone, ceramic, slate, granite, marble, porcelain,
and lapidary products.
NOTE: The MK-377 is not designed to cut plastic or metals.
MK-377 SAW PRODUCT SPECIFICATIONS

13
The MK-377 is designed with a rigid frame and removable Cutting Head making the saw easily
transportable. To lift the saw, grasp the front and back of the frame at the lift points shown below.
Cutting
Head
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Pump
Manual
05.2010
MK-377
OWNERS MANUAL
PARTS LIST &
OPERATING INSTRUCTIONS
www.mkdiamond.com
Caution: Read all safety and operating instructions
before using this equipment. This parts list MUST
accompany the equipment at all times.
Revision 100
Manual Part# 160030
UNPACKING
Use proper lifting techniques when lifting the MK-377
Remove the MK-377 and accessory box from the carton.
CONTENTS
MK-377
Cutting Surface
MK-377
Cutting Head
Splash Guard
Cooling
Transfer Tube
Blade Nut
Wrench
Shaft
Wrench
Rip Guide Electric
Water Pump
Flow
Adjusting Clamp
Warranty
Card
Owners
Manual
Diamond Blade
One (1) MK-377 cutting surface & water pan
One (1) MK-377 cutting head
One (1) 7-inch wet cutting blade
One (1) splash guard
One (1) blade nut wrench
One (1) extended rip guide
One (1) electric water pump
One (1) cooling transfer tube
One (1) flow adjusting clamp
One (1) shaft wrench
One (1) owners manual
One (1) pump manual
One (1) warranty card
CAUTION
MK-377 SAW UNPACKING
TRANSPORT
Lift Point
Lift Point
1. The MK-377 weighs approximately thirty (30) pounds; use care when transporting.
2. Never transport the MK-377 with water in the Water Pan.
CAUTION

14
MK-377 SAW INSTALLATION
(D)
Align the Cutting Head Retaining
Holes to the holes on the Post
Follow the assembly instructions to prepare your MK-377 for operation.
CUTTING HEAD INSTALLATION
(B)
Remove the Blade Guard
Wingnut and then remove
the Blade Guard
(A)
Loosen the Blade Guard
Retaining Knob
(C)
Locate and remove
the three Cutting Head
Retaining Screws using a
Phillips Screwdriver
(B)
Loosen the Blade Guard
Retaining Knob and open
the Blade Guard
(A)
Loosen the Blade Guard
Retaining Wingnut
(C)
Place the Shaft Wrench on the Motor
Shaft (NOTE: the Outer and Inner
Flanges and the Blade Nut are removed
in the photo above) rotate blade shaft so
shaft wrench is engaged.
DIAMOND BLADE INSTALLATION
When installing the Retaining Screw, do not "cross-thread" and DO NOT over tighten the screw.
NOTE:
(E)
Install the three Cutting Head
Retaining Screws using a Phillips
Screwdriver
(F)
Install the Blade Guard and
tighten Wingnut and Retaining
Knob

15
MK-377 SAW INSTALLATION
When installing the Retaining Screw, do not "cross-thread" and DO NOT over tighten the screw.
(E)
Install Diamond Blade onto
Blade Shaft
(D)
Place the Blade Wrench on
the Blade Retaining Nut and
remove the Blade Retaining
Nut and Outer Flange
(F)
Verify the Directional Arrow of
the Blade faces outward and
matches the Directional Arrow
of the Blade Guard
(H)
Close the Blade Guard and
tighten the Blade Guard
Retaining Knob
(G)
Install the Outer Flange and
Retaining Nut; install the Shaft
Wrench and Blade Wrench as
shown in Steps C and D and
tighten the Retaining Nut
(I)
Tighten the Blade Guard
Retaining Wingnut

16
(B)
Install the Thumbscrew
through the Washer and Splashguard
then align to the hole found on back
of the Blade Guard and tighten
MK-377 SAW ASSEMBLY
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 and
Ruler/Stop
(B)
Place the Adjustable Cutting Guide
onto the Movable Cutting and tighten
the retaining thumbscrew
SPLASH GUARD INSTALLATION
(A)
Remove Thumbscrew and washer
from back of Blade Guard
PRE-START INSPECTION
Prior to beginning work, a pre-start inspection of the saw should be performed.
(B)
Inspect the Pump Assembly for
damage - ensure the cord is
free of cracks or cuts
(A)
Ensure the ON/OFF Switch
is in the OFF position
(C)
Inspect the Diamond Blade for
damage – verify the blade is
correct for the type of material
being cut

17
WATER PUMP PREPARATION
(B)
Connect the Cooling Transfer
Tube to the inlet connection
of the Blade Guard
(A)
Press the end of the Cooling
Transfer Tube onto the Water
Pump
(E)
Verify the Movable Cutting
Table moves freely
(D)
Inspect the MK-377 for
damage – ensure the cord is
free of cracks or cuts
(D)
Fill the Water Pan with
clean water covering Pump
suction (this should be done
periodically during cutting)
(E)
Connect the Water Pump
power cord to the connection
found on the back of the motor
MK-377 SAW ASSEMBLY
(C)
Place the Water Pump in the
Water Pan with the suction down
and insert the Pump Cord to the
clip in the back. Ensure pump is
against back of water pan.

18
SETUP FOR OPERATION
1. Before connecting the MK-377 to a power supply, be sure the voltage, cycle
and phase meet the requirements of table below.
2. If using an extension cord, make sure the length and wire gauge
correspond to the requirements listed in the table on page 10. An extension
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.
3. Before connecting the MK-377 to a power supply, be sure the voltage,
cycle and phase of the job site power source meet the requirements in the
table below.
4. Use an approved Ground Fault Circuit Interrupter (GFCI).
5. Do not cover the motor vents as this could lead to motor overheating.
VOLTAGE 120v
CYCLE 60Hz
PHASE 1-phase
In order to avoid breaker tripping, a 20 amp circuit breaker should be used.
NOTE:
(A)
Plug MK-377 into the GFCI (A
GFCI should always be used
when operating the MK-377)
(C)
Plug the GFCI into the
power source
CAUTION
MK-377 SAW OPERATION

19
MK-377 SAW OPERATION
ADJUSTMENT & OPERATION
DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for
which it was designed.
CAUTION
(A)
Loosen the retaining thumbscrew
and place the Adjustable Cutting
Guide to the desired cut length
and tighten thumbscrew
(B)
Place the tile against the
Ruler/Stop and Cutting
Guide
(C)
Turn the motor ON and verify
proper cooling flow on both sides
of the blade (See Maintenance
Section to increase/decrease flow)
(D)
Perform the cut. Turn the motor
OFF when work is complete

20
(D)
Fill the Water Pan with
clean water
(B)
Dispose of the contents
of the Water Pan and
clean the pan. Replace
the Cutting Assembly.
(A)
Ensure the ON/OFF Switch is
in the OFF position. Remove
the Cutting Assembly from
the Water Pan
CLEANUP
Dispose of wastewater in accordance with applicable Federal, State and Local laws.
(C)
Clean the Water Pump of all
debris. (Refer to water pump
manual for more detail)
(E)
Run the MK-377 until clear
water is seen at the blade
cooling ports (Approx. 1
minute)
Ensure the saw is disconnected before completing the remainder of the
cleanup process.
CAUTION
NOTE:
MK-377 SAW MAINTENANCE
(F)
Dispose of the contents of
the Water Pan and clean the
MK-377 with soap and clear
water
(G)
Clean the Guide Bar
(H)
Clean the Roller Wheel
Guide Rail
(I)
Clean the Roller Wheels
CAUTION To extend the life of the MK377, lubricate the Motor Shaft with light oils such
as, 3 in 1, WD-40, etc.