MK Diamond Products MK-60 System manual

06.2016
MK-60 TILE SAW
OWNER'S MANUAL &
OPERATING INSTRUCTIONS
www.mkdiamond.com
Caution: Read all safety and operating instructions
before using this equipment. This owners manual MUST
accompany the equipment at all times.
Revision 100
Manual Part No. 172150

Congratulations on your purchase of a MK-60 Saw 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 diamond blades in the industry.
Operated correctly, your MK-60 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-60 Saw safely and correctly. Please take a few minutes to familiarize yourself
with the MK-60 Saw by reading and reviewing this manual.
If you should have questions concerning your MK-60 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 (90) ninety day limited warranty to be effective, complete
the warranty card (including the Serial Number) and mail it in as soon as
possible.
2
INTRODUCTION

SAFETY
Safety Messages..............................................................................................................4
Damage Prevention Message ..........................................................................................4
General Safety Precautions...........................................................................................4-7
Silica Dust Warning ..........................................................................................................8
California Proposition 65 Message...................................................................................8
Electrical Motor Safety.................................................................................................9-10
CONTENTS
Package Contents .......................................................................................................... 11
OVERVIEW AND OPERATION
General Description & Specications .............................................................................12
Overview of Components ..........................................................................................12-13
Setup for Operation ........................................................................................................14
Blade Change.................................................................................................................15
Cutting Depth..................................................................................................................16
Guide Fence...................................................................................................................16
Cutting ............................................................................................................................17
Laser Guide Operation ...................................................................................................18
Manual Cutting ...............................................................................................................18
Vacuum Hose Hookup....................................................................................................18
MAINTENANCE
Cleaning .........................................................................................................................19
Laser Battery Replacement............................................................................................19
Carbon Brushes..............................................................................................................19
MITER BASE
Overview.........................................................................................................................20
Setup .........................................................................................................................20-21
Adjustments ...................................................................................................................21
GUIDE RAIL
Overview.........................................................................................................................22
Setup ..............................................................................................................................22
ORDERING & RETURN INSTRUCTIONS
Ordering Information.......................................................................................................23
Return Material Policy ....................................................................................................23
Packaging Instructions ...................................................................................................23
Contact ...........................................................................................................................24
Warranty .........................................................................................................................24
3
TABLE OF CONTENTS

MK-60 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.
SAFETY PRECAUTIONS
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
warnings, 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 working 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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MK-60 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
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 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
prevent 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 saw 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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5

MK-60 SAW SAFETY
Consult the owner’s manual for recommended accessories. Using improper accessories
may increase the risk of personal or bystander 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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MK-60 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, over-tensioning 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/ground and follow all EPA/OSHA
Regulations.
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MK-60 SAW 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 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.
Sawing and drilling generate 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).
WARNING
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, 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
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 vacuum cleaner.
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MK-60 SAW SAFETY
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.
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CAUTION
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. 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
damaged cords immediately. Damaged cords increase the risk of electric shock.
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MK-60 SAW SAFETY
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:
1. Locate the length of extension cord needed in the table below.
2. 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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MOTOR SPECS EXTENSION CORD LENGTH
Voltage Amps 25' 50' 100' 200'
120V 1 Ph 5 18 ga 14 ga 12 ga 8 ga
TILE SAW SPECIFIC WARNINGS
Wear eye protection.
Disconnect saw before servicing, when changing cutting blades, and cleaning.
Replace damaged cutting blade before operating.
WARNING
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
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.
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 extension cord is used.
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MK-60 SAW CONTENTS
MK-60 Saw Saw Case Turbo Rim Diamond Blade
Continuous Rim Diamond Blade Dust Extraction Hose Guide Fence
Allen Wrench Owner's Manual Warranty Card
CONTENTS
One (1) MK-60 Saw
One (1) Saw case
One (1) 3-1/2 inch continuous rim blade
One (1) 3-1/2 inch turbo rim blade
One (1) Dust Extraction Hose
One (1) Guide Fence
One (1) Allen Wrench
One (1) Owners Manual
One (1) Warranty Card
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1
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15
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18
16
14
19
5
3
2
6
MK-60 SAW OVERVIEW
GENERAL DESCRIPTION
SPECIFICATIONS
The MK-60 Saw is portable, 3-1/2" dry cutting saw designed for cutting a variety of materials
including stone, ceramic, slate, granite, marble, porcelain, and lapidary products.
Motor specifications for the MK-60 Saw are listed in the table below.
Voltage 120V/5A
Frequency 60 Hz
Power 600 W
RPM 5500 rpm
Blade Size 3-1/2"
Arbor 10mm
Max cutting depth - tile 5/16"
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1
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MK-60 SAW OVERVIEW
1 Laser Line Generator
2 Laser Switch
3 Safety Lock Button for Blade Plunge
4 Cutting Depth Scale
5 Power Switch
6 Power Switch Lock
7 Cutting Depth Lock
8 Arbor Bolt with Washer
9 Saw Blade
10 Guide Fence Slot
11 Lock Screw for Guide Fence
12 Blade Guard
13 Storage for Allen Wrench
14 Power Indicator Bulb
15 Soft Grip
16 Arbor Lock Button
17 Dust Extraction Nozzle
18 Base Plate
19 Guide Fence
13

The saw blade continues to rotate after the tool is switched off.
Never cut materials that produce toxic dust or fumes such as PTFE or asbestos.
Never draw the tool backwards when the blade is rotating.
Very little force should be used to feed the tool along the cut. Excess force will
cause operator fatigue and excessive wear to the blade and tool. Excess force is
also likely to cause the temperature cut-out to trip.
CAUTION
CAUTION
CAUTION
CAUTION
SETUP FOR OPERATION
1. 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.
2. Verify the On/Off switch is in the OFF position.
3. Before connecting the MK-60 Saw to a power supply, be sure the voltage, cycle
and phase of the job site power source meet the requirements of the table
below.
4. Check that the saw blade is properly fitted and runs smoothly, and that the blade
flange is in place and the arbor bolt (8) is well tightened.
5. Plug in the MK-60 Saw. A wall outlet with a built-in GFCI is recommended.
6. Do not cover the motor vents as this could lead to motor overheating.
VOLTAGE 120V
CYCLE 60Hz
PHASE 1-phase
1. If using an extension power cord, make sure the length and wire gauge correspond
to the requirements listed in 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.
2. This tool should always be used with the dust hose connected and attached to a
suitable vacuum cleaner/dust extractor.
3. Place the material to be cut onto a flat surface such as a workbench, table or floor. Use
a piece of scrap material underneath if you do not wish to damage the work surface
NOTE:
NOTE:
NOTE:
CAUTION
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MK-60 SAW OPERATION

15
MK-60 SAW OPERATION
(B)
Press and hold the Arbor Lock
Button.
(A)
Set the Cutting Depth Lock to
maximum cutting depth.
(C)
Use the Allen Wrench to loosen
(clockwise) the arbor bolt and
blade flange.
(E)
Press the Safety Lock Button to
lift up the base plate.
(F)
Lift blade up off arbor shaft and
remove from saw.
(D)
Remove the Arbor Bolt and blade
flange.
(H)
Install blade flange on arbor
shaft.
(G)
Install new blade on arbor shaft.
The arrow on the saw blade must
match the arrow on the blade
guard indicating the direction of
arbor rotation.
(I)
Press the Arbor Lock Button
and tighten the arbor bolt. DO
NOT over tighten.
CAUTION Disconnect saw before servicing, when changing cutting blades, and cleaning.
DIAMOND BLADE CHANGE/INSTALLATION

MK-60 SAW OPERATION
SETTING THE GUIDE FENCE
SETTING THE CUTTING DEPTH
(B)
Set the guide fence in the guide
fence slot.
(A)
Release the guide fence lock
screw on the base plate.
(C)
Set a desired width and retighten
the lock screw for the guide
fence.
(B)
Move the Cutting Depth Set
Lock to the desired position on
the Cutting Depth Scale.
(A)
Flip the Cutting Depth Set Lock
up to the unlocked position.
(C)
Flip the Cutting Depth Set Lock
down to the locked position.
1. If possible we recommend that the cutting depth is set approximately 2 mm deeper
than the material thickness. This should help to ensure you achieve a clean cut.
NOTE:
16

MK-60 SAW OPERATION
CUTTING
The saw blade continues to
rotate after the tool is switched
off.
CAUTION
(B)
Push the Power Lock Switch
forward with the forefinger.
(A)
Connect the power cord to the
power supply. The LED power
indicator will be illuminated until
the tool is disconnected.
(C)
Pull the ON/OFF Power Switch
firmly upwards. Wait for the
blade to come up to speed.
(E)
Press the rear back of the safety
lock button downwards and keep
it depressed.
(F)
Keeping the base plate flat on
the cutting surface, pivot the saw
body upward to extend the blade
from the blade guard. Push the
tool forwards along the line to
be cut.
(D)
Place the base plate on the
material to be cut. Ensure that
the rear half of the base plate
overhangs the work surface.
(G)
Remove the saw from the cut
before switching off.
(H)
Release the ON/OFF Power
Switch to turn the saw off.
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Do not stare directly at the laser beam, do not deliberately aim the beam at
personnel and ensure that it is not directed towards the eye of a person for longer
than 0.25s.
CAUTION
LASER GUIDE OPERATION
MANUAL CUTTING (WITHOUT LASER GUIDE)
VACUUM HOSE
A V-shaped notch and diamond shaped cutout at the front of the Base Plate, and a
protruding pointer at the rear, allow user to accurately align the saw on the work-piece.
(B)
Connect the large end of the
Dust Extraction Hose to an
appropriate dust collector.
(A)
Press the small end of the Dust
Extraction Hose onto the Dust
Extraction Nozzle.
(B)
Line the laser up with cutting
marks on your work-piece and
make cut.
(A)
Press the laser switch to the "I"
position to turn laser on.
(C)
Press the laser switch to the "0"
position to turn laser off.
MK-60 SAW OPERATION
18

CLEANING AND MAINTENANCE
CARBON BRUSHES
LASER BATTERY REPLACEMENT
Regular cleaning is required for the safe operation of the tool, as an excessive build up of
dust will prevent the tool from operating correctly. The dust extraction hose may become
blocked and require cleaning occasionally.
• Unplug the saw from the power supply.
• Clean thoroughly with a small soft brush.
• Keep the cooling vents on the motor housing clean and unobstructed at all times.
• Never use any caustic agents or solvents to clean the plastic parts.
When the carbon brushes wear out, the tool will spark and/or stop. Discontinue use of
the saw immediately. The brushes must be replaced prior to using the saw. Continued
use of the saw when brushes need to be replaced may cause permanent damage. When
the carbon brushes need to be replaced, take the saw to a power tool repair shop for
replacement. Always replace both carbon brushes at the same time.
(B)
Remove the top of the Laser
Line Generator case.
(A)
Remove the screw from the top
of the Laser Line Generator (1).
(C)
Replace dead batteries with new
LR44 batteries. Replace case
cover and tighten cover screw.
MK-60 SAW MAINTENANCE
19

20
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22
23
24
25
Miter Scale Locking Knob
(Bottom side of Miter Base)
MITER BASE SETUP
(B)
To set the mitre angle, slide the
extendable fence along the mitre
angle scale.
(A)
Release the fence locking lever
by flipping it up.
(C)
Line the notch indictor up to your
desired angle on mitre angle
scale.
MITER BASE OVERVIEW
20 Fence Locking Lever
21 Notch Indicator
22 Miter Angle Scale
23 Clamp
24 Extension Base
25 Extendable Fence
20
MK-60 MITER BASE