MK Diamond MK-101 User Manual

quip

MK-101 Home Depot Rental
w/JCS Stand

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.

SAFETY

We at MK Diamond want to congratulate you on selecting the MK-101 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-101 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-101 safely
and correctly. Please take a few minutes to familiarize yourself with the MK-101 by reading and reviewing this manual.

If you should have questions concerning your MK-101, please feel free to call our friendly customer service department
at: 800 421-5830

Regards,
MK Diamond

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 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
JCS STAND: Key components for Set Up 12
JCS Stand – Set Up for Operation 13
JCS Stand – Take Down Instructions 14
Table Locking Instructions 15

Assembly 16
SETUP, ADJUSTMENT AND OPERATION

Setup 18
Adjustment and Operation 21
Cleanup 27

MAINTENANCE AND TROUBLESHOOTING

Maintenance 29
Troubleshooting 36

EXPLODED VIEW AND PARTS LIST

Exploded View 40
Parts List 44

THEORY

Theory of Diamond Saws 47

ACCESSORIES

Accessories 48

ORDERING and RETURN INSTRUCTIONS

Ordering Information 49
Return Material Policy 49
Packaging Instructions 49
Authorized Service Centers 49

Manual Part No. 162059 Revision No. 04/05

4

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 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 re sult 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-101 Home Depot Rental Revision 04/05, Effective Date April 21, 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 8 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 instructions 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 switch is in the OFF position before plugging in the saw.

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 finish ed.

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 5

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

Make sure the switch is in the OFF position before plugging in the saw.

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

• 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-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 6

SAFETY

ELECTRICAL REQUIREMENTS AND GROUNDING INSTRUCTIONS:

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

In case of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce
the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor
and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in
accordance with all local codes and ordinances.

• Do not modify the plug provided – if it will not fit the outlet; have the proper outlet installed by a qualified
electrician

• Improper connections of the equipment-grounding conductor can result in a risk of electric shock. The
equipment-grounding conductor is the insulated conductor that has an outer surface that is green, with or
without yellow stripes. If repair or replacement of the electric cord or plug is necessary, do not connect the
equipment-grounding conductor to a live terminal

• Check with a qualified electrician or service personnel if the grounding instructions are not completely
understood, or if in doubt as to whether the tool is properly grounded

• Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the
tool's plug

• Repair or replace a damaged or worn cord immediately

This tool is intended for use on a circuit that has an outlet that looks like the one shown in Sketch A of
Figure 1. The tool has a grounding plug that looks like the plug illustrated in Sketch A of Figure 1. A
temporary adapter, which looks like the adapter illustrated in sketches B and C,

may be used to connect this plug to a 2-pole receptacle as shown in
Sketch B, if a properly grounded outlet is not available. The temporary
adapter should be used only until a properly grounded outlet can be
installed by a qualified electrician. The green-colored rigid ear, lug,
and the like, extending from the adapter, must be connected to a
permanent ground such as a properly grounded outlet box.

NOTE: Use of a temporary adapter is not permitted in Canada.

Grounding

Pin

Metal Screw

Cover of Grounded

Outlet Box

Grounding

Pin

(B)

(D)

ADAPTER

Grounding

Means

(C)

(A)

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 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.

The pump requires a GFCI. To reduce risk of electric shock when operating the saw with the pump
plugged into the 3-pole receptacle on the motor, connect the saw to a GFCI outlet. See the pump manual
and informational tags enclosed separately for all pump information.

Shock Hazard. For replacement, use only an identical MK pump, model PE1 part #151271.

NOTE: Do not run the pump dry. Also, be sure to disconnect and remove the pump when cutting dry.

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

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d

SAFETY

When using the water pump plugged into the water pump receptacle, the saw must be plugged into a properly installed
and grounded GFCI outlet See Sketch A of Figure 2. If a GFCI outlet is not available, MK Diamond has available as an
accessory item, a plug-in GFCI that may be plugged into a properly installed and grounded 3-pole outlet. See Sketch A
of Figure 2.

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,"

A

FIGURE 2

B

shown in Figure 3, should be arranged by the user to properly position the power cord relative to the power
source.

Power

Cor

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

Drip Loop

or circuit breaker that supplies power to the tool. Then unplug and examine for
presence of water in the receptacle.

FIGURE 3

Use only extensions cords that are intended for outdoor use. These extension cords are identified by a
marking "Acceptable for use with outdo o r appl i a nce s ; store indoors while not in use." Use only extension
cords having an electrical rating not less than the rating of the product. Do not use damaged extension
cords. Examine extension cords before using and replace if damaged. Do not abuse extension cords and
do not yank on any cord to disconnect. Keep cords away from heat and sharp edges. Always disconnect
the extension cord from the receptacle before disconnection the product form the extension cord.

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 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

LOCK OUT METHOD:

In order to help prevent accidental starting and to help make your workshop “Kidproof,”
this saw is provided with a means to deactivate the functioning of the motor switch. The
switch is equipped with a Lockout plate that can be used with a lock to preven t the
movement of the toggle switch. With the toggle switch unable to move the motor cannot
be turned on. Removing the lock reactivates the switch.

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 8

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 considered a permanent part of your saw. If
a label comes off or becomes hard to read, contact MK Diamond or your dealer for a replacement

Item Location Description Part No.

1. Motor Side Warning Read and Follow Operating Instructions 155806

1B. Motor Front Label, Caution, GFCI, 1 X 2 1/8 155678

2. Blade Side Saw Serial Number Specifications 157500
3A Motor Rear Extension Cord Warnings 155038
3B Motor Rear Label, Caution, 5 Amp Max., 1 X 2-1/8 154822
3C Motor Rear Motor Specifications N/A
4A Pump Left Side Warning Connect to Grounded Receptacle N/A
4B Pump Right Side Pump Specifications N/A

A

A

1

B

3

C

B

2

A

4

B

B

TILE SAW SPECIFIC WARNINGS:

Wear eye protection.
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-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 9

SAFETY

PRODUCT SPECIFICATIONS:

The MK-101 is a versatile Tile Saw. Operated and used according to this manual, the MK-101 will provide
years of dependable service.

General Description:
The MK-101 Tile Saw is engineered as a tabletop or stand mounted wet tile saw. The saw includes a powerful 115v
totally enclosed capacitor start Baldor motor with a thermal protective overload. The saw is capable 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 one­half (3-1/2) inches thick in one pass.

Motor Specifications:
Motor specifications for the MK-101 are listed in Table 2 below.

Voltage 115 v
Overall Amperage 13 a
Motor Only Amperage 12.4 a
Frequency 60 Hz
RPM 3450 rpm
Horse Power 1.5 hp
Weight 128 lbs

Table 2

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

Blade Capacity:
The MK-101 uses a ten (10) inch (254mm) diameter, wet cutting continuous rim, MK Diamond blade with a one­sixteenth 1/16 inch (1.5875 mm) cutting width and a five-eighths (5/8) inch (15.875 mm) arbor.

Tile Types:
The MK-101 can cut a variety of tile types including Porcelain, Terracotta, Marble, Quarry and Slate, or almost any
other non-ferrous material.

NOTE:
The MK-101 is not designed to cut plastic or ferrous (metals) material.

The following warnings are for the MK-101 w/JCS Stand

Read and understand all instructions

Maximum material load 35 lbs. (15.9kg)
Place unit on a hard level surface.
DO NOT use as ladder or scaffolding.
Always use with Safety Arm in place (see SET UP section on pg. 12)

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 10

UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY

UNPACKING:

Your MK-101 has been shipped from the factory thoroughly inspected. Only minimal assembly is required.

Use proper lifting techniques when lifting the MK-101.

CONTENTS:

In your container, you will find one (1) MK-101 frame and water basin, one (1) MK-101 Cutting, one (1) 10­inch wet cutting continuous rim diamond blade, one (1) adjustable cutting guide, one (1) bull nose 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 Cli p, one (1) splash guard, one (1)
owners manual, one (1) pump manual and one (1) warranty card.

MK-101 w JCS Stand

& Water Basin

MK-101

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.

Lift the saw using the handle.
Follow instructions on page 12.

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

Wheels

Casters

Cutting Head

Handle

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005 Page 11

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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

Wheel Lock

Blue Knob

Green Knob

Cutting Head

Handle

Front Legs

Cross

Membe

Table Clip

Air Springs

Safety Arm

Front Legs

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 12

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.

Pull, turn & release Pin to lock

Place left foot on left wheel, left

hand on Handle and right hand on

(A)

Wheel

(D)

Front Legs

Pull Blue Knob and pull Front Legs

Tilt Saw forward and rest Front

(B)

out slowly

(E)

Legs on ground

Place foot on Cross Bar and lift saw up

vertically from Cutting Head Handle

Ensure that Safety Arm rests on

(G)

(J)

Rod

(H)

Push down lightly on Cutting Head

Handle to ensure saw is fully supported

Table Clip

(K)

Rotate Table Clip to unlock the

Table

(C)

Pull legs until they are locked by

Red Latch

Cutting Head

Handle

(F)

Move to rear end of Tile Saw

(I)

Pull Green Knob to release Safety

Arm

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 13

UNPACKING, TRANSPORT, JCS STAND and ASSEMBLY

JCS STAND - TAKE DOWN INSTRUCTIONS:

(A)

Rotate Clip to lock Table

(D)

Push down on Cutting Head Handle to

collapse the saw

(B)

Pull and hold Green Knob. Lift Safety

Arm until it hits bottom of Frame

(E)

Move to left side of saw and use

left hand on Handle and right hand

on Front Legs

(C)

Release Green Knob to secure

Safety Arm

(F)

Tilt Saw backwards to upright

position

(G)

Hold up Front Legs and flip Red Latch

to unlock Front Legs

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Push Front Legs against frame and

lock with Blue Knob and

your saw is ready for transport.

(H)

Page 14

UNPACKING, TRANSPORT, JCS STAND and ASSEMBLY

TABLE CLIP:

(A)

Slide table to the front

(B)

Line up Clip with Side Table Slot

(E)

The clip secures

Table in place

(C)

Swing clip over

side of the Table

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Page 15

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UNPACKING, TRANSPORT, JCS STAND and ASSEMBLY

ASSEMBLY:

Follow the assembly instructions to prepare your MK-101 for operation.

1. Cutting Head Installation:

Rear Pivot

Hole

Locate Rear Pivot Hole

(A)

on Cutting Head

(B)

Align and insert cutting head onto

pivot pin

Install the Adjusting Knob

(C)

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

(A)

(D)

onto Blade Shaft

Tighten

Wing-nut

Movable

Cutting Table

Blade

Shaf

Cutting

Head

Shaft Lock
Pushbutton

(B)

Locate the Shaft Lock pu shbutton

on the underside

of the Cutting Head

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

Rotation Direction

(E)
Verify the Blade is seated on
the Blade Shaft and direction

of rotation is correct

Rotate Blade

Wrench clockwise

to tighten

(F)

Install Retaining Nut and Outer

Flange, depress and hold the

Shaft Lock pushbutton

and Tighten

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 16

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

(A)

Turn clockwise

to tighten

Ruler/Stop

(B)

Place the Adjustable Cutting

Guide onto the Movable Cutting

Table Ruler/Stop and tighten

the retaining thumbscrew

Adjustable

Cutting Guide

Ruler/Stop

4. Splash Guard Installation:

Splash

Guard

Install the retaining thumbscrew

through the washer and Splash

Guard then align to the hole found on

back of the Blade Guard

Thumbscrew

(A)

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

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Page 17

SETUP, ADJUSTMENT and OPERATION

SETUP:

1. Pre-start Inspection:

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

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-101

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-101 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 Tran sfer

Tube to the inlet connection

of the Blade Guard

(A)

Inlet

connection

Pump

Connection

(B)

Connect the Water Pump power

cord to the connection found on the

back of the motor

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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

External

Containe

(B)

Place the Water Pump

In an external container

Cover Pump

Suction

(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 and Install the

Water Pump Clamp with two ¼-20

wing screws and nuts.

Cover Pump

Suction

(C)

Fill the Water Basin until water

completely covers the

Water Pump suction

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 19

SETUP, ADJUSTMENT and OPERATION

4 MK-101 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-101 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, made sure, the length and wire gauge correspond to the 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)

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

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

Portable Generator:
If using a portable generator, ensure the generator meets the following minimum requirements:

5 KW 120/240 volts 41.7/20.8 amps Single Phase

ON/OFF

Switch

Ensure the ON/OFF Switch

is in the OFF position

(A)

Off

Position

GFCI

(B)

Plug MK-101 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

* A GFCI wall socket is the preferred protective device.

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

Turn Clockwise

to tighten

Ensure the Adjusting Knob

(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)

is tight

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SETUP, ADJUSTMENT and OPERATION

ADJUSTMENT and OPERATION:

1. Cutting Straight Edges:

Turn Counter-

clockwise to loosen

Loosen the Adjustable Cutting

Guide retaining thumbscrew

Ruler/Stop and Cutting Guide

Hold Work

in Position

Direction

of Cu

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

Desired Cut length

indicated here

(A)

Position the Adjustable Cutting

Guide to desired cut length

(B)

Tighten the retaining

thumbscrew

indicated inside the diamond

Adjustable

Cutting Guide

Ruler/Stop

(D)

Place the tile against the

ON/OFF

Switch

Turn the motor ON

On

Position

Cooling Flow

Points

(E)

Verify proper cooling flow on

both sides of the blade (See

Maintenance Section to
increase/decrease flow)

(G)

Perform the cut

ON/OFF

Switch

(H)

Turn the motor OFF when

Off

Position

work is complete

Turn Clockwise

to tighten

(C)

(F)

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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 Ruler/Stop.

Position the tile against the Dual

45º Flat Angle Guide and the

Hold Work

in Position

Direction

of Cu

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

Turn counter-

(A)

Guide

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

Position the Dual 45º Flat Angle

Guide and tighten the
retaining thumbscrew

(D)

45º Flat Angle

Guide

Ruler/Stop

ON/OFF

Switch

(E)

Turn the motor ON

On

Position

Cooling Flow

Points

Verify proper cooling flow on

both sides of the blade (See

Ruler/Stop

Maintenance Section to
increase/decrease flow)

(G)

Perform the cut

ON/OFF

Switch

(H)

Turn the motor OFF when

Off

Position

work is complete

Turn Clockwise

to tighten

(C)

(F)

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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

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.

Turn counter-

(A)

Guide

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

Position the 45º Bullnose Miter

Guide and tighten the
retaining thumbscrew

(D)

Miter Guide and the

Ruler/Stop

ON/OFF

Switch

(E)

Turn the motor ON

On

Position

Cooling Flow

Points

Verify proper cooling flow on

both sides of the blade (See

Maintenance Section to
increase/decrease flow)

(G)

Perform the cut

Direction

of Cu

ON/OFF

Switch

(H)

Turn the motor OFF when

work is complete

Off

Position

Turn Clockwise

to tighten

(C)

(F)

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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) 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)

Remove the Adjustable Cutting

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 Cu

(G)

Perform the cut

Turn Clockwise

to tighten

Set Angle

(C)

Set the desired angle and tighten the

thumbscrew

ON/OFF

Switch

On

Position

(E)

Turn the motor ON

ON/OFF

Switch

Off

Position

(H)

Turn the motor OFF when

work is complete

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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

* A GFCI wall socket is the preferred protective device.

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

Position

(A)

is in the OFF position

Off

Unplug

(B)

Unplug the GFCI from the

power source*

Turn Counter-

clockwise to loosen

Remove Adjusting Knob

Turn Clockwise

to tighten

Front Pivot

Hole

(D)

The rear pivot hole

(G)

Install the Cutting Head onto

the front pivot hole

(E)

Install the Adjusting Knob

GFCI Plugged

Into Power

Source

(H)

Plug the GFCI into the

power source*

(C)

(F)

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SETUP, ADJUSTMENT and OPERATION

6. Adjusting the Post for Maximum Cutting Length:

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

ack in the Saw

* A GFCI wall socket is the preferred protective device.

The Cutting Head and Post are heavy! Use care when changing the position of the Cutting Head.

Off

Position

Unplug

(A)

Unplug the GFCI from the

is in the OFF position

(B)

Remove Water Basin

power source*

Hold the Post when removing the Post Support Plate.

(D)

(G)

Post retaining holes

(J)

Install the Water Basin

Rear

Holes

Turn counter-

clockwise to loosen

9/16-inch

Wrench

(E)

Loosen the Post Support Plate

and retaining bolts

Turn Clockwise

to tighten

9/16-inch

Wrench

(H)

Install and tighten the Post

Support Plate and retaining bolts

GFCI Plugged

Into Power

Source

(K)

Plug the GFCI into the

Post Support

Plate

Remove the Post Support Plate

and retaining bolts

Cutting

Head

Install the Cutting Head (See

Adjusting the Cutting Head

power source*

Slide Water Basin out

of the front of the Saw

(C)

(F)

(I)

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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-101 with

* A GFCI wall socket is the preferred protective device.

soap and clean water

(D)

(G)

Off

Position

Soap and

Fresh Wate

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

of the front of the Saw

(H)

Remove the Water Basin

from the MK-101

Cooling Flow

Points

(C)

Run the MK-101 until clear

water is seen at the blade

cooling ports (Approx. 1 minute)

GFCI

(F)

Unplug MK-101 from the GFCI

Clean Water

Basin

(I)

Clean the Water Basin

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SETUP, ADJUSTMENT and OPERATION

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

Clean the Movable Cutting

(J)

Table Guide Bar

Clean

Guide Ba

Roller Wheel

Frame Support

(K)

Clean the Movable Cutting

Table Roller Wheel Frame

Support

(L)

Clean the remainder of the

MK-101

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MAINTENANCE AND TROUBLESHOOTING

MAINTENANCE:

1. New Maintenance:

Perform the following after initial purchase and operation of the MK-101.

Check and adjust V-belt

tension Following 1

operation (See V-belt Inspection)

(A)

Inspect

V-

st

48 hours of

2. Maintenance Following Use:

To extend the life of the MK-101, 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

* A GFCI wall socket is the preferred protective device.

is in the OFF position

Lubricate the Roller

(A)

(A)

Wheel Assembly

Off

Position

Roller Wheel

Assembly

(B)

Unplug MK-101*

GFCI

Guide Ba

(C)

Lubricate the Guide Bar

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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)

(D)

good condition

Turn Counter-

clockwise to remove

(G)

Retaining

Screw and

Outer Flange

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 Shaf

(H)

Lubricate the Blade Guard

Pivot Shaft

(C)

Lubricate the Inner Flange

(F)

Verify the Motor Adjustment

Strap is tight

Inner

Flange

Verify Bolt

Tight

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MAINTENANCE AND TROUBLESHOOTING

Cutting

Head

Remove the Cutting Head (See

Adjusting the Cutting Head)

Lubricate the Cutting Head

(I)

(L)

Pivot Shaft

Pivot
Shaf

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 Clamp

(D)

Pull Tab
to loosen

Press Tab

to Restrict

Flow

(E)

Reduce cooling flow by

Pressing down on the Flow

Adjusting Clamp

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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

O

Setup the MK101 for operation

(See Setup, Adjustment

ON/OFF

Switch

ON/OFF

Switch

Ensure the ON/OFF Switch

is in the OFF position

(A)

and Operation)

(D)

Turn the motor ON

(G)

eration

On

Position

Off

Position

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)

Adjustable

Cutting Guide

Ruler/Stop

(C)

Position the Dressing Stick

Hold Work

in Position

Direction

of Cu

(F)

Cut the Dressing Stick 7 or 8

times to dress the Blade

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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 pu shbutton

of the Cutting Head

Diamond

Blade

Install the Diamond Blade

(A)

on the underside

(D)

onto Blade Shaft

Shaft Lock

Pushbutton

Blade

Shaf

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

(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

3. Cutting Head Stop Installation:

Remove the Cutting Head

(See Adjusting the Cutting Head)

Reinstall the Cutting Head

(A)

(D)

Rear

Pivot Hole

(B)

Install Head Stop UP, when the

Cutting Head is installed on the rear

Pivot Hole

(See Adjusting the Cutting Head)

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Blade

Stop Up

Blade

Stop Down

Front

Pivot Hole

(C)

Install Head Stop DOWN, when the

Cutting Head is installed on the

forward Pivot Hole

Page 33

belt

f

MAINTENANCE AND TROUBLESHOOTING

4. V-Belt Inspection, Adjustment and Replacement:

The MK-101 is designed with a power transmission V-belt. In order to ensure the MK-101 operates at pea k
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 (48) hours

ON/OFF

Switch

Ensure the ON/OFF Switch

Cutting

Head

Remove the Cutting Head (See

Adjusting the Cutting Head

Check the belt for proper tension

if tension is correct, go to step R

(proper tension 1/8-inch)

* A GFCI wall socket is the preferred protective device.

of operation.

Position

(A)

is in the OFF position

(D)

Check Tension

1/2-way

between pulleys

(G)

Off

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 the motor mounting bolts, i

re-tensioning only go

to step N

Diamond

Blade

(C)

Remove the Diamond Blade

(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

(I)

Loosen the Motor Adjustment

Strap

Inspect

V-

Adjustment

Strap Bolt

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MAINTENANCE AND TROUBLESHOOTING

Direction of push

Push the motor toward the

front of the Cutting Head to

Belt Seated

Verify the V-belt is seated in the

grooves of both pulleys

Continue Adjustment

Until Correc

Repeat steps N and O until

proper V-belt tension

(J)

loosen the V-belt

Pulley

(M)

(P)

is achieved

Old V-bel

(K)

Remove the V-belt

9/16-inch

Wrench

Rotate clockwise

to tighten

(N)

Tighten the Motor Adjustment

Strap to remove slack

Retaining

Rotate clockwise

to tighten

(Q)

Tighten the motor

mounting bolts

Bolts

1/2-inch

Wrench

ew V-belt

(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

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MAINTENANCE AND TROUBLESHOOTING

TROUBLESHOOTING:

1. 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

if needed)

to verify blade

the material being used

If not “Glazed”,

go to Step B

(A)

If Blade Correct,

go to Step E

(D)

Check for proper blade 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

2. Movable Cutting Table Does Not Move Correctly:

Clean Guide Bar

and Frame if dirty

Check the Guide Bar and

Frame for cleanliness –

(A)

clean if dirty

If clean,

go to Step B

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

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MAINTENANCE AND TROUBLESHOOTING

3. Cooling Flow:

If flow exists,

go to Step A

Verify the cooling flow

Adjusting Clamp is open

Pull to

Remove

If flow exist,

go to Step E

Remove the Cooling Transfer

Tube and check for flow

Phillips

Screwdrive

Remove the 3 Pump Casing

(A)

(D)

Once Screws

removed, go

(G)

Retaining Screws

Pull Tab
to loosen

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 for flow

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 in the casing. Check

the 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 –

clean the screen if necessary

Intake Fitting

Turn counter-

Clockwise

to loosen

Go to
Step J

(I)

Remove the Blade Guard

Intake Fitting

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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

Channels

If cooling channels
clear, go to Step L

(K)

Rod the Cooling Channels

and then recheck flow

Return to

MK Diamond

for Repair

(L)

Return to MK Diamond

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MAINTENANCE AND TROUBLESHOOTING

°

4. Blade Stops Turning:

Allow the motor to cool and

depress motor Overload

Check Breaker

20 Amps

or greater

Verify the circuit breaker is at least

20 amps – if not, move to

Return to MK Diamond

* A GFCI wall socket is the preferred protective device.

(A)

Reset Switch

(D)

a 20-amp 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 is 20

Amps or greater,

go to Step E

(G)

Verify all plugs

are connected

If all plugs are connected,

go to Step C

(B)

Verify all plugs are fully

installed*

If tripped, reset

once, if it trips again,

go to step F

If circuit breaker

Check Breaker

tripped

not tripped,

go to Step F

(E)

Verify circuit breaker is not tripped,

if it is tripped – reset the

circuit breaker once

Reset once

if tripped

If not tripped, or

If a re-trip occurs,

go to Step D

(C)

Check to see if the Ground

Fault Circuit Interrupter (GFCI)

is tripped*

Check for

correct circuit

voltage

If circuit breaker

is not tripped,

go to Step F

(F)

Check power source voltage is

115V, if it is not 115v –

move to another circuit

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 39

EXPLODED VIEW AND PARTS LIST

EXPLODED VIEW:

See Page 42 for

Sub-Assemblies F-J

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EXPLODED VIEW AND PARTS LIST

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 41

EXPLODED VIEW AND PARTS LIST

See Page 43 for

Sub-Assemblies “H” and “J”

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 42

EXPLODED VIEW AND PARTS LIST

Sub-Assembly “H”

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Sub-Assembly “J”

Page 43

EXPLODED VIEW AND PARTS LIST

PARTS LIST FOR THE MK-101 JCS HOME DEPOT RENTAL:

Item Description Qty Part #

A Accessories - -

A1 Carton, Accessory Pack, 101 1 153366
A2 Foam, Accessory Pack Carton 1 154022
A3 Wrench, 15/16 Closed End 1 134684
A4
A6
A7
A8

A9
A10
A11
A12 Rip Guide, Large Die Cast

A13 Miter, Large Bullnose

A14 Guide, Dual Flat 45

A15 Protractor, Tile Saw

A16 Dressing Stick, 8 X 2 X 1, 60 Grit 1 152792-RW
A18 Cord , Twist-Lock GFCI, 120V/15A

A19 Owner’s Manual, MK101 Home Depot Rental Portable Tile Saw 1 161289
A20 Card, Rental Saw Warranty Registration 1 155037
A21 Label, Do Not Return 1 157063
A22 Sell Sheet, Tile Accessory 1 156915
A23 Blade, MK-225, 10X050X5/8, 4mm Saws 1 160593
A24 Tag, Serial Number, Blank 1 157500
A25 Cord, L5-15x25’ Extension 1 158111
A26 Clip, Table Lock, 30 deg 1 160331-1
A27 Drain Plug, HD Rental 1 159529
A28 Strap, 9” Drain Plug 1 159530
A29 Pan, Plastic, 101 1 150634
A30 Clamp, Holding, Pump 1 162054
A31 Screw, Wing, 1/4-20x1/2 2 151888
A32 Nut, Hex, 1/4-20 2 151893
A33 Sheet, Set Up Instructions 1 162082

C Frames - -

C1 Assy, Port abl e Stand 1 160705

D Posts - -

D1 Post, DC, 101, Orange 1 158438-OR

D2 Shaft, 10.63” Pivot, 101 1 153254

D3 Screw, Set, 3/8-16 X 1/2 1 153710

D4 Spacer, 5/8x.385x1.4 2 160654

D5 Screw, Hex Head, 3/8-16 X 2 1/4 2 153529

D6 Washer, 3/8 Split Lock 2 150925

D7 Knob, 3/8-16 X 1.5 MK Adjustment 1 156770-02

D8 Washer, 3/8 SAE Flat 3 150923

D9 Plastic Post Cover 1 160157

E Stop, Cutting Head - -

Guard, Splash
Wingscrew, 1/4-20 X 1/2
Washer, 1/4 SAE Flat
Pump, Water, G-150A
Fitting, Plastic, 1/4 FNPT X 1/4 BARB
Hose, Vinyl, 1/4 ID
Clamp, Flow, 1/4-1/2

a) Knob, Rubber, 3/4" long

Knob, Rubber, 3/4" long

Knob, Rubber, 3/4" long

Knob, Rubber, 3/4" long
Washer, Flat Sae

Cord, 5-15 X 6’ GFCI, 120V15A
Connector, L5-15R, 125V/15A

- Kit, Stop, 10” Cutting Head 1 157728-MK

1
1
1
1
1

6’

1
1
1
1
2
1
1
1
2
1

1
1
1

160310
151888
151915
151271
128397
132951
154394
159751

159428-1

153201

159428-1

134577

159428-1

159429

159428-1

151915

157421
157779
157422

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005 Page 44

EXPLODED VIEW AND PARTS LIST

E1 Stop, 10” Cutting Head 1 157728

E2 Screw, Hex Head, 1/4-20 X 1 1/4 1 157145

E3 Washer, 1/4 Split Lock 1 152591

E4 Sheet, Cutting Head Stop Instruction 1 157728-IS

F-J Assembly, DC Cutting Head, PL-101R, Home Depot, Orange 1 158478-HD

F Belt Guards - -

F1 Belt Guard, MK-101, Orange

Insert, 3/8-16 AVK
F2 Bracket, Inner Belt Guard, 100/101 1 158611
F3 Screw, Hex Head, 1/4-20 x 3/4 3 152 37 0
F4 Screw, Hex Head, 1/4-20 x 1 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, MK-101R, Orange 1 155513

G1 Blade Guard, MK-101Rental, Orange 1 155303
G2 Tube, Water 2 155389
G3 Screw, Set, 5/16-18 X 1/2 3 152607
G4

H Motors - -

H1 Moto r, 1-1/2HP\120v\60Hz, for 30A switchbox, with L5-15P 1 159627-TL
H2 Pulley, 6J17 X 5/8 Bor e 1 158214
H3 Key, 3/16 x 3/16 x 1-1/8 Square 1 150344
H4 Screw, Set, 5/16-18 X 3/8 2 157083
H5 Label, Warning most motor... 2 3/4 X 2 7/16 1 155672
H6 Label, Caution, GFCI, 1 X 2 1/8 1 155678
H7 Label, Caution, 5 Amp Max., 1 X 2-1/8 1 154822
H8 Label, Warning, Read Owner’s Manual, 1-3/4 X 3-3/8 1 155806
H9 Label, MK Service Info., 2 1/8 X 1-13/16 1 155 03 8

H10 Label, HD Checklist 1 155231
H11 Box, Top Entry, 30A Switch 1 159487
H12 Cover, 30A Switch Box 1 159539
H13 Lever, Actuator, 30A Switch Box 1 159540
H14 Plate, Mounting, 30A Switch 2 159489
H15 Lever, On/Off, 30A Switch Box 1 159490
H16 Bushing, Nylon, 30A Switch Box 1 158799
H17 Seal, Urethane, 30A Switch Box 1 159492
H18 Gasket, 30A Switch Box 1 159491
H19 Switch, 30A/2HP/120V/DPST 1 159488
H20 Connector, LTF11 Cord 1 159582
H21 Screw, 6-32 X 5/16 Flat Head Phillips Machine 6 159493
H22 Screw, 10-24 X 1/4 Pan Head Phillips Machine 1 159494
H23 Screw, 6-32 X 5/8 Pan Head Phillips Machine 4 157393
H24 Screw, 10-24 X 5/16 Slotted Hex Washer Head Grounding 1 159597
H25 Washer, #10 SAE Flat 1 154369
H26 Washer, #10 Lock, Internal Teeth 2 158336
H27 Terminal, 16-14 X #10 Ring, Non-insulated 1 154540
H28 Label, Home Depot Tool Rental 1 160602

J Assembly, Cutting Head 1 158191-OR

J1 Cutt i ng Head, DC, 101, Orange 1 158224-OR
J2 Pin, Blade Shaft Lock 1 158200
J3 Spring, Blade Guard Lock 1 158201
J4 E-Ring, 1/4 Retaining 1 158202

Elbow, 1/8 MNPT X 1/4 BARB 90° Brass

- Assembly, Motor, 1-1/2HP\120v\60Hz\L5-15P\30A SBox 1 159709-TL

1
2

1 154652

158319-OR

158193

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 45

EXPLODED VIEW AND PARTS LIST

J5 Bearing, 17mm X 40mm X 12mm Ball (6203-2NSE) 2 137711
J6 Shaft, Blade 100/101 1 158222
J7 Flange, 2-3/8 Inner 1 137737
J8 Flange , 2- 3/ 8 Out er 1 135830

J9 Nut, 5/8-18 Hex 1 135848
J10 Pulley, 6J19 X 5/8 Bore 1 158199
J11 Key, 3/16 x 3/16 x 1 1/8 Square 1 150344
J12 Screw, 5/16-18 X 3/8 Socket Head Set, Cup Point 2 157083
J13 Bumper, 1/2 Dia Rubber 1 152674
J14 Screw, 5/16-18 X 1 Hex Head Ca p 4 151743
J15 Washer, 5/16 SAE Flat 4 151754
J16 Washer, 5/16 Split Lock 4 151747
J17 Nut, 5/16-18 Hex 4 101196
J18 Screw, 5/16-18 x 2 1/2 He x H ead Cap, Full Thread 1 151748
J19 Pivot, Blade Guard 1 153208
J20 Washer, 3/8 SAE Flat 2 150923
J21 Wingnut, 5/16-18 Nylock 1 151746
J22 Strap, Motor Adjustment 1 152673
J23 Screw, 3/8-16 X 3 1/2 He x H ead F ull T hread 1 153147

K-M Assembly, DC Table, MK-101 1 158477

K Guide Bars - -

K1 Bar, 3/4 X 32 Guide, 101 1 134759
K2
K3 Spacer, Guide Bar Cover, 101 2 152393
K4 Screw, 5/16-18 X 1 Hex Head Cap 2 151743
K5 Washer, 5/16 Split Lock 2 151747
K6 Washer, 5/16 SAE Flat 2 151754

L Tables - -

L1 Table, 100/101 1 157660
L2 Washer, 5/16 SAE Flat 2 151754
L3 Washer, 5/16 Split Lock 2 151747
L4 Screw, 5/16-18 X 1 Hex Head Cap 2 151743

M Assembly, Roller Wheel 1 151756
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

Cover, Guide Bar, 120° X 35”

1 158403

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 46

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 Suppor t 1 160700
4 Spring, Gas, 600N 2 160696
5

Fitting, End, Gas Spring

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

4 160695

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 47

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, non-abrasive 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 the 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-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005 Page 48

ACCESSORIES

ACCESSORIES:

ITEM NUMBER DESCRIPTION

1.

137166

2.

128074

3.

153252

4.

134577

6.

134569

7.

152792

8.

152610

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

90° Protractor

Dressing Stone

Ground Fault Circuit Interrupter

MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005 Page 49

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 Customer 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 foll o wing:

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-101, 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-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005

Page 50

p

MK-101 Home Depot Rental
w/JCS Stand

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 chrom ium, 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 specially designed to filter out
microsco

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

ic particles.