www.mkdiamond.com MK-101 Tile Saw OWNER'S MANUAL, PARTS LIST & OPERATING INSTRUCTIONS MK-101 Part # 167979 Revision 109 09.2013 Manual Part# 168237 Caution: Read all safety and operating instructions before using this equipment. This 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 SAFETY Safety Messages General Safety Precautions California Proposition 65 Message Hazard Symbols Electrical Requirements Safety Label Locations Product Specifications 4 4-6 6 7 8-10 11 12 UNPACKING, TRANSPORT and ASSEMBLY Unpacking Contents Transport Stand Assembly 13 13 14 15 16-17 SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Setup Operation Cutting Head Adjustment Cleanup 18-20 20-23 24-26 27 MAINTENANCE AND TROUBLESHOOTING Maintenance Troubleshooting 28-33 34 EXPLODED VI
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 PERSONAL PROTECTIVE EQUIPMENT always wear approved respiratory, head, ear and eye protection when operating this machine. ON )) (( (( (( ON (( ON ACCIDENTAL STARTS! )) )) Before starting the engine/motor, be sure the ON/OFF switch is in the OFF position to prevent accidental starting. Place the ON/OFF switch in the OFF position before performing any service operation. ALWAYS place the power ON/OFF switch in the OFF position when the saw is not in use.
)) (( ON (( ON USE 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. 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. (( ON DO)) NOT OVERREACH Keep proper footing and balance at all times by not overreaching.
)) (( ON (( ON 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 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.
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 )) ON (( In order to prevent 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 electrical current to reduce the risk of electric shock. This tool is equipped with an electric cord which has 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 ON SAFETY (( )) WARNING To avoid the possibility of the appliance or plug receptacle getting wet, position the machine to one side of a wall mounted receptacle. This will prevent water from dripping into the receptacle or plug. A "drip loop," shown in the picture below, should be arranged by the user to properly position the power cord relative to the power source. Use the drip loop as a way to prevent GFCI and plug from getting wet.
SAFETY (( ON MK-101 )) WARNING Use of undersized 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 customer’s expense. There will be no warranty claim.
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 Description The MK-101 Tile Saw is engineered as a tabletop or stand mounted wet tile saw. The saw includes a powerful 120V electric motor. The saw is capable of cutting tile up to twenty (20) inches in length, depth of cut 3". Motor Specifications Motor specifications for the MK-101 are listed in table below.
MK-101 CONTENTS 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. If not done, remove the MK-101, Cutting Head and accessory box from the carton.
MK-101 TRANSPORT TRANSPORT CAUTION 1. The MK-101 weighs approximately eighty-four and half (84) pounds; use care when transporting. 2. Never transport the MK-101 with water in the Water Pan. 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. The Cutting Head must be removed first, if one person is transporting the saw (see Cutting Head Installation and Removal in the following section).
MK-101 STAND STAND (Optional) CAUTION The MK-101 weighs eighty-four (84) pounds; follow the guidelines the Transport section when placing it on the stand (MK Diamond Part# 168244).
MK-101 ASSEMBLY ASSEMBLY Follow the assembly instructions to prepare your MK-101 for operation. CUTTING HEAD INSTALLATION Note: If the Cutting Head is installed, go to the next step. (A) Align Cutting Head rear Pivot Hole to the Post Pivot Shaft and slide onto shaft (B) Install the Cutting Head onto the Post Pivot Shaft and install the Cutting Head Tri-Knob and washer.
MK-101 ASSEMBLY ADJUSTABLE CUTTING GUIDE INSTALLATION Note: The Adjustable Cutting Guide can be used on either side of the Diamond Blade.
MK-101 SETUP PRE-START INSPECTION Prior to beginning work, a pre-start inspection of the saw should be preformed. (A) Ensure the ON/OFF Switch is in the OFF position (B) Verify the Movable Cutting Table moves freely (D) Inspection the Pump Assembly for damage. Ensure the cord is free of cracks of cuts (E) Inspect the MK-101 for damage. Ensure the cord is free of cracks or cuts 20 (C) Inspect the Diamond Blade for damage.
MK-101 SETUP CONNECTING WATER PUMP WARNING To prevent the possibility of electrical shock, the MK-101 MUST be de-energized when connecting the Water Pump. 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 from its power supply if cutting with a Dry Blade.
MK-101 SETUP RE-CIRCULATION NOTE: When using the re-circulation method, the water should be changed often for longer pump life. (A) Ensure the Drain Plug is installed in the Water Basin NOTE: (B) Place the Water Pump in the back of the Water Basin Ensure the power cord and cooling tube exit the water basin under the top rail of the frame.
MK-101 OPERATION PORTABLE GENERATOR If using a portable generator to provide power, ensure the generator meets the following minimum requirements: 8Kw 120 Volts 20 Amps Single Phase (A) Ensure the ON/OFF Switch is in the OFF position (B) Plug MK-101 into GFCI (C) Plug the GFCI into the power source Set Cutting Depth CAUTION When loosing the Cutting Head Adjusting Knob, the Cutting Head will pivot down unless held.
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 (D) Verify proper cooling flow on both sides of the blade (See Maintenance Section to increase/decrease flow) (B) Position the Adjustable Cutting Guide to desired cut length indicated inside the diamond and tighten. (C) Place the tile against the Ruler/ Stop and Cutting Guide.
MK-101 OPERATION (D) Perform the cut. Turn the motor OFF when work is complete 45° Miter Cutting CAUTION DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed. (A) Position the 45° Bullnose Miter Guide and tighten the retaining thumbscrews (B) Position the tile on the 45° Bullnose Miter Guide and the Ruler/Stop (D) Perform the cut.
MK-101 ADJUSTMENT Off-angle Cutting Note: CAUTION To cut angles other than 45° angles or Miter, a 90° 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.
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. Support the Cutting Head and then remove Adjusting Knob. (D) Install the Cutting Head onto the front pivot hole Note: Note: (B) Remove the Cutting Head from the rear pivot hole (E) Install the Adjusting Knob (C) Move Cutting Head Stop to down position (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 the Retaining Bolts. Be sure to remove Standoffs with the bolts.
MK-101 ADJUSTMENT CLEANUP NOTE: If an external water source was used, steps A through C may be skipped. 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. (B) Place the Water Pump in an external container (C) Run the MK-101 until clear water is seen at the blade cooling ports (Approx. 1 min.) (D) Remove the Water Basin and clean.
MK-101 MAINTENANCE MAINTENANCE Perform the following after initial purchase and operation of the MK-101. 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. (A) Lubricate the Guide Bar (B) Lubricate the Roller Wheel Assembly Monthly Maintenance The following maintenance should be performed Monthly.
MK-101 MAINTENANCE Monthly Maintenance Cont. (G) Remove the Blade Guard. Lubricate the Blade Guard Pivot Shaft (H) Remove the Cutting Head (See Adjusting the Cutting Head) (J) Lubricate the Cutting Head Adjustment Knob retaining holes (K) Lubricate the Cutting Head Pivot Shaft (I) Lubricate the threads on the Cutting Head Adjustment Tri-Knob 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.
MK-101 MAINTENANCE Micro-V Belt Inspection, Adjustment and Replacement The MK-101 is designed with power transmission Micro-V Belt. In order to ensure the MK-101 operates a peak efficiency, the Micro-V Belt should be inspected monthly, and changed if the Micro-V Belt shows damage and/or excessive wear. NOTE: When a new belt is installed, it should be inspected and re-tensioned after the first fortyeight (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 (L) Install the new Micro-V Belt (MK Diamond Part No.
MK-101 MAINTENANCE 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 Movable Cutting Table Does Not Move Correctly (A) Check that the Guide Bar is clean - clean if dirty (B) Check the Movable Cutting table Roller Wheels for wear, replace if necessary Blade will not cut properly (A) Check for Smoothness or "Glazing" (See Blade Dressing Section) Blade Stops Turning (A) Allow motor to cool and depress motor Overload Reset Switch NOTE: (B) Check for proper blade rotation.
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MK-101 EXPLODED VIEW 10 24 1 19 3 20 23 22 17 12 6 11 5 9 4 18 7 2 8 16 25 13 21 15 14 Saw Assembly Part# 167979 38
MK-101 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 PARTS LIST Description WRENCH, TILE SAW NUT 15/15 PAN, PLASTIC MK-101 WASHER, FLAT, SAE, 3/8 SCREW, HEX HD, 5/16 - 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 CLAMP, HOSE, 1/4 - 1/2 FLOW SCREW, HEX HD 1/4 - 20 X 1-1/4 STOP, CUTTING HEAD DRAIN PLUG, W/RING STRAP, 9" DRAIN PLUG RIP GUIDE, LARGE DIE CAST GUARD, SPLASH SHEET, WARNING L
MK-101 EXPLODED VIEW Frame Assembly Part# 170476 2 9 5 3 1 4 8 7 6 10 40
MK-101 Item 1 2 3 4 5 6 7 8 9 10 PARTS LIST 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 .
MK-101 EXPLODED VIEW Table Assembly Part# 158477-NC 2 3 4 5 6 1 42
MK-101 Item 1 2 3 4 5 6 PARTS LIST Description BAR, GUIDE PLATED MK-101 SCREW, HEX HD, 5/16 - 18 X 1 WASHER, LOCK, SPLIT, 5/16 WASHER, FLAT, SAE, 5/16 ASSY, WHEEL BRKT TSAW CASTING, TABLE MK-100 COMP 43 Part # 134759 151743 151747 151754 151756 157660 Qty 1 2 2 2 1 1
MK-101 EXPLODED VIEW Cutting Head Assembly Part# 168167 13 7 INCLUDED WITH ITEM 8 1 10 5 11 2 3 8 12 2 6 5 3 9 44 4
MK-101 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 PARTS LIST 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, 3400 RPM 45 Part # 150344 151915 152370 152582 152591 152676 157083 158191 158194 158199 158319-01 158611
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 46
MK-101 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PARTS LIST 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 2 Blade Guard Assembly Part# 152582 1 4 3 Roller Wheel Assembly Part# 151756 48
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 49
MK-101 ITEM NUMBER 1. 137166 ACCESSORIES DESCRIPTION MK-200, 10 x 5/8 Arbor Premium grade Diamond Blade for smooth, chip-free cutting on tile. 2. 128074 MK-215, 10 x 5/8 Arbor Supreme grade diamond blade for hard materials 3. 153252 MK-315, 10 x 5/8 Arbor Supreme super hi-rim diamond blade 4. 134577-MK Dual 45° Flat Angle Guide 5. 153201-MK 45° Bullnose Miter (large) 6. 152792 Dressing Stone 7. 152610 Ground Fault Circuit Interrupter 8.
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MK-101 ORDERING & RETURN 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 CONTACT & LIMITED 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.
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MK-101 TILE SAW OWNER'S MANUAL, PARTS LIST & OPERATING INSTRUCTIONS MK Diamond Products, Inc. 1315 Storm Parkway Torrance, CA 90501 Toll-Free: (800) 421-5830 Phone: (310) 539-5221 Fax: (310) 539-5158 www.mkdiamond.
