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.
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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
Page 7
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
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
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
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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
MK-101 Home Depot Rental Revision 04/05, Effective Date April 21, 2005
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t
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
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Page 16