MK CC-100 User manual

08.2016
CC-100
OWNER’S MANUAL,
OPERATING INSTRUCTIONS
& PARTS LIST
www.mkdiamond.com
Caution: Read all safety and operating instructions
before using this equipment. This owner’s manual
MUST accompany the equipment at all times.
Revision 100
Manual Part# 172021
Crack Chaser Saw

2
INTRODUCTION
Congratulations on your purchase of a Crack Chaser 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 Crack Chaser 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 Crack Chaser Saw safely and correctly. Please take the time to
familiarize yourself with the Crack Chaser Saw by reading and reviewing this manual.
Read and follow all safety, operating and maintenance instructions.
If you should have questions concerning your Crack Chaser 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 and Hazard Symbols 5-7
California Proposition 65 Message 8
Prestart Safety 9
Safety Label Locations 10
Product Specications 11
UNPACKING, TRANSPORT and ASSEMBLY
Unpacking 12
Contents 12
Transport 13
Assembly 14-15
STARTUP, OPERATION and SHUTDOWN
Startup 16-17
Operation 18-20
Shutdown 20
Cleanup 21
MAINTENANCE AND TROUBLESHOOTING
Maintenance 21-28
Troubleshooting 29
EXPLODED VIEW & PARTS LISTS 30-40
ACCESSORIES ORDERING and RETURN INSTRUCTIONS
Accessories 41
Ordering Information 42
Return Material Policy 42
Packaging Instructions 42
Authorized Service Centers 43
Warranty 43

4
CRACK CHASER SAW SAFETY
Safety precautions should be followed at all times when operating this equipment. Failure to read and
understand the Safety Precaution and Operating Instructions could result in injury to yourself and
others.
This Operation Manual has been developed to provide complete instructions for the safe and efcient
operation of the Crack Chaser Saw.
Descriptions, illustrations, and photos are as accurate as possible at the time of publication. Photos
may include optional equipment or accessories and may not show all models covered by this manual.
SAFETY MESSAGE / ALERT 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.
NOTICE
You can cause PROPERTY DAMAGE to your machine if you don’t follow directions.
Each message tells you what the hazard is, what can happen, and what you can do to avoid or
reduce injury. Other important messages are preceded by the word NOTICE.
The safety labels should be periodically inspected and cleaned by the user to maintain good legibility
at a safe viewing distance. If the label is worn, damaged or illegible, it should be replaced. Contact
MK Diamond or your dealer for replacement.
Before using this saw, ensure that the person operating the equipment has read and understands all
instructions in this manual.
DAMAGE PREVENTION AND INFORMATION MESSAGES
A Damage Prevention Message is to inform the user of important information and/or instructions that
could lead to equipment or other property damage if not followed. Information messages convey
information that pertains to the equipment being used. Each message will be preceded by the word
note, as in the example below.
NOTE: Equipment and/or property damage may result if these instructions are not followed.

5
CRACK CHASER SAW SAFETY
EXPLOSIVE FUEL!
Gasoline is extremely ammable, its vapors can explode if ignited; store only in approved
containers, in well-ventilated, unoccupied buildings and away from sparks or ames. Do not
ll the fuel tank while the engine is running or hot. Spilled fuel could ignite if it contacts hot
parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline
as a cleaning agent. Never operate the machine in an explosive atmosphere.
In order to prevent injury, keep guards in place and in working order at all times.
KEEP GUARDS IN PLACE
SAFETY PRECAUTIONS
GENERAL SAFETY PRECAUTIONS AND HAZARD SYMBOLS
(
(
)
)
ENGINE OVER-SPEED
Never tamper with the governor components or settings to increase the maximum speed of
the machine. Severe personal injury and/or equipment damage could result if the equip-
ment is operated speeds above design maximum.
LETHAL EXHAUST GASES
Engine exhaust gasses contain poisonous carbon monoxide, an odorless colorless gas
that can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine
in a closed building or conned area.
In order to prevent injury, the following safety precautions and symbols should be followed
at all times!
GENERAL SAFETY
DO NOT operate or service this equipment before reading this entire manual.
This equipment should not be operated by persons under 18 years of age.
NEVER operate this equipment when not feeling well due to fatigue, illness or taking
medicine.
NEVER operate this equipment under the inuence of drugs or alcohol.
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.

6
CRACK CHASER SAW SAFETY
KEEP CHILDREN AWAY
All visitors and children should be kept a safe distance from work area.
MAKE WORKSHOP KID PROOF
Make the workshops kid proof by using padlocks, master switches or by removing starter keys.
REMOVE ADJUSTING KEYS AND WRENCHES
Form a habit of checking to see that keys and adjusting wrenches are removed from the power tool
before it is turned on.
KEEP WORK AREA CLEAN
Cluttered work areas and benches invite accidents.
DO NOT USE IN DANGEROUS ENVIRONMENTS
Do not operate equipment in dangerous environments. Always keep the work area well lighted.
ALWAYS USE SAFETY GLASSES
Safety glasses should always be worn when working around power tools. Everyday eye-
glasses only have impact resistant lenses and may not prevent eye injury; they are NOT
safety glasses.
ALWAYS USE RESPIRATORY PROTECTION
Exhaust gases may be harmful if inhaled. Do not operate gas-powered equipment in
enclosed spaces. Respiratory protection should be worn when operating gas powered
equipment.
ALWAYS USE HEARING PROTECTION
To reduce the possibility of hearing loss, always use hearing protection when operating
equipment.
ROTATING OR MOVING PARTS
Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never
operate a power tool with shrouds or guards removed.
HOT PARTS
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.
on
ACCIDENTAL STARTS
Before starting the engine, 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.

7
CRACK CHASER SAW SAFETY
DO NOT OVERREACH
Keep proper footing and balance at all times by not overreaching.
MAINTAIN TOOLS WITH CARE
Keep tools sharp and clean for the best and safest performance. Always follow maintenance instruc-
tions for lubricating and when changing accessories.
SHUTDOWN TOOL
The saw should always be shutdown before servicing or when changing accessories such as blades,
bits, cutters, etc...
USE RECOMMENDED ACCESSORIES
Consult the owner’s manual for recommended accessories. Using improper accessories may in-
crease the risk of personal or by-stander injury.
NEVER STAND ON THE TOOL
Serious injury could occur if a power tool is tipped, or if a cutting tool is unintentionally contacted.
DO NOT FORCE THE TOOL
A power tool will do a job better and safer operating at the rate for which it was designed.
USE THE RIGHT TOOL
Do not force a tool or an attachment, to do a job that it was not designed to do.
WEAR PROPER APPAREL
Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry that may be caught in
moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair.
SECURE WORK
Clamps or a vise should be used to hold work whenever practical. Keeping your hands free to oper-
ate a power tool is safer.
NEVER LEAVE TOOL RUNNING UNATTENDED – TURN POWER OFF
Do not leave a tool until it comes to a complete stop. Always turn a power tool OFF when leaving the
work area, or, when a cut is nished.
CHECK FOR DAMAGED PARTS
Before using a power tool, check for damaged parts. A guard or any other part that is damaged
should be carefully checked to determine it would operate properly and perform its intended func-
tion. Always check moving parts for proper alignment or binding. Check for broken parts, mountings
and all other conditions that may affect the operation of the power tool. A guard or any damaged part
should be properly repaired or replaced.
DIRECTION OF FEED
Always feed work into a blade or cutter against the direction of rotation. A blade or cutter should al-
ways be installed such that rotation is in the direction of the arrow imprinted on the side of the blade
or cutter.

8
CRACK CHASER SAW SAFETY
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 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/consilic.html
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 those dust masks that are specially designed to lter out microscopic particles.
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.
SILICA DUST WARNING

9
• 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 modications will void all warranties. Manufacturer does not
assume responsibility for any accident due to equipment modications.
• NEVER use accessories or attachments, which are not recommended by MK Diamond for
this equipment. Damage to the equipment and/or injury to user may result.
WARNING
DO NOT use woodcutting, or carbide blades on this machine! Use ONLY Diamond blades on machine.
Before starting the machine, ALWAYS check that all guards are in position and correctly tted. Check
the machine for loose bolts before starting.
Keep area around the machine clear of obstructions which could cause persons to fall onto moving parts.
ALWAYS ensure that the machine is on level ground before using. Know how to stop the machine
quickly in case of emergency. NEVER try to stop a moving blade with your hands.
CRACK CHASER SAW PRE-START

10
OPERATION & SAFETY DECALS
Part # 164202
A
B
D
C
G
E
K
F
I
J
M
HL
WARNING
•Thisequipmentmayproducedustormistscontaining
 crystallinesilica.
•Silicaisabasiccomponentofmasonry,concrete,and
 othermaterials.
•Repeatedand/orsubstantialinhalationcancause
 seriousorfatalrespiratorydiseasesincludingsilicosis.
•RespirablecrystallinesilicaislistedbyCaliforniaand
 otherauthoritiesasasubstanceknowntocausecancer.
•Employdustcontrolsandprotectionper
 OSHA/NIOSH/MSHA.
!
Part # 155587 (2)
CAUTION
DO NOT
operate without
guards in place.
!
Part # 154398
DO NOT operate
this equipment
before reading the
owner’s manual.
WARNING
!
Part # 155038
SERVICE OR
WARRANTY
FOR INFORMATION ON
PLEASE CALL
1-800-474-5594
Part # 170480
Part # 155585
CAUTION
Keep
hands and
feet clear.
!
Part # 154399
NOTICE
Overtensioning of belts will
result in premature crank
and/or bearing failure.
!
Part # 155582
CAUTION
DO NOT
touch hot
surface.
!
Part # 155578
Part # 155580
Part # 155581
WARNING
When refueling
stop engine and
allow to cool.
DO NOT
overll tank.
!
DANGER
The exhaust from this product con-
tains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
!
DANGER
Lethal exhaust
gases. Use only
in well ventilated
areas. DO NOT
use indoors.
Part # 155579
CAUTION
Accidental start hazard.
Disconnect spark plug prior
to servicing.
!
Part # 170773
Blade Rotation Direction
Location Description
ABlade Guard Proposition 65, Dust Warning
BGas Tank/Side Read Manual
CBlade/Belt Guard Guards in Place
DFrame/Front Hand & Feet Clear
EBelt Guard Overtensioning Belts
FGas Tank /Side Refueling
GFrame Service / Warranty
HBelt Guard Accidental Start
I Blade Guard Blade Rotation
JGas Tank/Side Exhaust/Cancer
KGas Tank/Top Hot Surface
LGas Tank/Side Lethal Exhaust
MGas Tank/Side QR Code for Manuals
I
C
D
G
A
H
E
C
F
LJK
M
B
The CC-100 Concrete Saw is equipped with a number of safety decals. These decals are provided for
operator safety and maintenance information. Should any of these operation or safety decals become
unreadable, replacements can be obtained by calling [phone].
CRACK CHASER SAW SAFETY

11
Blade
The CC-100 uses an 8 inch diameter diamond blade.
Concrete Saw Usage
The CC-100 is designed to cut or widen cracks in asphalt or concrete surfaces for repair.
PRODUCT SPECIFICATIONS
CC-100 Dimensions
CRACK CHASER SAW PRODUCT SPECIFCATIONS
20.39
40.26
44.25
The CC-100 is a versatile gas powered Crack Chaser Saw. Operated and used according to this
manual, the CC-100 will provide years of dependable service.
General Description
The CC-100 is engineered as a portable concrete saw powered by a Honda gas engine.The saw is
capable of 1-1/8” depth of cut with an 8” blade.
MotorandWeightSpecications
Motor and Weight specications for the CC-100 are listed below.
Motor Honda GX270 Honda GX390
Horse Power 8.5 HP 11.7 HP
Max Cutting Depth 1-1/8" 1-1/8"
Blade Diameter 8" 8"
Blade Width .250" - .500" .250" - .500"
Blade Arbor 1" with Drive Pin Hole 1" with Drive Pin Hole
Weight 126 lbs. 140 lbs.
Part# 171320-9H 171320-13H

12
UNPACKING
Crack Chaser Saw Engine Manual Warranty
Card
Crack Chaser Saw
Owner’s Manual
CRACK CHASER SAW UNPACKING
01.2016
CC100
OWNER’S MANUAL,
OPERATING INSTRUCTIONS
& PARTS LIST
www.mkdiamond.com
Caution: Read all safety and operating instructions
before using this equipment. This owner’s manual
MUST accompany the equipment at all times.
Revision 100
Manual Part# 172021
Crack Chaser Saw
Your saw has been shipped from the factory thoroughly inspected. Only minimal assembly and
service is required. Check each, item, making certain all items are accounted for and in good visual
condition before discarding any packing materials. If there are any missing or damaged parts call MK
Diamond Customer Service at 800-421-5830.
CONTENTS
In the containers, you will nd one (1) Crack Chaser Saw, one (1) Crack Chaser Saw Owner’s Manu-
al, one (1) Engine Owners Manual and one (1) Warranty Card.
WARNING Never start engine until all initial servicing and set up steps are completed accord-
ing to this operations manual and engine manual. Read and familiarize yourself
with all controls and features of the saw before beginning operations.

13
TRANSPORT
CRACK CHASER SAW TRANSPORT
CAUTION 1. The Crack Chaser Saw weighs approximately one hundred and forty (140
pounds), use care when transporting.
2. Two people are required to lift and transport the Crack Chaser Saw.
1. The raise lower handle raises the blade.
2. Depth control knob must be adjusted for desired depth of cut.
3. Kill switch.
1
2
3

14
CRACK CHASER SAW ASSEMBLY
Filling Oil Reservoir
(A)
Verify the Oil Drain Cap is
installed onto the Oil Drain Line
and is tight. Refer to Engine
Manual for details.
The engine is shipped with no oil in the crankcase. Refer to the engine manual for de-
tails on the type and amount of oil required.
To ll the crankcase with oil, place the engine level. In order for this to be accomplished
the blade must not be installed, and the depth adjustment must be down (until the en-
gine is level).
NOTE:

15
CRACK CHASER SAW ASSEMBLY
1. When installing the blade retaining-bolt, ensure the threads of the bolt are
aligned with the threads of the drive shaft so as not to “cross-thread” the bolt.
2. When installing the blade ensure that the blade shaft and anges are free from dirt
and all foreign material before mounting blade on the blade shaft. Tightening a blade
against an uneven surface can cause fracture or cause the blade to run out of alignment.
3. Blade shaft threads are left-handed.
(A)
Loosen the Blade Guard Nut.
(Remove the Blade Guard
Cover).
NOTE:
Diamond Blade Installation
(B)
Loosen the Blade Shaft Nut while
holding the Shaft Wrench steady.
(F)
Install the Blade Shaft Nut.
(C)
Remove the Blade Nut and
Outer Flange.
(D)
Install the Diamond Blade onto
the Blade Shaft. Ensure direc-
tional arrow on the blade indi-
cates proper rotational direction.
(G)
Tighten Blade Shaft Nut holding the Blade
Shaft steady. Replace the Blade Guard
and tigten Blade Guard Nut.
(E)
Install the Outer Flange. Verify the
drive pin is seated; it must project
through the hole in the blade and
into the ange.
WARNING
NOTICE
Do not operate the saw without the proper
Blade Guard covering. Ensure that the blade
exposure does not exceed 180 degrees during
operation.
The blade turns clockwise when facing the
blade shaft. Ensure directional arrow on the
blade indicates proper rotational direction. In-
correct rotation will reduce blade life.

16
Filling Fuel Tank
CRACK CHASER SAW START UP
WARNING 1. Gasoline is highly ammable and explosive. You can be burned or seriously
injured when handling fuel.
2. To fuel, stop engine if running, and allow it to cool.
3. Refuel in a well-ventilated area.
4. Keep gasoline away from appliance pilot lights, barbeques, electric appliances,
power tools, etc.
5. Wipe up spills immediately. Do not start engine until spill is dry.
1. Fuel can damage paint and plastic. Be careful not to spill fuel when lling the
fuel tank. Damage caused by spilled fuel IS NOT covered under the warranty.
2. DO NOT use stale or contaminated gasoline, or an oil/gasoline mixture.
NOTE:
(A)
Remove the Fuel Cap. Refer to
Engine Manual for details.
(B)
Ensure fuel level is 1” below the
throat of the Fuel Tank.
1 inch (25mm)
from throat
The pre-start inspection should be performed before beginning any job. If Diamond Blade is worn,
replace the blade before starting work.
Pre-Start Inspection
(A)
Inspect Blade for damage or
cracks. Verify the Blade is a dry
cutting blade and correct for the
material being cut.
(C)
Inspect the saw for general dam-
age and/or loose hardware.
(B)
Inspect Engine for leaks.
Maximum
Fuel Level
(C)
Ensure fuel level is below the
top of the strainer lter.
Maximum
Fuel Level

17
(D)
Check for proper oil level.
Refer to Engine Manual for
details.
Low Level
Proper Oil Level
(G)
Check the Air Filter for
cleanliness. Refer to Engine
Manual for details.
1. Carbon monoxide gas is toxic, breathing it can cause unconsciousness
and/or death.
2. Avoid any areas or actions that expose you to carbon monoxide.
Engine Start
WARNING
CRACK CHASER SAW START UP
(E)
Ensure fuel level is 1” below the
throat of the Fuel Tank.
1 inch (25mm)
from throat
Maximum
Fuel Level
(F)
Ensure fuel level is below the
top of the strainer lter.
Maximum
Fuel Level

18
CRACK CHASER SAW OPERATION
Adjusting Depth of Cut
Dust Collection Systems
The common depth of cut for crack chasing repair is ½”.
The CC-100 has two 3” ports for connection with a dust collection system. The vacuum system
required must have a CFM of 129 and a HEPA lter guaranteed 99.99% efcient at .3 micron. We
carry the Ermator line of dust collections systems and recommend the Ermator S13 HEPA Dust
Extractor or Ermator S26 HEPA Dust Extractor. Visit mkdiamond.com for more information.
(B)
If the blade is resting on the
ground note the distance be-
tween the front caster wheel and
the ground. This indicates the
current depth of cut.
(A)
Raise the raise/lower handle.
(C)
If the blade is raised above the
ground, adjust the Depth Control
Knob until the caster is approximate-
ly ½” above the ground. Tighten the
lock nut on the Depth Control Knob.
As the blade wears adjustments will be required.
NOTICE
OR

19
CRACK CHASER SAW OPERATION
Standard Operation
The Crack Chaser Saw is intended for industrial applications and operated by experienced profes-
sionals. The operator must be aware of the machine’s capabilities and limitations. 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...
(A)
Use the Raise/Lower Handle to
raise the blade clear of the oor.
(B)
Attach the dust collection
system to the vacuum ports.
(C)
Start the Saw using the Engine Start
procedure in the engine manual.
Prior to operation of this machine the operator must determine the existence
and location of any subsurface features that may be hazardous or could
damage the equipment, (i.e. electric cable, natural gas line etc...)
The CC-100 operates on a down cut principle and you pull the saw toward you
as gently guiding the blade to follow the crack. The saw has three swiveling
casters allowing easy movement to follow random cracks.
CAUTION
NOTICE
1. Ensure the blade you are using is clearly marked for dry cutting.
2. Check the condition of the air lter at least every four hours of operation.
Refer to Engine Manual for details.
Airow helps to cool the blade during dry cutting. Cutting too deep with one pass, or exerting exces-
sive forward or side pressure can be dangerous and cause damage.
NOTE:
Perform the cut using only enough pressure to follow the crack. The saw has a natural
tendency to follow the crack. Steer the saw smoothly and slowly. Sudden and severe
corrections can cause the blade to be damaged or broken. Do not cut more than 3/4”
deep per pass as blade will overheat. Run the engine at full throttle so the blade is turn
at maximum RPM to keep blade cool.
NOTE:

20
(K)
When the cut is complete, raise
the Blade completely out of the
cut by lifting the Raise/Lower
handle. Turn off saw.
CRACK CHASER SAW OPERATION
Emergency Engine Shutdown
(A)
Place Engine Master Switch in
the OFF position.
(J)
Align the Blade with the crack
and slowly lower blade into
crack. Cut with engine at full
throttle.