MK Diamond MK-100 User Manual

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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