MK Diamond MK-100 User Manual

quip

MK-100 JCS Tile Saw

TILE SAW
OWNER’S MANUAL &
OPERATING INSTRUCTIONS

CAUTION:

Read all safety and
operating instructions
before using this
e

ment

Enter the Serial Number of your new saw in the
space below. The Serial Number is located on the
left side of the blade guard.

SERIAL NUMBER:

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.

INTRODUCTION

We at MK Diamond want to congratulate you on selecting the MK-100 Tile Saw. We are certain that you will
be pleased with your purchase. MK Diamond takes pride in producing the finest products in the industry.

Operated correctly, your MK-100 should provide you with years of quality service. In order to help you, we
have included this manual. This owners manual contains information necessary to operate and maintain your
MK-100 safely and correctly. Please take a few minutes to familiarize yourself with the MK-100 by reading
and reviewing this manual.

If you should have questions concerning your MK-100, please feel free to call our friendly customer service
department at: 800 421-5830

Regards,
MK Diamond

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 2

TABLE OF CONTENTS

Page

SAFETY:

Safety Messages 4
Damage Prevention Message 4
General Safety Precautions and Hazard Symbols 4
California Proposition 65 Message 6
Electrical Requirements and Grounding Instructions 7
Safety Label Locations 9
Tile Saw Specific Warnings 9
Product Specifications 10

UNPACKING, TRANSPORT, UNIVERSAL STAND, and ASSEMBLY

Unpacking 11
Contents 11
Transport 11
Universal Stand 12
Assembly 13

SETUP, ADJUSTMENT AND OPERATION
Setup 15
Adjustment and Operation 18
Cleanup 24

MAINTENANCE AND TROUBLESHOOTING

Maintenance 26
Troubleshooting 29

EXPLODED VIEW AND PARTS LIST

Exploded View 37
Parts List 38

THEORY

Theory of Diamond Saws 41

ACCESSORIES

Accessories 42

ORDERING and RETURN INSTRUCTIONS

Ordering Information 43
Return Material Policy 43
Packaging Instructions 43
Authorized Service Centers 43

Manual Part No. 162494 Revision No. 06/05

4

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 3

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:

Safety messages inform the user about potential hazards that could lead to injury, death and/or equipment
damage. Each safety message will be preceded by one of the following (3) three words that identify the
severity of the message.

Not following instructions WILL lead to DEATH or SERIOUS INJURY

Not following instructions COULD lead to DEATH or SERIOUS INJURY

Not following instructions CAN lead to injury

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.

GENERAL SAFETY PRECAUTIONS AND HAZARD SYMBOLS:

In order to prevent injury, the following safety precautions and symbols should be followed at all times!

Safety Precautions:

KEEP GUARDS IN PLACE.

In order to prevent injury, keep guards in place and in working order at all times.

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 use power tools in damp or wet locations nor expose them to rain. Always keep the work area well
lighted.

KEEP CHILDREN AWAY.

All visitors and children should be kept a safe distance from work area.

MAKE THE WORKSHOP KID PROOF.

Make the workshops kid proof by using padlocks, master switches or by removing starter keys.

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.

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 4

SAFETY

USE THE PROPER EXTENSION CORD.

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 7 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.

WEAR 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 covering to contain long hair.

ALWAYS USE SAFETY GLASSES.

Safety glasses should always be worn when working around power tools. In addition, a face,
dust mask or respirator should be worn if a cutting operation is dusty. Everyday eyeglasses only
have impact resistant lenses and may not prevent eye injury-they are NOT safety glasses.

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.

DO NOT OVERREACH.

Keep proper footing and balance at all times by not overreaching.

MAINTAIN TOOLS WITH CARE.

Keep tools clean for the best and safest performance. Always follow maintenance instructio ns for
lubricating, and when changing accessories.

DISCONNECT TOOLS.

Power tools should always be disconnected before servicing or when changing accessories, such as blades,
bits, cutters, and the like.

REDUCE THE RISK OF UNINTENTIONAL STARTING.

on

Make sure the trigger switch; locking button is in the RELEASE position before plugging in a power
tool.

USE RECOMMENDED ACCESSORIES.

Consult the owner's manual for recommended accessories. Using improper accessories may increase 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.

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 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.

DIRECTION OF FEED.

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.

NEVER LEAVE A 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 finished.

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

SAFETY

Hazard Symbols:

ELECTRICAL SHOCK!

Never touch electrical wires or components while the motor is running. Exposed, frayed or worn
electrical motor wiring can be sources of electrical shock that could cause severe injury or burns.

ACCIDENTAL STARTS!

on

Before plugging the equipment into an electrical outlet, be sure the trigger switch, locking button is in
the "RELEASE" position to prevent accidental starting. Unplug the power tool before performing any
service operation.

ROTATING OR MOVING PARTS!

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate a
power tool with covers, shrouds, or guards removed.

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.

CALIFORNIA PROPOSITION 65 MESSAGE:

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-slc.gov/sltc/silicarystalline/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.

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

etal Scre

(A) (B) (C) (D)

A

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 oute r 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 n ot
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.

Grounding
Pin

DAPTER

Grounding

Means

M

Cover of Grounded

Outlet Box

Grounding

Pin

w

FIGURE 1

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 the Tile Saw. Receptacles are available having built-in GFCI protections and may be used for
this measure of safety.

When using an extension cord, the GFCI should be installed closest to the power source, followed
by the extension cord and lastly, the saw.

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

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.

Power
Cord

FIGURE 2

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 he at and
sharp edges. Always disconnect the extension cord from the receptacle before disconnection the
product form the 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 of undersize 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

As an example, a fifty (50) foot extension cord would require an AWG size of 16.

Power
Tool

Supporting
Surface

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.

Drip Loop

for that length of extension cord.

Extension Cord Minimum Gage for Length

Volts Total Length of Cord in Feet

120V

25 ft. 50 ft. 100 ft 150 ft.

AWG AWG AWG AWG
14 12 Not Recommended

TABLE 1

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

SAFETY

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 consid ered 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 Rear Caution Use Ground Fault Interrupt 155678
1B. Motor Rear Caution Receptacle for Pump Only 154822
1C. Motor Rear Service or Warranty Information 155038

2. Blade Guard Serial Number (Laser Marked) 157500
3A Motor Front Warning Read and Follow Operating Instructions 155806
3B Motor Front Motor Specifications N/A
4A Pump Left Side Warning Connect to Grounded Receptacle N/A
4B Pump Right Side Pump Specifications N/A

A

1

A

3

B

C

2

B

A

4

B

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.
Use tool only with smooth edge cutting blades free of openings and grooves.
Replace damaged cutting blade before operating.

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

SAFETY

PRODUCT SPECIFICATIONS:

The MK-100 is a versatile Tile Saw. Operated and used according to this manual, the MK-100 will provide
years of dependable service.

General Description:
The MK-100 Tile Saw is engineered as a tabletop or stand mounted wet tile saw. The saw includes a powerful
115v totally enclosed capacitor start GE motor with a thermal protective overload. The saw is capabl e of
cutting tile up to twenty (20) inches in length, or diagonal cutting tile up to fourteen (14) inches. The saw can
cut an object three and one-half (3-1/2) inches thick in one pass.

Motor Specifications:
Motor specifications for the MK-100 are listed in Table 2 below.

Voltage 115 v
Overall Amperage 13.4 a
Motor Only Amperage 12.8 a
Frequency 60 Hz
RPM 3450 rpm
Horse Power 1.5 hp
Weight 97 lbs

Thermal Overload Protection:
The motor is protected by a thermal overload equipped with a manual reset.

Blade Capacity:
The MK-100 uses a ten (10) inch (254mm) diameter, wet cutting continuous rim, MK Diamond blade with a
one-sixteenth 1/16 inch (15.875 mm) cutting width and a five-eighths (5/8) inch (15.875 mm) arbor.

Tile Types:
The MK-100 can cut a variety of tile types including Porcelain, Terracotta, Marble, Quarry and Slate, or almost
any other non-ferrous material.

NOTE:
The MK-100 is not designed to cut plastic or ferrous (metals) material.

Table 2

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

pag

UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY

UNPACKING:

Your MK-100 has been shipped from the factory thoroughly inspected. Only minimal assembly is required.

Use proper lifting techniques when lifting the MK-100.

If not done, remove the MK-100, Cutting Head and accessory box from the carton.

CONTENTS:

In your container, you will find one (1) MK-100 frame and water basin, one (1) MK-100 Cutting, one (1) 10­inch wet cutting continuous rim diamond 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) Table Clip, one (1) splash gu ard, one (1) owners manual, one (1) pump manual
and one (1) warranty card.

MK-100 Frame

and Water Basin

MK-100

Cutting Head

Diamond Blade Adjustable

Cutting Guide

Water Pump Clamp

and Wing Screws

Electric

Water Pump

Pump

Discharge Fitting

Cooling

Transfer Tube

Flow

Adjusting Clamp

Drain Plug

Blade Wrench and

Table Clip

Splash

Guard

Owners
Manual

Pump

Manual

Warranty

Card

TRANSPORT:

1. The MK-101 weighs approximately one hundred and twenty eight (128) pounds.

2. Never transport the MK-101 with water in the Water Basin.

Lift the saw using the handle.
Follow instructions on

e 12.

Wheels

Casters

Cutting Head

Handle

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 11

g

y

r

UNPACKING, TRANSPORT, JCS STAND and ASSEMBLY

JCS STAND: Key Components for Set Up

Note: Familiarize with the following components before proceeding to SET UP.

Handle

Cutting Head

Handle

Knob to release

Front Le

Knob to release

Arm

Safet

Table Clip

Front Legs

Cross

Membe

s

Wheel Lock

Air Springs

Safety Arm

Front Legs

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

UNPACKING, TRANSPORT, JCS STAND and ASSEMBLY

JCS STAND - SET UP FOR OPERATION:

The MK-101 w/ JCS Stand weighs approximately one hundred and twenty eight (128) pounds. Read and
understand all instructions. Failure to follow all instructions in SEQUENCE could result in serious injury.

Handle

(A)

Position Saw on a hard level

surface

(D)

Lock Wheel

(B)

Hold the Saw from Handle and

swing to Upright position

Knob

(E)

Locate the Knob to release

Front Legs

(C)

Locate Wheel Lock

Front Legs

(F)

Pull Knob and Front Legs will be

released

(G)

Place your foot on Cross

Member for support

(J)

Front Legs rest on the ground

Hold from handle

Locate the Cutting Head Handle

(H)

and swing down

Handle

(K)

(I)

Make sure to extend Front Legs

as they swing down

(L)
Pull from the Cutting Head Handle
until Air Springs are fully extended

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

UNPACKING, TRANSPORT, JCS STAND and ASSEMBLY

Air Springs

Knob

Air Springs are fully extended

and saw is in Horizontal position

(M)

(N)

Locate the Knob to unlock the

Safety Arm

The Safety Arm will swing down as the

Ensure that Safety Arm rests on

(P)

Your Saw is ready!

Frame

(Q)

JCS STAND – TAKE DOWN INSTRUCTIONS:

(O)

Pull Knob to unlock the Safety Arm

Knob is pulled

(A)

Lock Table in place with Clip

(See pg. 14 for instructions)

(D)

Push down on Cutting Head until

Air Springs are fully compressed

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

Swing up Safety Arm

Hold saw from Handle and

swing up to upright position

(B)

(E)

(C)

Lock the Safety Arm with Knob

(F)

Push legs against frame to lock

in place with Knob

UNPACKING, TRANSPORT, JCS STAND and ASSEMBLY

Unlock the wheel

(G)

(H)

Make sure that the wheel is

properly unlocked

Your saw is ready for transport!

TABLE CLIP:

(I)

Slide table to the front

(A)

(B)

Line up Clip with Side Table Slot

(E)

The clip secures

the Table in place

(C)

Swing clip over

the side of the Table

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

UNPACKING, TRANSPORT, JCS STAND and ASSEMBLY

ASSEMBLY:

Follow the assembly instructions to prepare your MK-100 for operation.

1. Cutting Head Installation:

NOTE: If the Cutting Head is installed, go to step 2.

Turn Counter-

clockwise to remove

Remove Adjusting Knob

(A)

Post

(B)

Align Cutting Head rear Pivot

Hole to the Post, Pivot Shaft

Rear Pivot

Hole

Pivot Shaft

Turn Clockwise

to tighten

(C)

Install the Cutting Head onto the

Post, Pivot Shaft and Install

The Adjusting Knob

2. Diamond Blade Installation:

NOTE: When installing the Retaining Screw, do not “cross-thread" and DO NOT over tighten the screw.

Pivot Blade
Guard up

Position Movable Cutting Table

to the front of the saw and

raise the Blade Guard

Diamond

Blade

Install Diamond Blade

onto Blade Shaft

(A)

(D)

Tighten

Wing-nut

Movable

Cutting Table

Blade

Shaft

Cutting

Head

Shaft Lock

Pushbutton

(B)

Locate the Shaft Lock

pushbutton on the underside

of the Cutting Head

Rotation Direction

(E)

Verify the Blade is seated on

the Blade Shaft and direction

of rotation is correct

Press and

Hold

Blade

Wrench

Turn counter-

clockwise to

loosen

Retaining Screw
and Outer Flange

(C)

Depress and hold the Shaft Lock

pushbutton and remove Retaining

Screw and Outer Flange using

the Blade Wrench

Rotate Blade

Wrench clockwise

to tighten

Retaining

Nut and

Outer Flange

(F)

Install Retaining Nut and Outer

Flange, depress and hold the

Shaft Lock pushbutton

and Tighten

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

UNPACKING, TRANSPORT, JCS STAND and ASSEMBLY

3. Adjustable Cutting Guide Installation:

NOTE: The Adjustable Cutting Guide can be used on either side of the Diamond Blade.

Turn counter-

clockwise to loosen

Loosen Adjustable Cutting

Guide retaining thumbscrew

and place it over the Movable

Cutting Table Ruler/Stop

Adjustable

Cutting Guide

Ruler/Stop

(A)

Turn clockwise

to tighten

Place the Adjustable Cutting

Guide onto the Movable Cutting

Table Ruler/Stop and tighten

the retaining thumbscrew

Adjustable

Cutting Guide

Ruler/Stop

(B)

4. Splash Guard Installation:

Splash

Guard

Thumbscrew

Install the retaining thumbscrew

through the washer and Splash

Guard then align to the hole found

on back of the Blade Guard

(A)

Retaining

Hole

Turn clockwise

To tighten

(B)

Install the Splash Guard

onto the Blade Guard

5. Water Pump Preparation: :

Turn clockwise

to tighten

Install Water Pump

Discharge Fitting

Discharge

Fitting

(A)

Cooling

Transfer

Tube

Press on

(B)

Press one end of the Cooling

Transfer Tube onto the Water

Pump Discharge Fitting

Flow Adjusting

Clamp

Press on

(C)

Slide Cooling Flow Adjusting

Clamp onto the Cooling

Transfer Tube

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

SETUP, ADJUSTMENT and OPERATION

SETUP:

1. Pre-start Inspection:

Prior to beginning work, a pre-start inspection of the saw should be preformed.

ON/OFF

Switch

Ensure the ON/OFF Switch

is in the OFF position

Inspect for

cracks or cuts

Inspect for

damage

Inspect the Pump Assembly

for damage – ensure the cord

is free of cracks or cuts

(A)

(D)

Off

Position

Verify ease of movement

(See Maintenance section

if problems exist)

(B)

Verify the Movable Cutting Table

moves freely

Inspect for

damage

(E)

Inspect the MK-100

for damage – ensure the cord

is free of cracks or cuts

Inspect for cracks,

de-bonding, etc.

(C)

Inspect the Diamond Blade for

damage – verify the blade is

correct for the material being cut

2. Connecting the Water Pump:

1. To prevent the possibility electrical shock, the MK-100 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.

Cooling

Transfer

Tube

Press on

Connect the Cooling Transfer

Tube to the inlet connection

of the Blade Guard

(A)

Inlet

connection

Pump

Connection

Press

together

(B)

Connect the Water Pump power

cord to the connection found on

the back of the motor

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 18

r

r

SETUP, ADJUSTMENT and 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.

Place Water Pump in Water Pan

(A)

(B)

Place Water Pump Clamp as

shown

Secure Clamp with ¼-20

wingscrews and nuts.

(C)

I. External Water Source:

This is the preferred method of cooling.

Remove the Drain plug

(A)

Drain Plug

Water Pump

In containe

(B)

Place the Water Pump

In an external container

Cover Pump

Suction

External

Containe

(C)

Fill the external container until

water completely covers the

Water Pump suction

II. Re-circulation:

NOTE: When using the re-circulation method, the water should be changed often for longer pump life.

Ensure the Drain Plug is

Installed in the Water Basin

(A)

Drain Plug

Installed

Water
Pump

(B)

Place the Water Pump in the

back of the Water Basin

Cover Pump

Suction

(C)

Fill the Water Basin until water

completely covers the

Water Pump suction

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

SETUP, ADJUSTMENT and OPERATION

4 MK-100 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-100 to a power supply, be sure the voltage, cycle and phase of the
job site power source meet the requirements of TABLE 3

VOLTAGE: 115v
CYCLE: 60hz
PHASE: 1-phase

TABLE 3

4. 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.

5. Use an approved Ground Fault Circuit Interrupter (GFCI)

6. Do not cover the motor vents as this could lead to motor overheating.

NOTE: In order to avoid breaker tripping, a 20-amp circuit breaker should be used.
Portable Generator:

If using a portable generator to provide power, ensure the generator meets the following minimum
requirements:

8 KW 120/240 volts 66.7/33.3 amps Single Phase

ON/OFF

Switch

Ensure the ON/OFF Switch

is in the OFF position

(A)

Off

Position

GFCI

(B)

Plug MK-100 into the GFCI

GFCI Plugged

Into Power

Source

(C)

Plug the GFCI into the

Power source

5. Set Cutting Depth:

Turn Counter-

clockwise to loosen

When loosing the Cutting Head Adjusting Knob, the Cutting Head will pivot down unless held.

Turn Clockwise

to tighten

Ensure the Adjusting Knob

is tight

(A)

Loosen Cutting Head

Adjusting Knob

Adjust Cutting
Head to Cut Depth
of Approx ¼” to ½”

(B)

Set cutting depth approximately

1/4 to 1/2 inch below the surface

of the Movable Cutting Table

(C)

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

SETUP, ADJUSTMENT and OPERATION

ADJUSTMENT and 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

Turn Counter-

clockwise to loosen

Loosen the Adjustable Cutting

Guide retaining thumbscrew

Place the tile against the

Ruler/Stop and Cutting Guide

Hold Work
in Position

Direction

of Cut

designed.

(A)

Adjustable

Cutting Guide

Ruler/Stop

(D)

(G)

Perform the cut

Desired Cut length

indicated here

(B)

Position the Adjustable Cutting

Guide to desired cut length

indicated inside the diamond

ON/OFF

Switch

On

Position

(E)

Turn the motor ON

ON/OFF

Switch

Off

Position

(H)

Turn the motor OFF when

work is complete

Turn Clockwise

to tighten

(C)

Tighten the retaining

thumbscrew

Cooling Flow

Points

(F)

Verify proper cooling flow on

both sides of the blade (See

Maintenance Section to
increase/decrease flow)

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

p

SETUP, ADJUSTMENT and OPERATION

2. Diagonal Cutting:

NOTE: To cut diagonal, the Dual 45º Flat Angle Guide (MK Diamond Part No. 134557-MK) should be used.

clockwise to loosen

Remove the Adjustable Cutting

NOTE: If Cutting the tile in two equal halves, align the tile in the V-notch of the Movable Cutting Table

Position the tile against the Dual

45º Flat Angle Guide and the

Hold Work
in Position

Direction

of Cut

DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.

(A)

Adjustable

Cutting Guide

Ruler/Stop

Turn counter-

clockwise to loosen

Align Guide

to Ruler/Sto

Ruler/Stop

(B)

Place the Dual 45º Flat Angle

Guide on the Ruler/Stop

Turn Clockwise

(C)

Position the Dual 45º Flat Angle

Guide and tighten the

Turn counter-

Guide

retaining thumbscrew

Ruler/Stop.

45º Flat

Angle Guide

Ruler/Stop

(D)

ON/OFF

Switch

Turn the motor ON

(E)

On

Position

Cooling Flow

Points

(F)

Verify proper cooling flow on

both sides of the blade (See

Ruler/Stop

Maintenance Section to
increase/decrease flow)

Off

Position

(G)

Perform the cut

ON/OFF

Switch

(H)

Turn the motor OFF when

work is complete

to tighten

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

p

r

SETUP, ADJUSTMENT and OPERATION

3. 45º Miter Cutting:

NOTE: To cut 45º Miters, the 45º Bullnose Miter Guide (MK Diamond Part No. 134585-MK) should be used.

clockwise to loosen

Remove the Adjustable Cutting

Bull Nose

Mite

Ruler/Stop

Position the tile on the 45º

Bullnose Miter Guide and the

Hold Work
in Position

DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.

(A)

Adjustable

Cutting Guide

Ruler/Stop

Ruler/Stop

Align Guide

to Ruler/Sto

Turn counter-

clockwise to loosen

(B)

Place the 45º Bullnose Miter

Guide on the Ruler/Stop

Turn Clockwise

(C)

Position the 45º Bullnose Miter

Guide and tighten the

Turn counter-

Guide

retaining thumbscrew

Ruler/Stop

(D)

ON/OFF

Switch

(E)

Turn the motor ON

On

Position

Cooling Flow

Points

(F)

Verify proper cooling flow on

both sides of the blade (See

Maintenance Section to
increase/decrease flow)

(G)

Perform the cut

ON/OFF

Switch

Direction

of Cut

(H)

Turn the motor OFF when

work is complete

Off

Position

to tighten

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

p

SETUP, ADJUSTMENT and OPERATION

4. Off-angle Cutting:

NOTE: To cut angles other than 45º angles or Miters, a 90º Protractor (MK Diamond Part No. 134569-MK)

Remove the Adjustable Cutting

should be used.

DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.

Turn counter-

clockwise to loosen

Adjustable

Cutting Guide

Ruler/Stop

(A)

Guide

Turn Clockwise

to tighten

(D)

Position the 90º Protractor

and tighten the

retaining thumbscrew

Cooling Flow

Points

(F)

Verify proper cooling flow on

both sides of the blade (See

Maintenance Section to
increase/decrease flow)

Turn counter-

clockwise to loosen

Align Guide

to Ruler/Sto

Ruler/Stop

(B)

Place the 90º Protractor on

the Ruler/Stop

Protractor

Ruler/Stop

(D)

Position the tile against the 90º

Protractor and the Ruler/Stop

Hold Work
in Position

Direction

of Cut

(G)

Perform the cut

Turn Clockwise

to tighten

Set Angle

(C)

Set the desired angle and

tighten the thumbscrew

ON/OFF

Switch

(E)

Turn the motor ON

ON/OFF

Switch

(H)

Turn the motor OFF when

work is complete

On

Position

Off

Position

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

SETUP, ADJUSTMENT and OPERATION

5. Adjusting the Cutting Head:

ON/OFF

Switch

Ensure the ON/OFF Switch

Remove

Cutting Head

Rear Pivot

Hole

Remove the Cutting Head from

Adjust Cutting
Head to Cut Depth
of Approx ¼” to ½”

Set cutting depth approximately

1/4 to 1/2 inch below the surface

of the Movable Cutting Table

The Cutting Head is heavy! Care must be used when changing the position of the Cutting He ad.

Position

(A)

is in the OFF position

Off

Unplug

(B)

Unplug the GFCI from the

power source

Turn Counter-

clockwise to remove

(C)

Remove Adjusting Knob

Turn Clockwise

to tighten

Front Pivot

Hole

(D)

The rear pivot hole

(G)

(E)

Install the Cutting Head onto

the front pivot hole

GFCI Plugged

Into Power

Source

(H)

Install the Adjusting Knob

(F)

Plug the GFCI into the

power source

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

SETUP, ADJUSTMENT and OPERATION

6. Adjusting the Post for Maximum Cutting Length:

The Cutting Head and Post are heavy! Care must be used when changing the position of the

ON/OFF

Switch

Ensure the ON/OFF Switch

Cutting

Head

Remove the Cutting Head (See

Adjusting the Cutting Head

Post

Relocate the Post to the rear

Slide Water Basin

in back of Saw

Install the Water Basin

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

Cutting Head.

Off

Position

Unplug

(A)

Unplug the GFCI from the

is in the OFF position

power source

Hold the Post when removing the Post Support Plate.

Turn counter-

clockwise to loosen

(D)

Loosen the Post Support Plate

and retaining bolts

Rear

Holes

Turn Clockwise

to tighten

(G)

Install and tighten the Post

Post retaining holes

Support Plate and retaining bolts

(J)

Plug the GFCI into the

power source

(B)

(E)

(H)

GFCI Plugged

(K)

9/16-inch

Wrench

9/16-inch

Wrench

Into Power

Source

Slide Water Basin

out front of Saw

(C)

Remove Water Basin

Post Support

Plate

(F)

Remove the Post Support Plate

and retaining bolts

Cutting

Head

(I)

Install the Cutting Head (See

Adjusting the Cutting Head

r

r

r

SETUP, ADJUSTMENT and OPERATION

7. Cleanup:

NOTES: 1. If an external water source was used, steps A through C may be skipped.

2. Dispose of waste water in accordance with applicable Federal, State and Local laws.

Pump

Suction

Clean the Water Pump

suction of all debris

(A)

Ensure the saw is disconnected before completing the remainder of the cleanup process.

ON/OFF

Switch

Ensure the ON/OFF Switch

is in the OFF position

Clean the MK-100 with

soap and clean water

(D)

Soap and

Fresh Wate

(G)

Off

Position

Water Pump

In containe

External

Containe

(B)

Place the Water Pump

In an external container

Unplug

(E)

Unplug the GFCI from the

Power source

Slide Water Basin

out front of Saw

(H)

Remove the Water Basin

from the MK-100

Cooling Flow

Points

(C)

Run the MK-100 until clear

water is seen at the blade

cooling ports (Approx. 1 minute)

GFCI

(F)

Unplug MK-100 from the GFCI

Clean Water

Basin

(I)

Clean the Water Basin

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

r

SETUP, ADJUSTMENT and OPERATION

Ensure water is not forced into the motor casing when cleaning.

Clean the Movable Cutting

Table Guide Bar

(J)

Clean

Guide Ba

Roller Wheel

Frame Support

(K)

Clean the Movable Cutting

Table Roller Wheel Frame

Support

(L)

Clean the remainder of the

MK-100

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

r

MAINTENANCE AND TROUBLESHOOTING

MAINTENANCE:

1. New Maintenance:

Perform the following after initial purchase and operation of the MK-100.

Check and adjust V-belt

tension Following 1

operation (See V-belt Inspection)

(A)

Inspect

V-belt

st

48 hours of

2. Maintenance Following Use:

To extend the life of the MK-100, the following procedure should be performed after each use. Lubricate all
points listed below with light oils such as, 3 in 1, WD-40, etc.

ON/OFF

Switch

Ensure the ON/OFF Switch

is in the OFF position

Lubricate the Roller

Wheel Assembly

(A)

(A)

Off

Position

Roller Wheel

Assembly

(B)

Unplug MK-100

GFCI

Guide Ba

(C)

Lubricate the Guide Bar

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 29

MAINTENANCE AND TROUBLESHOOTING

3. Monthly Maintenance:

The following maintenance should be performed Monthly.

Rotate Blade Wrench

counter-clockwise

to loosen

Remove the Diamond Blade

Verify the Roller Wheel

Assembly is tight and in

Remove the Blade Guard

(A)

good condition

clockwise to remove

(G)

Retaining

Screw and

Outer Flange

(D)

Turn Counter-

Verify

Tight

Outer

Flange

(B)

Lubricate the Outer Flange

and Retaining-nut

Verify Four
Bolts Tight

(E)

Verify all motor mounting

Bolts are tight

Blade Guard

Pivot Shaft

(H)

Lubricate the Blade Guard

Pivot Shaft

(C)

Lubricate the Inner Flange

(F)

Verify the Motor Adjustment

Strap is tight

Outer

Flange

Verify Bolt

Tight

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

MAINTENANCE AND TROUBLESHOOTING

Cutting

Head

Remove the Cutting Head (See

Adjusting the Cutting Head)

Lubricate the Cutting Head

(I)

Pivot
Shaft

(L)

Pivot Shaft

Lubricate the Cutting Head

Adjustment Knob

(J)

Adjustment

Knob

Retaining

Holes

(K)

Lubricate the Cutting Head

Adjustment Knob retaining holes

4. Flow Adjustment:

NOTE: If flow to the diamond blade requires adjustment, perform the following actions.

Increase cooling flow by

releasing the Flow Adjusting

(D)

Clamp

Pull Tab

to loosen

Press Tab

to Restrict

Flow

(E)

Reduce cooling flow by

Pressing down on the Flow

Adjusting Clamp

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

p

MAINTENANCE AND TROUBLESHOOTING

1. Blade Dressing:

Like most cutting instruments, a diamond blade performs best when it is dressed. Over time and use,
diamonds on the outer edge of the blade will become smoothed or “glazed” over. This will reduce grinding
efficiency and may cause the blade to “wander” or bend giving the illusion of an alignment problem. When
this occurs, the blade will need to be dressed. The diamond blade can be dressed using the MK Dressing
Stick (part number 152972) and by following the steps below.

Setup for

eration

O

Setup the MK100 for operation

(See Setup, Adjustment

ON/OFF

Switch

Turn the motor ON

ON/OFF

Switch

Ensure the ON/OFF Switch

is in the OFF position

(A)

and Operation)

On

Position

(D)

Off

Position

(G)

Set Adjustable

Cutting Guide

(B)

Set the Adjustable Cutting Guide

to cut a 1/16-strip

Cooling Flow

Points

(E)
Verify proper cooling flow on
both sides of the blade (See

Maintenance Section to
increase/decrease flow)

(C)

Position the Dressing Stick

Hold Work
in Position

Direction

of Cut

Cut the Dressing Stick 7 or 8

times to dress the Blade

Adjustable

Cutting Guide

Ruler/Stop

(F)

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

MAINTENANCE AND TROUBLESHOOTING

2. Diamond Blade Change-out:

NOTE: When installing the Retaining Screw, do not “cross-thread" and DO NOT over tighten the screw.

Cutting

Head

Locate the Shaft Lock

pushbutton on the underside

of the Cutting Head

Diamond

Blade

Install the Diamond Blade

onto Blade Shaft

(A)

(D)

Shaft Lock

Pushbutton

Rotate Blade

Wrench counter-

clockwise to loosen

Retaining

Nut and

Outer Flange

(B)

Remove Retaining Nut and

Outer Flange, depress

and hold the Shaft Lock

pushbutton and loosen

Rotation Direction

Blade

Shaft

(E)

Verify the Blade is seated on

the Blade Shaft and direction

of rotation is correct

Diamond

Blade

(C)

Remove the Diamond Blade

Rotate Blade

Wrench clockwise

to tighten

Retaining

Nut and

Outer Flange

(F)

Install Retaining Nut and Outer

Flange, depress and hold the

Shaft Lock pushbutton

and tighten

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

MAINTENANCE AND TROUBLESHOOTING

3. V-Belt Inspection, Adjustment and Replacement:

The MK-100 is designed with a power transmission v-belt. In order to ensure the MK-100 operates a peak
efficiency, the v-belt should be inspected monthly, and changed if the v-belt shows damage and/or excessive
wear.

NOTE: 1. When a new belt is installed, it should be inspected and re-tensioned after the first forty-eight

ON/OFF

Switch

Ensure the ON/OFF Switch

is in the OFF position

Cutting

Head

Remove the Cutting Head (See

Adjusting the Cutting Head

Check belt for proper tension

if tension correct, go to step R

(proper tension 1/8-inch)

(48) hours of operation.

Off

Position

(A)

(D)

Check Tension

1/2-way

between pulleys

(G)

Unplug

(B)

Unplug the GFCI from the

Power source

7/16-inch

Wrench

Three

Bolts

Rotate Counter-

clockwise to

loosen

(E)

Remove the Belt Guard

Rotate Counter-

clockwise to

loosen

Retaining

Bolts

1/2-inch
Wrench

(H)

Loosen motor mounting bolts

If re-tensioning only, go

to step N

Diamond

Blade

(C)

Remove the Diamond Blade

Inspect

V-belt

(F)

Inspect the V-belt for cracks,

Fraying, separation and wear. Go

to step H if replacement required

Rotate Counter-

clockwise to

loosen

9/16-inch

Wrench

Adjustment

Strap Bolt

(I)

Loosen the Motor Adjustment

Strap

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

MAINTENANCE AND TROUBLESHOOTING

Direction of push

Push the motor toward the

front of the Cutting Head to

Verify the V-belt is seated in the

loosen the V-belt

Belt Seated

grooves of both pulleys

Continue Adjustment

Until Correct

Repeat steps N and O until

proper V-belt tension

(J)

Pulley

(M)

(P)

is achieved

Old V-belt New V-belt

(K)

Remove the V-belt

Rotate clockwise

to tighten

(N)

Tighten the Motor Adjustment

Strap to remove slack

Rotate clockwise

to tighten

(Q)

Tighten the motor

mounting bolts

9/16-inch

Wrench

Retaining

Bolts

1/2-inch
Wrench

(L)

Install the new V-belt

(MK Diamond Part No. 158194)

Check Tension

1/2-way

between pulleys

(O)

Check V-belt tension

(proper tension 1/8-inch)

7/16-inch

Wrench

Three

Bolts

Rotate clockwise

to tighten

(R)

Install the Belt Guard

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

r

MAINTENANCE AND TROUBLESHOOTING

TROUBLESHOOTING:

4. Blade will not cut properly:

If “Glazed”, Dress Blade

(See Blade Dressing)

Check for Smoothness

or “Glazing” (Dress blade

Contact place of purchase or
MK Diamond (800 421-5830)

Verify the blade is correct for

the material being used

if needed)

to verify blade

If not “Glazed”,

go to Step B

(A)

If Blade Correct,

go to Step E

(D)

Check for proper rotation

Return to MK Diamond

If Rotation incorrect,

reverse Blade

If Rotation Correct,

go to Step C

(B)

Return to

MK Diamond

for Repair

(E)

If Blade Core is Bent,

Change Blade

If not “Glazed”, go

to Step D

(C)

Ensure the Blade Core

is not bent

5. Movable Cutting Table Does Not Move Correctly:

Clean Guide Bar

and Frame if dirty

Check that the Guide Bar

are clean – clean if dirty

(A)

go to Step B

If clean,

Check Roller

Wheel for wea

If Wheel not worn,

go to Step C

(B)

Check the Movable Cutting Table

Roller Wheels for wear replace

if necessary

Return to

MK Diamond

for Repair

(C)

Return to MK Diamond

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

r

MAINTENANCE AND TROUBLESHOOTING

6. Cooling Flow:

If flow exists,

go to Step A

Check cooling flow

Adjusting Clamp open

Pull to

Remove

If flow exist,

go to Step E

Remove the Cooling Transfer

Tube and check flow

Phillips

Screwdrive

Remove the 3 Pump Casing

Retaining Screws

(A)

(D)

(G)

Pull Tab

to loosen

Once Screws

removed, go

to Step H

Pull to

Remove

Go to

Step C

(B)

Remove the Cooling Transfer

Tube from the Blade Guard inlet

Remove

Discharge Fitting

If flow exist,

go to Step F

(E)

Remove the Pump Discharge

Fitting and check

Check Impeller

for damage

If no damage

Check for

restriction

or restrictions,

go to Step I

(H)

Remove the Pump Casing

and check for restriction;

check Impeller damage

Cover Pump suction

with water

If flow exist, go

to Step D

(C)

Place Pump into a bucket of

water and check flow

Pull Intake Screen

to remove

If Screen clean,

go to Step G

(F)

Remove the Pump Intake

Screen and check for debris

Intake Fitting

Turn counter-

Clockwise

to loosen

Go to

Step J

(I)

Remove the Blade Guard

Intake Fitting

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

MAINTENANCE AND TROUBLESHOOTING

NOTE: “Rodding” cooling channels is performed by inserting a small wire rod through the cooling inlet on top

of the Blade Guard and directing the rod out through each of the cooling flow tubes located on the
underside o the Blade Guard. The cooling channels should be “rodded” until all ports are free of
foreign debris.

Allan Wrench Rod

Cover

screws

Remove the Cooling Channel

cover screws

(J)

Turn counter-

Clockwise

to loosen

Go to

Step K

If cooling channels

clear, go to Step L

(K)

Rod Cooling Channels

and recheck flow

Channels

Return to

MK Diamond

for Repair

(L)

Return to MK Diamond

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

MAINTENANCE AND TROUBLESHOOTING

°

7. Blade Stops Turning:

Allow motor to cool and

depress motor Overload

Check Breaker

20 Amps

or greater

Verify circuit breaker at least 20

amps – if not, move to 20-amp

Return to MK Diamond

(A)

Reset Switch

(D)

circuit

Return to

MK Diamond

for Repair

Overload

Reset Switch

If motor does not

start, go to Step B

If less than 20

Amps move saw

to 20 Amp circuit

If circuit 20 Amp

or greater

go to Step E

(G)

Verify all plugs

connected

If all plugs connected,

go to Step C

(B)
Verify all plugs fully installed

If tripped, reset

once if trips again,

go to step F

If circuit breaker

Check Breaker

tripped

not tripped

go to Step F

(E)

Verify circuit breaker not tripped

If tripped, reset once

Reset once

if tripped

If not tripped, or

If re-trip occurs,

Go to Step D

(C)

Check Ground Fault Circuit

Interrupter (GFCI) tripped

Check for

correct circuit

voltage

If circuit breaker

not tripped

go to Step F

(F)

Check power source voltage is

115V – if not 115v, move to

another circuit

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

EXPLODED VIEW AND PARTS LIST

EXPLODED VIEW:

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 40

EXPLODED VIEW AND PARTS LIST

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

Page 41

EXPLODED VIEW AND PARTS LIST

PARTS LIST:

Item Description Qty Part #

A Accessories

- n/a
A1 Wrench, 15/16 Closed End 1 134684
A2
A3
A4
A5
A6
A7
A8

Guard, Splash
Wing screw, 1/4-20 X 1/2
Washer, 1/4 SAE Flat
Pump, Water 115V/60Hz UL
Fitting, Plastic, 1/4 FNPT X 1/4 BARB
Hose, Vinyl, 1/4 ID
Clamp, Flow, 1/4-1/2

1
1
1
1
1

6’

1

160310
151888
151915

151271-VP

128397
132951
154394

A9 Rip Guide, Large Die Cast 1 159751

A10 Blade, MK-100, 10X060X5/8 1 154380
A11 Owner’s Manual, MK-100 Portable Tile Saw 1 162494
A12 Carton, Accessory Pack, 101 1 153366
A13 Foam, Accessory Pack Carton 1 154022
A14 Card, MK Warranty Registration 1 155037
A15 Label, Do Not Return 1 157063
A16 Sell Sheet, Tile Accessory 1 156915
A17 Clip, Table Lock, 30 deg 1 160331-1
A18 Tag, Serial Number, Blank 1 157500
A19 Drive Screw, Round Head, #7 x 5/16 2 157849
A20 Pan, Plastic,101 1 150634
A21 Plug, Rubber Drain 1 153439
A22 Clamp, Pump Holding, MK100 1 162073
A23 Screw, Wing, ¼-20x1/2 2 151888
A24 Nut, Hex, ¼-20 2 151893

B Packaging

- n/a
B1 Cart Tray 1 162531
B2 Base Self Locking Tray 1 162532
B3 Motor Tray 1 162533
B4 Filler Pad 1 162534
B5 Corner supports 4 162535
B6 Outer Cover 1 162536

C Frame

n/a

C1 Assembly, Portable Stand 1 160705

D Post

n/a
D1 Post, DC, 101, MK Red 1 158438
D2 Shaft, 10.63” Pivot, 101 1 153254
D3 Screw, 3/8-16 X 1/2 Socket Head Set 1 153710
D4 Spacer, 5/8x.385x1.4 1 160654
D5 Screw, 3/8-16 X 2 1/2 2 156030
D6 Washer, 3/8 Split Lock 2 150925
D7 Plastic Post Cover 1 160157
D8 Knob, 3/8-16 X 1.5 MK Adjustment 1 156770-2
D9 Washer, 3/8 SAE Flat 1 150923

E Stop, Cutting Head

E1 Stop, 10” Cutting Head 1 157728
E2 Screw, 1/4-20 X 1 1/4 Hex Head Cap 1 157145
E3 Washer, 1/4 Split Lock 1 152591
E4 Sheet, Cutting Head Stop Instruction 1 157728-IS

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 42

EXPLODED VIEW AND PARTS LIST

F Belt Guard

F1 Belt Guard, MK-100 1 158319-00
F2 Bracket, Inner Belt Guard, 100/101/101Pro 1 158611
F3 Screw, 1/4-20 x 3/4 Hex Head Cap 3 152370
F4 Screw, 1/4-20 x 1 Hex Head Cap 1 152676
F5 Washer, 1/4 Split Lock 4 152591
F6 Washer, 1/4 SAE Flat 4 151915
F7 Belt, 260J6 Micro-V 1 158194

G Assembly, Blade Guard
G1 Blade Guard, 101/115 1 153659
G2 Tube, Water 2 155389
G3 Screw, 5/16-18 X 1/2 Socket Head Set 3 152607
G4

H Assembly, Cutting Head, MK-100
H1 Head, 10” Cutting 1 158224
H2 Pin, Blade Shaft Lock 1 158200
H3 Spring, Blade Guard Lock 1 158201
H4 E-Ring, 1/4 Retaining 1 158202
H5 Bearing, 17mm X 40mm X 12mm Ball (6203-2NSE) 2 137711
H6 Shaft, Blade 880/101/1080 1 158222
H7 Flange, 2-3/8 Inner 1 137737
H8 Flange, 2-3/8 Outer 1 135830
H9 Nut, 5/8-18 Hex 1 135848

H10 Pulley, 6J19 X 5/8 Bore 1 158199
H11 Key, 3/16 x 3/16 x 1 1/8 Square 1 150344
H12 Screw, 5/16-18 X 3/8 Socket Head Set, Cup Point 2 157083
H13 Bumper, 1/2 Dia Rubber 1 152674
H14 Screw, 5/16-18 X 1 Hex Head Cap 4 151743
H15 Washer, 5/16 SAE Flat 4 151754
H16 Washer, 5/16 Split Lock 4 151747
H17 Nut, 5/16-18 Hex 4 101196
H18 Screw, 5/16-18 x 2 1/2 Hex Head Cap, Full Thread 1 151748
H19 Pivot, Blade Guard 1 153208
H20 Washer, 3/8 SAE Flat 2 150923
H21 Wing nut, 5/16-18 Nylock 1 151746
H22 Strap, Motor Adjustment 1 152673
H23 Screw, 3/8-16 X 3 1/2 Hex Head Full Thread 1 153147

J Motors
J1 Motor, 1.5HP\115V\60Hz 1 158297
J2 Pulley, 6J17 X 5/8 Bore 1 158214
J3 Key, 3/16 x 3/16 x 1-1/8 Square 1 150344
J4 Screw, 5/16-18 X 3/8 Socket Head Set, Cup Point 2 157083
J5 Label, Warning, Read Owner’s Manual, 1-3/4 X 3-3/8 1 155806
J6 Label, Caution, GFCI, 1 X 2 1/8 1 155678
J7 Label, Caution, 5 Amp Max., 1 X 2-1/8 1 154822
J8 Label, MK Service Info., 2 1/8 X 1-13/16 1 155038

K Table
K1 Table, 100 1 157660
K2 Washer, 5/16 SAE Flat 2 151754

Elbow, 1/8 MNPT X 1/4 BARB 90° Brass

n/a

1 152582

1 154652

1 158191

- -

n/a

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

EXPLODED VIEW AND PARTS LIST

K3 Washer, 5/16 Split Lock 2 151747
K4 Screw, 5/16-18 X 1 Hex Head Cap 2 151743

L Guide Bar
L1 Bar, 3/4 X 32 Guide, 101 1 134759
L2 Screw, 5/16-18 X 1 Hex Head Cap 2 151743
L3 Washer, 5/16 Split Lock 2 151747
L4 Washer, 5/16 SAE Flat 2 151754

M Assembly, Roller Wheel
M1 Bracket, Roller Wheel 1 154021
M2 Wheel, Roller 1 151799
M3 Screw, 1/4-20 X 1 1/2 Hex Head Cap 1 151914
M4 Washer, 1/4 SAE Flat 1 151915
M5 Nut, 1/4-20 Hex 1 151893

n/a

1 151756

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

EXPLODED VIEW AND PARTS LIST

PARTS LIST FOR JCS STAND (SHOWN IN PAGE 41):

Item Description Qty MK p/n

- Assembly, Portable Stand, MK100/101/770EXP 1 160705
1 Weldment, Integrated Frame 1 160690
2 Weldment, Rear Support 1 160693
3 Weldment, Front Support 1 160700
4 Spring, Gas, 600N 2 160696
5 Fitting, End, Gas Spring 4 160695
6 Washer, 5/16 SAE 10 151754
7 Nut, Hex, Nylok, 5/16-18 5 158289
8 Screw, Hex, 5/16-18x2 3 155494
9 Screw, Shoulder, 5/16x3/4 4 160726

10 Nut, Hex, Nylok, 1/4-20 4 159857
11 Spacer, 1/2x5/16x1-1/8 2 160732
12 Washer, 3/8 SAE 8 150923
13 Wheel, 8x2-1/4 2 155986
14 Spacer, 3/4x3/8x2-1/4 2 160728
15 Nut, Hex, Nylok, 3/8-16 4 152505
16 Screw, Hex Hd, 3/8-16x4 2 153531
17 Plug, Plastic, 1 SQ., 10-14 Ga 6 160727-2
18 Plug, Plastic, 1 SQ., 14-20 Ga 1 160727-1
19 Caster, Swivel, 3” w/ 3/8-16 Stem 2 160735
20 Bumper, Rubber 2 159855
21 Rivet, Dome Style, 3/16 Dia x.251-.375 Grip 2 160729-3
22 Screw, Hex Hd, 5/16-18x2-3/4 2 152520
23 Weldment, Vertical Support 1 160934
24 Plate, Spring 1 160694
25 Rivet, Dome Style, 5/32 Dia x.063-.125 Grip 4 161226-1
26 Pin, Locking 1 160936
27 Spring, 1/2x.04x1.75 1 160697
28 Ring, Retaining, 3/8x.035 1 161171
29 Knob, Plastic 1 159428-1
30 Pin, Frame Locking 1 162055
31 Pin, Wheel Locking 1 162051
32 Ring, Retaining, 1/2x.042 1 162053
33 Spring, .600x.045x2.25 1 162052
34 Cap, Vinyl, 1/2-9/16x3/4 3 162057

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

THEORY

THEORY OF DIAMOND BLADES:

Diamond blades do not really cut; they grind the material through friction. Diamond crystals, often visible at
the leading edge and sides of the rim/segment, remove material by scratching out particles of hard, dense
materials, or by knocking out larger particles of loosely bonded abrasive material. This process eventually
cracks or fractures the diamond particle, breaking it down into smaller pieces. As a result, a diamond blade
for cutting soft, abrasive material must have a hard metal matrix composition to resist this erosion long
enough for the exposed diamonds to be properly utilized. Conversely, a blade for cutting a hard, non­abrasive material must have a soft bond to ensure that it will erode and expose the diamonds embedded in
the matrix. These simple principles are the foundation of “controlled bond erosion”.

Types of Cutting:
There are two basic types of cutting-Dry or Wet. The choice of which type of blade to use depends on:

• The requirements of the job

• The machine/tool utilizing the diamond blade

• The preference of the operator

In the case of DRY cutting, the overwhelming popularity and quantity of hand-held saws and the flexible
nature of MK Diamond blades to professionally handle most ceramic, masonry, stone and concrete materials,
make the DRY cutting blade a very attractive tool. When using a DRY blade, the user must be aware of
distinct operating practices to ensure optimum performance. DRY cutting blades require sufficient airflow
about the blade to prevent overheating of the steel core. This is best accomplished by shallow, intermittent
cuts of the material with periods of “free-spinning” (for several seconds) between each cut, to maximize t he
cooling process.

For WET cutting applications, MK has the exact blade to compliment both the material to be cut and the wet
cutting machine to be used. During cutting operations, liberal amounts of water act as a coolant to support
the cutting effectiveness and longevity of the WET blade. Additionally, using water adds to the overall safety
of cutting operations by keeping the dust signature down.

Know All You Can About the Material You Wish to Cut

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 46

ACCESSORIES

ACCESSORIES:

ITEM NUMBER DESCRIPTION

1.
137166

2.
128074

3.
153252

4.
134577

5. 134585
(small)
or
153201
(large)

6.
134569

7.
152792

8.
152610

9.
151889

MK-200, 10 x 5/8 Arbor

MK-215, 10 x 5/8 Arbor

MK-315, 10 x 5/8 Arbor

Dual 45° Flat Angle Guide

45° Bullnose Miter

90° Protractor

Dressing Stone

Ground Fault Circuit Interrupter

Universal Stand

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005 Page 47

ORDERING and RETURN INFORMATION

ORDERING INFORMATION:

You may order MK Diamond products through your local MK Diamond distributor or, you may order direct
from MK Diamond.

NOTE: There is a $25.00 minimum order when ordering direct from MK Diamond. All purchases must be
made using VISA or MasterCard.

When ordering direct from MK Diamond, please have the following information ready before calling:

• The Model Number of the saw

• The Serial Number of the saw

• Where the saw was purchased and when

• The Part Number for the part(s) being ordered

• The Part Description for the part(s) being ordered

All parts may be ordered by calling toll free to – 800 421-5830 or 310 539-5221 and asking for Custome r
Service. For technical questions, call – 800 474-5594.

RETURN MATERIALS POLICY:

To expedite the service relative to the return of a product purchased through MK Diamond, please observe
the following:

NOTE: When returning all items, they must have been purchased within the previous twelve (12) months.

• Have the Model Number of the saw

• Have the Serial Number of the saw

• Have the location of where the saw was purchased

• Have the date when the saw was purchased

• Contact Customer Service for approval to return the item(s)

• Obtain a Returned Goods Number (RGA) authorizing the return

• Follow the packaging instructions in the following section

• Ensure your item(s) are prepaid to the destination

For returned items, call toll free to – 800 421-5830 or 310 539-5221 and ask for Customer Service. For
technical questions, call – 800 474-5594 or 310 257-2845.

PACKAGING INSTRUCTIONS:

• Remove the Blade guard and Support Angle Assembly

• Dry the saw before shipping

• When packing, include the following: MK-100, Diamond Blade, Blade guard and Support Angle Assembly

and Adjustable Cutting Guide (Other Accessories are not required)

• Package the unit in its original container or one of comparable size (do not ship the unit partially exposed)

• Ensure all parts are secured in the packaging to prevent moving

AUTHORIZED SERVICE CENTERS:

For quicker repair time, you may contact MK Diamond Customer Service, toll free, at – 800 421-5830 or 310
539-5221 for the Authorized Service Center closest too you. For technical questions, call – 800 474-5594.

MK-100 JCS Tile Saw Revision 06/05, Effective Date June 27, 2005

p

MK-100 SERIES

TILE SAW
OWNER’S MANUAL &
OPERATING INSTRUCTIONS

CALIFORNIA PROPOSITION 65 MESSAGE:

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

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

MK DIAMOND PRODUCTS, INC
1315 STORM PARKWAY, TORRANCE, CA 90509-2803
310 539 5158

ecially designed to filter out microscopic particles.

s