MK Diamond MK-1590 User Manual
www.mkdiamond.com
MK DIAMOND
TRACK RAIL SAW
OPERATION & PARTS MANUAL
03.2012Revision 302
Manual Part No. 166110
Caution: Read all safety and operating instructions
before using this equipment. This manual MUST
accompany the equipment at all times.
TRACK RAIL SAW INTRODUCTION
Congratulations on your purchase of a Track Rail Saw. We are certain that you will be pleased with
your purchase. MK Diamond takes pride in producing the nest construction power tools and diamond blades in the industry.
Operated correctly, your Track Rail Saw should provide you with years of service. In order to help
you, we have included this manual. This owners manual contains information necessary to operate
and maintain your Track Rail Saw safely and correctly. Please take the time to familiarize yourself
with the Track Rail Saw by reading and reviewing this manual.
Read and follow all safety, operating and maintenance instructions.
If you should have questions concerning your Track Rail Saw, please feel free to call our friendly customer service department at: 800 421-5830
Regards,
MK Diamond
NOTE THIS INFORMATION FOR FUTURE USE:
MODEL NUMBER:
SERIAL NUMBER:
PURCHASE PLACE:
PURCHASE DATE:
NOTE: For your (1) one year warranty to be effective, complete the warranty card
(including the Serial Number) and mail it in as soon as possible.
22
TRACK RAIL SAW TABLE OF CONTENTS
MK DIAMOND TRACK RAIL SAW
SAFETY
Safety Message/Alert Symbols
Safety Warnings
Hazard Symbols
Electric Motor Safety
Rules for Safe Operation
Operation & Safety Decals
PRODUCT SPECIFICATIONS
Specications
SET-UP
Rail Assembly
Rail Assembly Connector
Cutting Head Assembly
Material Clamps & Alignment
Hose Set-Up
OPERATION
Plunge Cutting for a 90º Cut
Plunge Cutting for a Miter Cut
PAGE NO.
4
5
6
7
8-9
10
11
12
13
14
15
16
17
18
MAINTENANCE
Blade Replacement
Filter Replacement
Roller Wheel Replacement
GENERAL PRODUCT INFORMATION
Parts List: Final Assembly
Parts List: Main Carrier Assembly
Parts List: Cutting Head Assembly
Parts List: Blade Guard Assembly
Parts List: Parallel Rail Support Bracket
Parts List: Rail Connector Plate
Parts List: Rail Saw Material Clamp
Ordering Information
Contact Information and Limited Warranty
19
20
21-23
24-25
26-27
28-29
30
31
32
33
34
35
3
TRACK RAIL SAW SAFETY
Safety precautions should be followed at all times when operating this equipment. Failure to read and
understand the Safety Precaution and Operating Instructions could result in injury to yourself and
others.
This Operation Manual has been developed to provide complete instructions for the safe and efcient
operation of the CX-3
®
Concrete Saw.
Before using this saw, ensure that the person operating the equipment has read and understands all
instructions in this manual.
SAFETY MESSAGE / ALERT SYMBOLS
A safety message alerts you to potential hazards that could hurt you or others. Each safety message is
preceded by a safety alert symbol ( ) and one of three words: DANGER, WARNING, or CAUTION.
DANGER
You WILL be KILLED or SERIOUSLY INJURED if you do not follow directions.
WARNING
You CAN be KILLED or SERIOUSLY INJURED if you do not follow directions.
CAUTION
You CAN be INJURED if you do not follow directions. It may also be used
to alert against unsafe practices.
Each message tells you what the hazard is, what can happen, and what you can do to avoid or
reduce injury. Other important messages are preceded by the word NOTICE.
NOTICE
You can cause PROPERTY DAMAGE to your machine if you don’t follow directions.
The safety labels should be periodically inspected and cleaned by the user to maintain good legibility
at a safe viewing distance. If the label is worn, damaged or illegible, it should be replaced. Contact
MK Diamond or your dealer for replacement.
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.
4
TRACK RAIL SAW SAFETY
SILICA DUST WARNING
Grinding/cutting/drilling of masonry, concrete, metal and other materials with silica in their composition
may give off dust or mists containing crystalline silica. Silica is a basic component of sand, quartz,
brick clay, granite and numerous other minerals and rocks. Repeated and/or substantial inhalation of
airborne crystalline silica can cause serious or fatal respiratory diseases, including silicosis. In addition, California and some other authorities have listed respirable crystalline silica as a substance
known to cause cancer. When cutting such materials, always follow respiratory precautions.
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.gov/dsg/topics/silicacrystalline/index.html
http://www.cdc.gov/niosh/consilic.html
http://oehha.ca.gov/prop65/law/P65law72003.html
http://www.dir.ca.gov/Title8/sub4.html
Your risk from these exposures varies depending on how often you do this type of work. To reduce
your exposure to these chemicals, work in a well-ventilated area, and work with approved safety
equipment, such as those dust masks that are specially designed to lter out microscopic particles.
5
TRACK RAIL SAW SAFETY
Potential hazards associated with the MK Diamond Track Rail Saw will be referenced with Hazard
Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Message Alert Symbols.
HAZARD SYMBOLS
ALWAYS read this Owner’s Manual before operating the machine.
ALWAYS wear approved eye protection.
ALWAYS wear approved ear protection.
ALWAYS wear approved respiratory protection.
ALWAYS wear a hard hat.
ALWAYS avoid inhalation of and skin contact with silica dust and/or mist.
6
TRACK RAIL SAW SAFETY
WARNING
DO NOT use woodcutting, or carbide blades on this machine! Use ONLY Diamond blades on ma-
chine. Use machine only to cut tile and masonry products. DO NOT use machine to cut wood or wood
products.
ELECTRIC MOTOR SAFETY
For maintenance care and operation of the electric motor, refer to your electric motor instruction booklet
furnished with the electric motor.
Protect the electric motor from dust as much as possible and keep ventilating openings clean.
CAUTION
DO NOT spray water at any time on the electric motor.
•
DO NOT operate electric motor in an explosive environment.
•
Electric Motor Connection
The table below shows the matching NEMA approved connector for the required extension cord.
ALWAYS make certain that the power source required for the electric motor is correct and always use
the correct NEMA conguration plug. Failure to supply the correct voltage to the motor can severely
damage the motor. Make certain that the correct size grounded (3-wires) extension cord is used. See
the table below.
Motors can burn out when the line voltage falls 10% below the voltage rating of the motor. Failure to
use proper voltage will cause the motor to overheat.
NOTICE
Most Motor Problems are caused by improper
voltage and extension cords. Cord should be
one-piece and short as possible. Cord
selection should match the following table.
1-2 H.P.
115v 230v
25’
100’
50’
150’
75’
250’
Max. Cord Length
Max. Cord Length
Max. Cord Length
No. 12 Wire
No. 10 Wire
No. 8 Wire
7
TRACK RAIL SAW SAFETY
RULES FOR SAFE OPERATION
DANGER
Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is
to be operated by trained and qualied personnel only! This equipment is for industrial use only.
The following safety guidelines should always be used when operating the MK-2000 Electric Saw.
GENERAL SAFETY
•DONOT operate or service this equipment before reading this entire manual.
• This equipment should not be operated by persons under 18 years of age.
• NEVER operate this equipment without proper protective clothing, shatterproof glasses, steeltoed
boots and other protective devices required by the job.
• NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.
• NEVER operate this equipment under the inuence of drugs or alcohol.
• Whenever necessary, replace nameplate, operation and safety decals when they become difcult
to read.
• ALWAYS check the machine for loose bolts before starting.
•ALWAYS wear proper respiratory (mask) hearing and eye protection
equipment when operating this machine.
• ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean,
dry location out of the reach of children.
ON / OFF
•NEVER leave the machine unattended. Turn off electric motor when unattended.
• CAUTION must be observed while servicing the machine. Rotating parts can cause injury if contacted.
• Ensure that any electrical extension cord is protected against damage. Always ensure that the
electrical extension cord is not trapped underneath the machine. 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. The Table shown
on page 11 shows the correct AWG size to use depending on cord length and nameplate ampere
rating. If in doubt, use the next heaviest gage. The smaller the gage number, the heavier the cord.
• DONOT allow extension cord to come into contact with water or uids.
• DO NOT spray water onto electric motor.
•NEVER operate the machine in an explosive atmosphere.
• Before starting the machine, check that all guards are in position and correctly tted.
• Keep area around the machine clear of obstructions which could cause persons to fall onto moving parts.
• ALWAYS ensure that the machine is on level ground before using.
• DONOT overreach. Keep proper footing and balance at all times.
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TRACK RAIL SAW SAFETY
•NEVER stand on the tool. Serious injury could occur if a power tool is tipped, or if a cutting tool is
unintentionally contacted.
•Become familiar with the controls of the machine before operating. Know how to stop the machine
quickly in case of emergency.
•ALWAYS secure work. Clamps or a vise should be used to hold work whenever practical. Keep-
ing your hands free to operate a power tool is safer.
•ALWAYS disconnect AC power plug from power source before moving, cleaning or servicing the
machine.
•NEVER leave a tool running unattended. Do not leave a tool until it comes to a complete stop.
ALWAYS turn a power tool OFF when leaving the work area, or when a cut is nished.
•Make sure the OFF/ON power switch on the electric motor is always in the OFF position before
inserting the machine’s power plug into an AC receptacle.
•Operate electric motor only at the specied voltage indicated on the nameplate.
•NEVER disconnect any “emergency or safety devices”. These devices are intended for operator
safety. Disconnection of these devices can cause severe injury, bodily harm or even death! Disconnection of any of these devices will void all warranties.
•Unauthorized equipment modications will void all warranties. Manufacturer does not assume respon-
sibility for any accident due to equipment modications.
•NEVER use accessories or attachments, which are not recommended by MK Diamond for this
equipment. Damage to the equipment and/or injury to user may result.
• Replace damaged cutting blade before operating.
• NEVER try to stop a moving blade with your hand.
WARNING
NEVER use this machine with any cutter designed for wood working.
MAINTENANCE SAFETY
•NEVER lubricate components or attempt service on a running machine.
•Keep the machinery in proper running condition.
•Before using a power tool, check for damaged parts. A guard or any other part that is damage
should be carefully checked to determine if 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.
SAW SAFETY
WARNING
•Wear eye protection.
•Disconnect saw before servicing, when changing cutting blades and cleaning.
•Replace damaged cutting blade before operation.
•Remove adjusting keys and wrenches.
9
TRAIL RACK SAW SAFETY
OPERATION & SAFETY DECALS
The MK Diamond Track Rail Saw is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below also shows the location
of these decals. Should any of these operation or safety decals become unreadable, replacements
can be obtained by calling (800) 262-1575.
WARNING
!
!
WARNING
DO NOT operate
this equipment
before reading
the owners’
manual!
Decal A Decal B
!
NOTICE
Most Motor Problems are caused by improper
voltage and extension cords. Cord should be
one-piece and short as possible. Cord
selection should match the following table.
1-2 H.P.
115v 230v
25’
100’
50’
150’
75’
250’
Max. Cord Length
Max. Cord Length
Max. Cord Length
No. 12 Wire
No. 10 Wire
No. 8 Wire
Decal C
Figure 1. MK Diamond Track Rail Saw Safety Decal Sheet, Part No. 166011
Grinding/cutting/drilling of masonry, concrete, metal and other materials with silica in
their composition may give off dust or mists containing crystalline silica. Silica is a basic
component of sand, quartz, brick clay, granite and numerous other minerals and rocks.
Repeated and/or substantial inhalation of airborne crystalline silica can cause serious
or fatal respiratory diseases, including silicosis. In addition,California and some other
authorities have listed respirable crystalline silica as a substance known to cause cancer.
CAUTION
!
This saw is to be used
with a Ground Fault
Circuit Interrupter.
Decal D
CAUTION
!
DO NOT
operate without
guards in place.
Decal E
C
FOR INFORMATION ON
SERVICE OR
WARRANTY
PLEASE CALL
1-800-474-5594
Decal F
A
B
D & F
(behind)
E
10
TRACK RAIL SAW PRODUCT SPECIFICATIONS
TrackRailSawSpecications
Model 166110
Motor 115V 50/60 Hz
Amps 13
Horsepower 1-3/4 HP
Blade RPM 3,500
Blade Capacity 12” (254 mm)
Arbor Size 1” (25.4 mm)
Standard Length of Cut 130” (3,202mm)
Maximum Depth of Cut 2-7/8” (73mm)
Depth of Cut at 45º 2-1/4 (57mm)
Weight 95 lbs. (43kgs.)
Dimensions(LxWxH)-inches 144” x 16” x 13”
Dimensions(LxWxH)-millimeters 3,658 x 406 x 330
• Adjustable height plunge-cutting head
• Lightweight precision extruded aluminum rails provide accurate and even tracking during all
cutting operations
• Rails have replaceable slip-on pads to protect material surface from scratches
• Precision, maintenance-free bearings provide smooth and reliable tracking of the cutting head
• Replaceable dust lter
• Valve controlled water feed
• 72” 115V standard U-ground electrical cord
• Saw comes complete with two sets of 72” track, track connector plate, 12” blade capacity cutting
head, two hold-down clamps and standard garden hose water connector
• Additional rails for extending cutting capacity sold separately
11
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