www.mkdiamond.com MK-1600 OWNER’S MANUAL & OPERATING INSTRUCTIONS Gas Powered Concrete Saw Revision 202 03.2013 Manual Part# 157841 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-1600 Concrete 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-1600 Concrete 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-1600 Concrete Saw safely and correctly.
TABLE OF CONTENTS SAFETY Safety Messages Damage Prevention Message General Safety Precautions and Hazard Symbols California Proposition 65 Message Prestart Safety Safety Label Locations Product Specifications 4 4 5 8 9 10 11 UNPACKING, TRANSPORT and ASSEMBLY Unpacking Contents Transport Assembly 12 12 13 14-15 STARTUP, OPERATION and SHUTDOWN Startup Operation Shutdown Cleanup 16-17 18-20 21 21 MAINTENANCE AND TROUBLESHOOTING Maintenance Troubleshooting 22-30 31 EXPLODED VIEW & PARTS LIST Exploded Vi
MK-1600 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 efficient operation of the MK-1600 Concrete Saw. Before using this saw, ensure that the person operating the equipment has read and understands all instructions in this manual.
MK-1600 SAFETY GENERAL SAFETY PRECAUTIONS AND HAZARD SYMBOLS Safety Precautions In order to prevent injury, the following safety precautions and symbols should be followed at all times! GENERAL SAFETY DO NOT 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 when not feeling well due to fatigue, illness or taking medicine.
MK-1600 SAFETY ACCIDENTAL STARTS on Before starting the engine, 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. ROTATING OR MOVING PARTS Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate a power tool with shrouds or guards removed. HOT PARTS Engine components can become extremely hot from operation.
MK-1600 SAFETY 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. WEAR PROPER APPAREL Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry that may be caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair.
MK-1600 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-1600 PRE-START Before starting the machine, ALWAYS check that all guards are in position and correctly fitted. Check the machine for loose bolts before starting. 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. Know how to stop the machine quickly in case of emergency. NEVER try to stop a moving blade with your hands. • NEVER disconnect any “emergency or safety devices”.
MK-1600 SAFETY OPERATION & SAFETY DECALS The MK-1600 Concrete Saw is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. Should any of these operation or safety decals become unreadable, replacements can be obtained by calling (800) 262-1575. DANGER ! WARNING H F Lethal exhaust gases. Use only in well ventilated areas. DO NOT use indoors.
MK-1600 PRODUCT SPECIFICATION PRODUCT SPECIFICATIONS The MK-1600 is a versatile gas powered Concrete Saw. Operated and used according to this manual, the MK-1600 will provide years of dependable service. General Description The MK-1600 is engineered as a portable concrete saw powered by a Honda, Vanguard or Kohler gas engine.The saw is capable of 6-5/8” depth of cut with an 18” blade. Motor and Weight Specifications Motor and Weight specifications for the MK-1600 are listed below.
MK-1600 UNPACKING UNPACKING Your saw has been shipped from the factory thoroughly inspected. Only minimal assembly and service is required. Check each, item, making certain all items are accounted for and in good visual condition before discarding any packing materials. If there are any missing or damaged parts call MK Diamond Customer Service at 800-421-5830. WARNING Never start engine until all initial servicing and set up steps are completed according to this operations manual and engine manual.
MK-1600 TRANSPORT TRANSPORT CAUTION 1. The MK-1600 weighs approximately two hundred and thirty-five (235 pounds), use care when transporting. 2. Two people are required to lift and transport the MK-1600. 3. A lifting bail is included on Premium models or available as an option. 9 1 8 7 2 5 3 6 4 1. 2. 3. 4. 5. 6. 7. 8. 9. The raise lever wheel raises the blade when rotated clockwise, and lowers the blade when rotated counterclockwise.
MK-1600 ASSEMBLY Follow the assembly instructions to prepare your saw for operation. Handlebar Assembly (A) Locate the threaded holes on both sides of the handlebar. (B) Align the handlebar with the holes on both sides of the frame at the desired height. (C) Install one Washer onto each bolt. Install bolt through the Handlebar and into the holes and tighten. Filling Oil Reservoir NOTE: The engine is shipped with no oil in the crankcase.
MK-1600 ASSEMBLY Diamond Blade Installation NOTE: 1. When installing the blade retaining-bolt, ensure the threads of the bolt are aligned with the threads of the drive shaft so as not to “cross-thread” the bolt. 2. When installing the blade ensure that the blade shaft and flanges are free from dirt and all foreign material before mounting blade on the blade shaft. Tightening a blade against an uneven surface can cause fracture or cause the blade to run out of alignment. 3.
MK-1600 START UP Filling Fuel Tank WARNING 1. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. 2. To fuel, stop engine if running, and allow it to cool. 3. Refuel in a well-ventilated area. 4. Keep gasoline away from appliance pilot lights, barbeques, electric appliances, power tools, etc. 5. Wipe up spills immediately. Do not start engine until spill is dry. NOTE: 1. Fuel can damage paint and plastic.
MK-1600 STARTUP Proper Oil Level Low Level (D) Check for proper oil level. Refer to Engine Manual for details. 1 inch (25mm) from throat Maximum Fuel Level (E) Ensure fuel level is 1” below the throat of the Fuel Tank. Maximum Fuel Level (F) Ensure fuel level is below the top of the strainer filter. (G) Check the Air Filter for cleanliness. Refer to Engine Manual for details. Engine Start WARNING 1. Carbon monoxide gas is toxic, breathing it can cause unconsciousness and/or death. 2.
MK-1600 OPERATION Front Pointer Alignment The Front Pointer is set in line at the factory. However, the pointer should be checked for proper alignment with the blade after every use. (B) With the Blade centered over the line and the Saw Frame parallel to the line, lower the front Pointer assembly and position the pointer over the line. (C) Adjust the Pointer in or out if the orange wheel is off the line by loosening the thumbscrew on the end of pointer.
MK-1600 OPERATION Standard Operation The MK-1600 is intended for industrial applications and operated by experienced professionals. The operator must be aware of the machine’s capabilities and limitations. It is the operators responsibility to use this machine under safe working conditions and conform with federal, state and local codes or regulations pertaining to safety, air, pollution, noise etc...
MK-1600 NOTE: OPERATION Perform the cut using only enough pressure to follow the original marked line. The saw has a natural tendency to pull towards the side on which the blade is mounted. To assure straight line cutting, apply pressure to the appropriate handle. If excessive pressure is required reduce the forward speed of the saw. Driving the saw too fast while cutting may cause the front wheels to lift causing the blade to cut at uneven depths. Do not attempt to steer the saw.
MK-1600 CLEANUP Emergency Engine Shutdown (A) Place Engine Master Switch in the OFF position. cleanup (B) Move the Throttle Lever to lower blade speed. Place Fuel Valve in the OFF position. Caution Engine parts are extremely hot following use, allow engine to cool 1/2-hour before cleaning. Use care during cleanup to avoid injury. NOTE: 1. To extend operating life, the Concrete Saw should be cleaned following every use. 2.
MK-1600 MAINTENANCE Blade Repositioning WARNING Do not operate saw with any guards removed. Turn master engine switch to off position to avoid accidental starts when removing guards. (A) Remove Diamond Blade. (B) Remove the Cooling Transfer Hose from the Blade Guard by pressing the quick release. (C) Locate the four Blade Guard Retaining Bolts. (D) Remove the Blade Guard Retaining Bolts and remove the Blade Guard. (E) Locate the Blade Shaft Cover Retaining Bolts.
MK-1600 (J) Install the Blade Shaft Cover. MAINTENANCE (K) Remove the Pointer. (L) Install the Pointer on the opposite side, next to Blade Guard. (M) Verify the stop Clip is installed as shown. MAINTENANCE SAFETY • Always turn the master engine switch to the off position. • NEVER lubricate components or attempt service on a running machine. • Keep the machinery in proper running condition. • Fix damage to the machine immediately and always replace broken parts, or missing decals.
MK-1600 MAINTENANCE Maintenance Following Use The following maintenance should be performed following each use. (A) Shut down the Engine. Let saw cool before proceeding. (B) Check Air Filter (See Engine Manual). (D) Lubricate the pivot point of the Pointer. (E) Lubricate the Cooling Supply Valve. (C) Lubricate the Grease Fitting. (F) Verify the tightness of all bolts and screws. Clean the saw (except the engine) with soap and water.
MK-1600 (D) Clean engine Air Filter weekly and replace monthly. Refer to Engine Manual for details. MAINTENANCE (E) Clean Spark Plug Weekly and readjust Spark Plug monthly. Refer to Engine Manual for details. NOTE: (F) Clean and lubricate the Blade Shaft. Definitive information on engine maintenance is contained in the engine manual provided separately. Perform all maintenance procedures as recommended by the engine manual. (G) Clean and lubricate the Blade Retaining Bolt.
MK-1600 MAINTENANCE Yearly and Two-Year Maintenance Perform the following maintenance every year. (A) Inspect belts for proper tension and wear. Check Fuel Level For all Engine related maintenance and troubleshooting refer to the Engine Manual. WARNING 1. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. 2. To fuel, stop engine if running and allow it to cool. 3. Refuel in a well-ventilated area. 4.
MK-1600 MAINTENANCE Checking Oil Level NOTE: When installing the Oil Dipstick, ensure the threads are aligned with the threads of the Oil Reservoir so as not to “cross-thread.” (A) Verify the Engine is upright and level. Refer to Engine Manual for details. Engine Maintenance Engine maintenance and adjustment is necessary to keep the saw in good operation condition. Maintenace operations include oil changes, filter changes, air cleaner, spark plug, fuel filter etc...
MK-1600 MAINTENANCE Spark Plug Adjustments and Replacement For all Engine related maintenance and troubleshooting refer to the Engine Manual. Caution DO NOT work around the engine while hot. (A) When installing the Spark Plug, ensure the threads are aligned with the threads in the engine so as not to “cross-thread” the plug. Diamond Blade Removal (A) Open the Blade Guard Cover. (D) Install the new Blade, Retaining Bolt and Outer Flange. (B) Remove the Blade Shaft Nut and the Outer Flange.
MK-1600 MAINTENANCE Belt Adjustment and Replacement In order to ensure the saw operates at peak efficiency, the power transmission belt should be inspected monthly and changed if any signs of damage and/or excessive wear is observed. NOTE: 1. W hen a new belt is installed, it should be inspected and retensioned after the first forty-eight (48) hours of operation. 2. Do not over tension belts as damage to belts and bearings may occur.
MK-1600 MAINTENANCE (J) Clean and verify the alignment of the Engine and Blade Shaft Pulleys. (K) Install new belts onto the Engine Blade Shaft Pulleys. (L) Verify the belts are seated in all grooves of the Engine and Blade Shaft Pulleys. (M) Tighten the Engine Tension Arm Nuts. (N) Check belt for proper tension (Proper tension is approximately 1/8-inch deflection of the belt). (O) Repeat Steps L and M until proper tension is achieved. (P) Tighten the Engine Mounting Bolts.
MK-1600 TROUBLESHOOTING TROUBLESHOOTING When trouble occurs, be sure to check the simple causes which, at first, may seem too obvious to be considered. Refer to the table below for problems and their possible causes.
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MK-1600 EXPLODED VIEW 34
MK-1600 EXPLODED VIEW 35
MK-1600 EXPLODED VIEW 36
MK-1600 Item A1 A2 A3 A4 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15A D15B F1 F2 F3 F4 F5 F6 PARTS LIST Description Owner’s Manual, MK-1600 Warranty Card Wrench Key, 1/4 Hex Belt Guard Washer, 5/16 SAE Flat Washer, 5/16 Split Lock Screw, 5/16-18 X 1 Hex Head Cap Screw, 5/16-18 X 3/4 Hex Head Cap Back Plate, Belt Guard Washer, 1/4 SAE Flat Washer, 1/4 split lock Screw, 1/4-20 X 1/2 Hex Head Cap
MK-1600 Item F7 F8 F9 F10 F11 F12 F13 F14 G1 G2 G3 G4 G5 G6 G7 G8 G9 G10 G11 G12 G13 G14 G15 H1 H2 H3 H4 J1 JA1 JB1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11 J12 J13 J14 J15 J16 J17 J18 J19 J20 K1 K2 K3 K4 K5 K6 K7 K8 K9 PARTS LIST Description Nut, 3/8-16 Nylock Hex Screw, 3/8-16 X 2 Hex Head Cap Bearing, Flange, w/ zerk fitting Screw, 3/8-16 X 1 1/4 Hex Head Cap Nut, 3/8-16 Nylock Hex Spacer, Depth Control Nut, 3/4-10 Hex Screw, Depth Control Screw, 1/4 - 20 X 1/2 Pan Head Phillips Cap Bracket, Depth Indicator Nut
MK-1600 Item L1 L2 L3 L4 L5 M1 M2 M3 M4 M5 M6 M7 M8 N1 N2 N3 N4 N5 P1 P2 P3 P4 Q1 Q2 Q3 Q4 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 S S1 S2 S3 S4 S5 S6 T T1 T2 T3 T4 T5 U U1 U2 U3 U4 U5 U6 U7 U8 PARTS LIST Description Handlebar Handgrip, Neoprene Handlebar Plugs Screw, 3/8-16 X 2 Hex Head Cap Washer, 3/8 SAE Flat Arm, Pointer Pointer Wheel, Pointer Screw, 1/4-20 X 3/4 Thumb Clip, Stop Screw, 3/8-16 X 1 1/2 Hex Head Cap Washer, 3/8 SAE Flat Nut, 3/8-16 Nylock Hex Guard, Shaft Washer, 3/8 SAE Flat Washer, 3/8 Spl
MK-1600 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.
MK-1600 ACCESSories ACCESSORIES ITEM NUMBER DECRIPTION 134965 MK-500 18” x .125 x 1” Standard grade wet cutting blade for cured concrete 129072 MK-505 18” x .125 x 1” Premium grade, wet cutting blade for cured concrete 134965 MK-525 18” x .125 x 1” Supreme grade, wet cutting blade for cured concrete 133850 MK-705W 18” x .142 x 1” Premium grade, wet cutting blade for asphalt 139162 MK-610W 18” x .142 x 1” Supreme grade, wet cutting blade for green concrete 6 153550 MK-465D 18” x .
MK-1600 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-1600 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-1600 Concrete Saw OWNERS MANUAL & 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.
