www.mkdiamond.com MK-101 Tile Saw OWNER’S MANUAL, PARTS LIST & OPERATING INSTRUCTIONS Part # 151991 Revision 106 11.2013 Manual Part# 153754 Caution: Read all safety and operating instructions before using this equipment. This owner’s manual MUST accompany the equipment at all times.
INTRODUCTION Congratulations on your purchase of a MK-101 Tile Saw. We are certain that you will be pleased with your purchase. MK Diamond takes pride in producing the finest construction power tools and diamond blades in the industry. Operated correctly, your MK-101 Tile 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 MK-101 Tile Saw safely and correctly.
TABLE OF CONTENTS Page SAFETY Safety Messages Damage Prevention Message General Safety Precautions California Proposition 65 Message Electrical Requirements and Grounding Instructions Electric Motor Safety Safety Label Locations Product Specifications 4 4 4-7 8 9-10 11-12 10 13 ASSEMBLY Unpacking Contents Transport Stand Assembly 14 14 15 15 16-18 SETUP, ADJUSTMENT AND OPERATION Setup Operation Adjustment Cleanup 19-121 22-25 26-27 28 MAINTENANCE AND TROUBLESHOOTING Maintenance Troubleshooting 29-34
MK-101 SAFETY Read and follow all safety, operating and maintenance instructions. Failure to read and follow these instructions could result in injury or death to you or others. Failure to read and follow these instructions could also result in damage and/or reduced equipment life. Safety warnings and guidelines do not by themselves eliminate danger. They are not substitutes for proper accident prevention procedures and good judgement.
MK-101 SAFETY 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 SAFETY USE RECOMMENDED ACCESSORIES Consult the owner’s manual for recommended accessories. Using improper accessories may increase the risk of personal or by-stander injury. Unauthorized equipment modifications will void all warranties. Manufacturer does not assume responsibility for any accident due to equipment modifications. Always ensure that the machine is on level ground before using.
MK-101 SAFETY WARNING 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 ELECTRICAL SHOCK NEVER touch electrical wires or components while the engine is running.
MK-101 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.
MK-101 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! WARNING 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.
MK-101 SAFETY 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 ON )) ventilating openings clean. Before plugging in the machine, make sure that the outlet voltage is within the voltage marked on the machines's data plate. CAUTION DO NOT spray water on the electric motor. Do not touch the plug with wet hands.
MK-101 SAFETY WARNING The “drip loop” is that part of the cord below the level of the receptacle, or the connector, if an extension cord is used. This method of positioning the cord prevents the travel of water along the power cord and coming in contact with the receptacle. If the plug or receptacle gets wet, DO NOT unplug the cord. Disconnect the fuse or circuit breaker that supplies power to the tool. Then unplug and examine for presence of water in the receptacle.
MK-101 SAFETY SAFETY LABEL LOCATIONS Safety 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. G ! WARNING ! WARNING C For Your Own Safety Read Instruction Manual Before Operating Saw. Wear Eye Protection. Disconnect Saw Before Servicing, when Changing Cutting Wheels and Cleaning.
MK-101 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 Specifications The MK-101 Tile Saw is engineered as a tabletop or stand mounted wet tile saw. The saw includes a powerful 120V 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.
MK-101 ASSEMBLY UNPACKING Your MK-101 has been shipped from the factory thoroughly inspected. Only minimal assembly is required. CAUTION Use proper lifting techniques when lifting the MK-101.
MK-101 TRANSPORT transport CAUTION 1. The MK-101 weighs approximately ninety-two (92) pounds. 2. Never transport the MK-101 with water in the Water Basin. The MK-101 is designed with a rigid frame and removable Cutting Head. Two people are required to transport the MK-101 with the Cutting Head installed. Remove the Cutting Head if one person is transporting the saw (see Cutting Head Installation and Removal in the following section). Lift the saw using the lift points shown.
MK-101 ASSEMBLY Follow the assembly instructions to prepare your MK-101 for operation. NOTE: If the cutting head is installed, go to the next step. Cutting Head Installation (A) Align Cutting Head rear Pivot Hole to the Post Pivot Shaft and slide onto shaft (D) For maximum cutting length, the Cutting Head should be in the front pivot hole and the Post should be in the rear post retaining hole.
MK-101 ASSEMBLY Diamond Blade Installation NOTE: When installing the Retaining Nut, do not “cross-thread” and DO NOT over tighten. (A) Position Movable Cutting Table to the front of the saw and raise the Blade Guard.
MK-101 ASSEMBLY Splash Guard Installation (A) Install the retaining thumbscrew through the washer and Splash Guard then align to the hole found on back of the Blade Guard (B) Install the Splash Guard onto the Blade Guard Water Pump Preparation (A) Press one end of the Cooling Transfer Tube into the Water Pump Discharge Fitting (B) Slide Cooling Flow Adjusting clamp on to the Cooling Transfer Tube 18
MK-101 SETUP Pre-start Inspection Prior to beginning work, a pre-start inspection of the saw should be performed. (A) Ensure the ON/OFF Switch is in the OFF position (B) Verify the Movable Cutting Table moves freely (D) Inspect the Pump Assembly for damage – ensure the cord is free of cracks or cuts (E) Inspect the MK-101 for damage (C) Inspect the Diamond Blade for damage – verify the blade is correct for the material being cut Connecting the Water Pump WARNING NOTE: 1.
MK-101 SETUP 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. External Water Source This is the preferred method of cooling. (A) Remove the Drain Plug.
MK-101 SETUP VOLTAGE CYCLE PHASE 120V 60hz 1-phase 4. If using an extension power cord, made sure, the length and wire gauge correspond to the requirements listed in the table on page 10. An extension power cord that is too small in wire gauge (diameter), or too long in length, will cause the motor to overheat and could cause premature failure. 5. Use an approved Ground Fault Circuit Interrupter (GFCI) 6. Do not cover the motor vents as this could lead to motor overheating.
MK-101 OPERATION Cutting Straight Edges CAUTION DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed. (A) Loosen the Adjustable Cutting Guide retaining thumbscrew (B) Position the Adjustable Cutting Guide to desired cut length (C) Tighten the retaining thumbscrew (D) Place the tile against the Ruler/Stop and Cutting Guide.
MK-101 OPERATION Diagonal Cutting NOTE: To cut diagonal, the Dual 45º Flat Angle Guide (MK Diamond Part No. 134557-MK) should be used. CAUTION DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.
MK-101 OPERATION 45° Miter Cutting NOTE: To cut 45º Miters, the 45º Bullnose Miter Guide (MK Diamond Part No. 134585-MK) should be used. CAUTION DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed. (A) Remove the Adjustable Cutting Guide (B) Place the 45º Miter Guide on the Ruler/Stop (D) Position the tile on the 45º Miter Guide and the Ruler/Stop.
MK-101 OPERATION 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. CAUTION DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed. (A) Place the 90º Protractor on the Ruler/Stop (B) Set the desired angle and tighten the thumbscrew and tighten retaining thumbscrews (D) Turn the motor ON. Verify proper cooling flow on both sides of the blade (E) Perform the cut.
MK-101 ADJUSTMENT Adjusting the Cutting Head CAUTION The Cutting Head is heavy. Care must be used when changing the position of the Cutting Head. (A) Remove the blade and then Adjusting Knob (B) Remove the Cutting Head from the rear pivot hole (C) Move Cutting Head Stop to down position (D) Install the Cutting Head onto the front pivot hole (E) Install the Adjusting Knob (F) Install Diamond Blade. Set cutting depth approx.
MK-101 ADJUSTMENT Adjusting the Post for Maximum Cutting Length CAUTION The Cutting Head and Post are heavy. Care must be used when changing the position of the Cutting Head. (A) Remove Water Basin (B) Remove the Cutting Head (See Adjusting the Cutting Head) (C) Loosen the Retaining Bolts. (D) Remove both the Standoffs and Retaining Bolts. (E) Relocate the Post to the rear Post retaining holes. Insert Standoffs and Retaining Bolts (F) Secure the Post Support by tightening Retaining Bolts.
MK-101 NOTE: CLEANUP 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. (A) Clean the Water Pump suction of all debris. Refer to water pump manual. CAUTION (C) Run the MK-101 until clear water is seen at the blade cooling ports (Approx. 1 min.) Ensure the saw is disconnected before completing the remainder of the cleanup process. (D) Remove the Water Basin and clean.
MK-101 MAINTENANCE New Maintenance Perform the following after initial purchase and operation of the MK-101. (A) Check and adjust V-belt tension following 1st 48 hours of operation (See V-belt Inspection) 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.
MK-101 MAINTENANCE Monthly Maintenance The following maintenance should be performed Monthly. (A) Remove the Diamond Blade (B) Lubricate the Outer Flange and Retaining-nut (C) Lubricate the Inner Flange (D) Verify the Roller Wheel Assembly is tight and in good condition.
MK-101 (J) Lubricate the Cutting Head Adjustment Knob retaining holes MAINTENANCE (K) Lubricate the Cutting Head Pivot Shaft Flow Adjustment NOTE: If flow to the diamond blade requires adjustment, perform the following actions.
MK-101 MAINTENANCE 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.
MK-101 MAINTENANCE BELT INSPECTIOIN, ADJSTMENT AND REPLACEMENT MK-101 is designed with a power transmission V-belt. In order to ensure the MK-101 operates at peak efficiency, the V-belt should be inspected monthly, and change 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 of operation.
MK-101 MAINTENANCE (J) Push the motor toward the front of the Cutting Head to loosen the Micro-V Belt (K) Remove the Micro-V Belt (M) Verify the Micro-V Belt is seated in the grooves of both pulleys (N) Tighten the Motor Adjustment Strap to remove slack (P) Tighten the four motor mounting bolts (Q) Install the Belt Guard 34 (L) Install the new Micro-V Belt (MK Diamond Part No.
MK-101 TROUBLESHOOTING Blade will not Cut Properly (A) Check for Smoothness or "Glazing" (See Blade Dressing Section) (B) Check for proper blade rotation. Ensure arrow engraved on blade matches the directional arrow on blade guard Movable Cutting Table does not move Correctly (A) Check the Guide Bar and Frame for cleanliness clean if dirty (D) Verify the Roller Wheel Assembly is tight and in good condition. 35 (C) Ensure the Blade Core is not bent.
MK-101 TROUBLESHOOTING cooling flow (A) Check cooling flow Adjusting Clamp open (B) Remove the Cooling Transfer Tube from the Blade Guard inlet (C) Place Pump into a bucket of water and check flow (D) Remove the Cooling Transfer Tube and check flow (E) Inspect and clean pump.
MK-101 TROUBLESHOOTING Blade Stops Turning (A) Allow motor to cool and depress motor Overload Reset Switch NOTE: (B) Verify all plugs fully installed. Check Ground Fault Circuit Interrupter Verify circuit breaker at least 20 amps - if not, move to 20-amp circuit. Verify circuit breaker not tripped. If tripped, reset once. Check power source voltage is 120V - if not 120V, move to another circuit.
MK-101 EXPLODED VIEW 12 27 1 23 3 24 26 25 21 14 6 13 5 4 9 16 2 7 8 20 15 17 11 19 10 18 28 Saw Assembly Part# 151991 38
MK-101 PARTS LIST Saw Assembly Part# 151991 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Description WRENCH, TILE SAW NUT 15/16 PAN, PLASTIC MK-101 WASHER, FLAT, SAE, 3/8 SCREW, HEX HD, 5/6 - 18 X 1 WASHER, LOCK, SPLIT, 15/16 WASHER, FLAT, SAE, 5/16 SCREW, WING, 1/4 20 X 1/2 WASHER, FLAT, SAE, 1/4 WASHER, LOCK, SPLIT 1/4 CASTING, ACC BULLNOSE LRG - COMP MK-100 10 X 060 X 5/8 CLAMP, HOSE, 1/4 - 1/2 FLOW SCREW, HEX HD 1/4 - 20 X 1-1/4 STOP, CUTTING HEAD ASSY, DC TABLE, M
MK-101 EXPLODED VIEW Frame Assembly Part# 170476 2 9 5 3 1 4 8 7 6 10 Table Assembly Part# 158477 4 2 3 5 1 7 6 8 40
MK-101 PARTS LIST Frame Assembly Part# 170476 Item 1 2 3 4 5 6 7 8 9 10 Description WASHER, LOCK, SPLIT, 3/8 SHAFT, 10.63 PIVOT SCREW, SET, SOC, CUPT, 3.8 - 16 X 1/2 PLATE, PRESSURE SCREW, 3/8 16 X 2 -1/2 HEX HEAD CAP CASTING, POST, DC, 101 MKRED-COMP POST COVER, PLASTIC SPACER, 5.8 X .385 X 1.
MK-101 EXPLODED VIEW Cutting Head Part# 158478 INCLUDED WITH ITEM #8 13 INCLUDED WITH ITEM #8 7 4 1 10 5 3 2 8 12 2 3 6 5 9 5 2 11 42
MK-101 PARTS LIST Cutting Head Part# 158478 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Description KEY, 3/16 SQ X 1-1/8 WASHER, 1/4 SAE FLAT SCREW, HEX HD, 1/4 -20 X 3/4 ASSY, BLADE GUARD, 101 WASHER, 1/4 SPLIT LOCK SCREW, HEX HD TAP, 1/4 - 20 X 1 SCREW, 5/16 -18 X 3/8 SOCKET HEAD SET ASSY, SBU, CUTTING HEAD MK-101 BELT, 6J260 PULLEY, 6J19 X 5/8 BORE CASTING, 101 BELT GUARD-COMP Bracket, inner beltguard MTR, 1-1/2 HP, 115V, 60HZ-VP 43 Part # 150344 151915 152370 152582 152591 152676 157083 158191 158194 15819
MK-101 EXPLODED VIEW 16 21 15 7 10 13 9 1 22 5 11 17 14 6 8 12 18 20 4 3 23 2 Cutting Head Assembly Part# 158191 44
MK-101 PARTS LIST Cutting Head Assembly Part# 158191 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Description NUT, HEX, 5/16 - 18 FLANGE, OUTER, 2 - 3/8 NUT, HEX, 5/8 18 BEARING, BALL, 17 X 40 X 12MM key, 3/16 sq x 1 - 1/8 WASHER, FLAT, SAE, 3/8 screw, hex head, 5/16 - 18 x 1 NUT, WING, NYLK, 5/16 - 18 WASHER, 5/16 SPLIT LOCK washer, 5/16 sae flat STRAP, 1 INCH MOTOR ADJ. BUMPER, RUBBER, 1/2 DIA.
MK-101 EXPLODED VIEW Blade Guard Assembly Part# 152582 2 1 4 3 Roller Wheel Assembly Part# 151756 46
MK-101 PARTS LIST Blade Guard Assembly Part# 152582 Item 1 2 3 4 Description SCREW, 5/16 - 18 X 1/2 SOCKET HD SET ELBOW, 1/8MNPT X 1/4 BARB, 90 DEG TUBE, WATER CASTING, 101 BLD GUARD-DC-COMP Part # 152607 154652 155389 162481 Qty 3 1 2 1 Part # 151799 151893 151914 151915 154021 Qty 1 1 1 1 1 Roller Wheel Assembly Part# 151756 Item 1 2 3 4 5 Description WHEEL, ROLLER NUT, HEX, 1/4 - 20 SCREW, HEX HEAD 1/4 -20 X 1-1/2" WASHER, 1/4 SAE FLAT BRACKET, ROLLER WHEEL 47
MK-101 ACCESSORIES ACCESSORIES: ITEM NUMBER 1. 137166 DESCRIPTION MK-200. 10 X 5/8 ARBOR Premium grade Diamond Blade for smooth, chip-free cutting on tile. MK-215, 10 X 5/8 ARBOR Supreme grade diamond blade for hard materials 2. 128074 3. 153252 4. 134577-MK DUAL 45° FLAT ANGLE GUIDE 6. 134569-MK 90° PROTRACTOR 7. 152792 DRESSING STONE 8. 152610 GROUND FAULT CIRCUIT INTERRUPTER 9. 168244 FOLDING STAND 10.
NOTES 49
MK-101 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. 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 NOTE: There is a $25.
MK-101 WARRANTY CONTACT: Please contact MK Diamond Products, Inc. Customer Service Department with any questions you might have regarding distributors, parts or service. Telephone: (800) 421-5830 Fax: (310) 539-5158 E-mail: Customer_Service@MKDiamond.com Customer Service Hours: Monday through Friday, 6AM-4PM PST MK Diamond Products, Inc. 1315 Storm Parkway Torrance, CA 90501 MK DIAMOND PRODUCTS, INC. LIMITED WARRANTY MK DIAMOND PRODUCTS, INC.
MK-101 Tile Saw OWNER’S MANUAL & OPERATING INSTRUCTION MK Diamond Products, Inc. 1315 Storm Parkway Torrance, CA 90501 Toll-Free: (800) 845-3729 Phone: (310) 539-2221 Fax: (310) 539-5158 www.mkdiamond.
