MK Diamond Products MK-770 EXP System manual

MK-770 EXP TILE SAW
OWNERS MANUAL &
OPERATING INSTRUCTIONS
www.mkdiamond.com
Caution: Read all safety and operating instructions before
using this equipment.This owner manual MUST accompany
the equipment at all times.
03.2011Revision 205
Manual Part No. 160434

2
SAFETY INSTRUCTIONS FOR THE MK-770 EXP TILE SAW
Congratulations on your purchase of a MK-770 EXP 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-770 EXP 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-770
EXP safely and correctly. Please take a few minutes to familiarize yourself with the MK-770 EXP by reading and
reviewing this manual.
If you should have questions concerning your MK-770 EXP, please feel free to call our friendly customer service
department at: 800 421-5830
Regards,
MK Diamond

3
TABLE OF CONTENTS
SAFETY
SAFETY MESSAGES _____________________________________________ 4
DAMAGE PREVENTION AND INFORMATION MESSAGES _______________ 4
GENERAL SAFETY PRECAUTIONS AND HAZARD SYMBOLS ____________ 4
CALIFORNIA PROPOSITION 65 MESSAGE ___________________________ 6
ELECTRICAL REQUIREMENTS AND GROUNDING INSTRUCTIONS_______ 8
TILE SAW SPECIFIC WARNINGS __________________________________ 10
SAFETY LABEL LOCATIONS ______________________________________ 10
PRODUCT SPECIFICATIONS ______________________________________ 11
UNPACKING, TRANSPORT, STAND and ASSEMBLY
UNPACKING ___________________________________________________ 12
CONTENTS____________________________________________________ 12
TRANSPORT __________________________________________________ 13
ASSEMBLY ____________________________________________________ 14
SETUP, ADJUSTMENT & OPERATION
SETUP___________________________________________________ 17
ADJUSTMENT & OPERATION ________________________________ 20
CLEANUP ________________________________________________ 25
MAINTENANCE AND TROUBLESHOOTING
MAINTENANCE____________________________________________ 27
TABLE ALIGNMENT ________________________________________ 32
TROUBLESHOOTING_______________________________________ 37
EXPLODED VIEW AND PARTS LIST
EXPLODED VIEW __________________________________________ 40
PARTS LIST ______________________________________________ 41
THEORY
THEORY OF DIAMOND BLADES______________________________ 43
ACCESSORIES
ACCESSORIES____________________________________________ 44
ORDERING & RETURN INSTRUCTIONS
ORDERING INFORMATION __________________________________ 45
RETURN MATERIALS POLICY _______________________________ 45
PACKAGING INSTRUCTIONS ________________________________ 45
AUTHORIZED SERVICE CENTERS____________________________ 45

4
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 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 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.
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

5
SAFETY
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 9 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 EXTENTION 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

6
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 parts. A guard or any other part that is damaged should
be carefully checked to determine 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 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
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
engine 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
SAFETY
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 current
to reduce the risk of electric shock. This tool is equipped with an electric cord having 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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
This tool is intended for use on a circuit that has an outlet that looks like the one shown in Sketch A of
Figure 1. The tool has a grounding plug that looks like the plug illustrated in Sketch A of FIGURE 1. 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 electrician. 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
FIGURE 1
To reduce the risk of electrocution, keep all connections dry and off the ground.
Plug the MK-770EXP into a wall outlet with built-in GFCI protection.
WARNING
WARNING
WARNING

9
SAFETY
To avoid the possibility of the appliance plug or receptacle getting wet, position the saw to one side of a
wall mounted receptacle. This will prevent water from dripping onto the receptacle or plug. A “drip loop,”
shown in FIGURE 2, 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 extension 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.
Use of under size 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 customers expense. There will be no warranty claim.
To choose the proper extension cord,
• LocatethelengthofextensioncordneededinTABLE1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.
Use only extensions 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 disconnection the
product form the extension cord.
FIGURE 2
Extension Cord Minimum Gage for Length
Volts Total Length of Cord in Feet
120 V 25 ft. 50 ft. 100 ft. 150 ft.
AWG AWG AWG AWG
14 12 Not Recommended
TABLE 1
Drip Loop
WARNING
WARNING
WARNING

10
SAFETY LABEL LOCATIONS
Safety labels are located according to Figures 1 through 4 below. The 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
Item Location Description Part No.
1A Motor – Right Side Caution – Receptacle is for Water Pump Only 154822
1B Motor – Right Side Motor Specifications 156428
2Motor – Left Side Caution – Use with GFCI Outlet 155678
3A Cutting Head – Top MK-770 EXP Serial Number 157249-4
3B Cutting Head – Top Warning – Read Owners Manual 155806
4A Pump – Left Side Warning – Connect to Grounded Receptacle N/A
4B Pump – Right Side Pump Specifications N/A
SAFETY
TILE SAW SPECIFIC WARNINGS:
Wear eye protection.
Use splash hood 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.
2
4
AB
3
AB
1
AB
WARNING

11
SAFETY
PRODUCT SPECIFICATIONS
The MK-770 EXP is a versatile Tile Saw. Operated and used according to this manual, the MK-770 EXP will
provide years of dependable service.
General Description
Motor Specifications
Blade Capacity:
Tile Types:
The MK-770 EXP Tile Saw is engineered as a tabletop or stand mounted wet tile saw. The saw includes a
powerful 115V electric motor. The saw is capable of cutting tile up to twenty (20) inches in length. The saw can
cut an object one and one-half (1-1/2) inches thick in one pass.
Motor specifications for the MK-770 EXP are listed in Table 2 below.
Voltage 115V
Overall Amperage 7.4 A
Frequency 60Hz
RPM 6000 rpm
Horse Power 1-1/4 hp
Table 2
The MK-770 EXP uses a 7 (7) inch (178mm) diameter, wet cutting continuous rim, MK Diamond blade with a
five-eighths (5/8) inch (15.875 mm) arbor.
The MK-770 EXP can cut a variety of tile types including stone, masonry, and lapidary products.
NOTE: The MK-770 EXP is not designed to cut plastic or metals.

12
UNPACKING, TRANSPORT, and ASSEMBLY
UNPACKING
Use proper lifting techniques when lifting the MK-770 EXP
If not done, remove the MK-770 EXP, accessory box from the carton.
CONTENTS
In your container, you will find
One (1) MK-770 EXP frame and water pan
One (1) MK-770 EXP cutting head
One (1) cutting head height adjusting knob
One (1) height adjusting knob flat washer
One (1) Table Clip
One (1) Wet cutting blade
One (1) adjustable cutting guide
One (1) electric water pump
One (1) pump discharge fitting
One (1) cooling transfer tube
One (1) flow adjusting clamp
One (1) drain plug
One (1) blade wrench
One (1) inner flange wrench
One (1) splash guard
One (1) owners manual
One (1) pump manual and
One (1) warranty card
MK-770 EXP Frame
and Water Pan
MK-770 EXP
Cutting Head
Flat Washer and
Table Clip
Diamond Blade
Pump
Discharge Fitting
Cooling
Transfer Tube
Blade Nut
Wrench
Inner Flange
Wrench
Adjustable
Cutting Guide
Electric
Water Pump
Flow
Adjusting Clamp
Drain
Plug
Pump
Manual
Warranty
Card
Splash
Guard
Owners
Manual
Height Adjusting
Knob
CAUTION

13
UNPACKING, TRANSPORT, TILE SAW STAND and ASSEMBLY
TRANSPORT:
1. The MK-770 EXP weighs approximately forty-six (46) pounds; use care when transporting.
2. Never transport the MK-770 EXP with water in the Water Pan.
The MK-770 EXP is designed with a rigid frame and removable Cutting Head making the saw easily
transportable. Always use proper lifting techniques when lifting the MK-770 EXP. Never transport the MK-770
EXP with water in the Water Pan.
To lift the saw, grasp the front and back of the frame at the lift points shown below.
Cutting
Head
Lift Point
Lift Point
CAUTION

(D)
Install the Height Adjusting Knob
through the Post into the Cutting
Head and tighten the Knob
14
UNPACKING, TRANSPORT, TILE SAW STAND and ASSEMBLY
ASSEMBLY:
Follow the assembly instructions to prepare your MK-770 EXP for operation.
1. Cutting Head Installation:
NOTE: If the Cutting Head is installed, go to step 2.
(B)
Align Cutting Head Pivot Hole
to the Post, Pivot Shaft
(A)
Place the Flat Washer onto
the Height Adjusting Knob
(C)
Verify the Cutting Head is
completely installed and
seated on the Post
(B)
Loosen the Blade Guard,
Retaining Wing nut
(A)
Loosen and remove the Blade
Guard, Retaining Knob
(C)
Open the Blade Guard
2. Diamond Blade Installation:
NOTE: When installing the Retaining Screw, do not "cross-thread" and DO NOT over tighten the screw.
Flat Washer
Post
Pivot Shaft
Installed
Rotate ClockWise
to open

15
UNPACKING, TRANSPORT, TILE SAW STAND and ASSEMBLY
(E)
Using the Blade and Shaft
Wrenches, loosen and remove
the Retaining Nut and Outer
Flange
(D)
Place the Shaft Wrench
between the Inner Blade
Guard and the Motor and onto
the Motor Shaft
(F)
Install Diamond Blade
onto Blade Shaft
(H)
Close the Blade Guard
(G)
Install the Retaining Nut and
Outer Flange and then tighten
using the Blade and Shaft
Wrenches
(I)
Verify the Blade is seated on
the Blade Shaft and direction
of rotation is correct
(K)
Tighten the Blade Guard,
Retaining Knob
(J)
Tighten the Blade Guard
Retaining, Wing nut
Motor Shaft Wrench
Motor Shaft Inner blade
Guard
Blade Wrench
Turn CW
Turn Counter-
ClockWise
Rotate CCW to
close

16
UNPACKING, TRANSPORT, TILE SAW STAND and ASSEMBLY
3. 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
4. Splash Guard Installation
5. Water Pump Preparation:
(A)
Install Water Pump
Discharge Fitting
(B)
Press one end of the Cooling
Transfer Tube onto the Water
Pump Discharge Fitting
(C)
Slide Cooling Flow Adjusting
Clamp onto the Cooling
Transfer Tube
(A)
Install the retaining thumbscrew
through the washer and Splash
Guard then align to the hole found on
back of the Blade Guard
(B)
Install the Splash Guard
onto the Blade Guard
Adjustable
cutting guide
Ruler/Stop
Splash Guard
Thumbscrew

17
SETUP, ADJUSTMENT & OPERATION
SETUP:
1. Pre-start Inspection:
Prior to beginning work, a pre-start inspection of the saw should be performed.
(B)
Verify the Movable Cutting
Table moves freely
(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
(E)
Inspect the MK-770 EXP for
damage–ensurethecordis
free of cracks or cuts
(D)
Inspect the Pump Assembly
fordamage–ensurethecord
is free of cracks or cuts
1. To prevent the possibility of electrical shock, the MK-770 EXP MUST be de-energized
when connecting the Water Pump.
2. 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 if cutting with a Dry Blade.
2. Connecting the Water Pump:
(B)
Connect the Water Pump power
cord to the connection found on
the back of the motor
(A)
Connect the Cooling Transfer
Tube to the inlet connection of
the Blade Guard
WARNING

(A)
Place Water Pump in
Water Pan
(B)
Place Water Pump Clamp
as shown, lining the holes.
(C)
Secure Clamp with 1/4-20
wing screws and nuts.
18
SETUP, ADJUSTMENT & OPERATION
3. Water Pump Setup for Operation:
The Water Pump can be setup for operation in two ways: external Water Source or Re-circulation.
NOTE: If using a dry blade for operation, DO NOT connect the water pump.
I. External Water Source:
(A)
Remove the Drain plug (C)
Fill the external container until
water completely covers the
Water Pump suction
(B)
Place the Water Pump
In an external container
This is the preferred method of cooling
II. 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
installed in the Water Pan
(C)
Fill the Water Pan until water
completely covers the Water
Pump suction
(B)
Place the Water Pump in the
back of the Water Pan

19
SETUP, ADJUSTMENT & OPERATION
4. MK-770 EXP 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-770 EXP to a power supply, be sure the voltage, cycle and phase
of the job site power source meet the requirements of TABLE 3
4. Use GFCI outlet
5. Do not cover the motor vents as this could lead to motor overheating.
VOLTAGE 115V
CYCLE 60Hz
PHASE 1-phase
TABLE 3
If using an extension power cord, make sure the length and wire gauge correspond to he
requirements listed in TABLE 1 on page 9. 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.
NOTE:
If using a portable generator to provide power, ensure the generator meets the following minimum requirements:
8 kW 120/240 V 66.7/33.3 Amps Single Phase
Portable Generator:
5. MK-770 EXP Table Clip
(A)
(E)
(D)
(C)(B)
(F)
(A) Slide table to the front as shown. (D) Swing clip over the back stop of the table.
(B) Snap hook end of the clip to the rail. (E) The table is secured.
(C) Ensure that clip is secure. (F) Move table to ensure it is secured in place.
Clip
CAUTION

20
SETUP, ADJUSTMENT & OPERATION
ADJUSTMENT & OPERATION
1. Cutting Straight Edges:
DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was
designed.
(B)
Position the Adjustable
Cutting Guide to desired cut
length
(A)
Loosen the Adjustable Cutting
Guide retaining thumbscrew
(C)
Tighten the retaining
thumbscrew
(E)
Turn the motor ON
(D)
Place the tile against the
Ruler/Stop and Cutting Guide
(F)
Verify cooling flow on both
sides of the blade
(G)
Perform the cut
(H)
Turn the motor OFF when
work is complete
Ruler/Stop
CAUTION