MK-101 Pro MK-101 Pro 24 TILE SAW OWNER’S MANUAL & OPERATING INSTRUCTIONS CAUTION: Read all safety and operating instructions before using this equipment 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.
INTRODUCTION We at MK Diamond want to congratulate you on selecting the MK-101 Pro Series 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.
TABLE OF CONTENTS SAFETY: Safety Messages Damage Prevention Message General Safety Precautions and Hazard Symbols California Proposition 65 Message Electrical Requirements and Grounding Instructions Safety Label Locations Tile Saw Specific Warnings Product Specifications Page 4 4 4 4 6 7 9 9 10 UNPACKING, TRANSPORT, UNIVERSAL STAND, and ASSEMBLY Unpacking Contents Transport Universal Stand Assembly 11 11 11 12 13 SETUP, ADJUSTMENT AND OPERATION Setup Adjustment and Operation Cleanup 15 18 24 MAINTENAN
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 MESSAGES: Safety messages inform the user about potential hazards that could lead to injury, death and/or equipment damage.
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.
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.
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.
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.
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 1. 1B. 2. 3.
SAFETY MK-101 PRO SERIES PRODUCT SPECIFICATIONS: The MK-101 Pro Series are versatile Tile Saws. Operated and used according to this manual, the unit will provide years of dependable service. The MK-101 Pro and the MK-101 Pro 24 are engineered as tabletop or stand mounted wet tile saws. The saws include a powerful 115v totally enclosed capacitor start motor with a thermal protective overload. The MK-115 Pro 24 includes a powerful 120v or 240v.
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 PRO SERIES.
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY UNIVERSAL STAND: The MK-101 PRO SERIES weighs approximately one hundred and seven (107) pounds; follow the guidelines for transport in the TRANSPORT section, when placing it on the stand. Note: If using the MK Diamond, Universal Stand, follow the following steps.
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY ASSEMBLY: Follow the assembly instructions to prepare your MK-101 for operation. 1. Diamond Blade Installation: NOTE: When installing the Retaining Screw, do not “cross-thread" and DO NOT over tighten the screw.
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY 3. Splash Guard Installation: Splash Guard Retaining Hole Turn clockwise To tighten Thumbscrew (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 4.
SETUP, ADJUSTMENT and OPERATION SETUP: 1. Pre-start Inspection: Prior to beginning work, a pre-start inspection of the saw should be performed. ON/OFF Switch Off Position (A) Ensure the ON/OFF Switch is in the OFF position Verify ease of movement (See Maintenance section if problems exist) (B) Verify the Movable Cutting Table moves freely Inspect for cracks, de-bonding, etc.
SETUP, ADJUSTMENT and OPERATION 3. 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. (A) Place Water Pump in Water Pan (B) Place Water Pump Clamp as shown (C) Secure Clamp with ¼-20 wingscrews and nuts. I. External Water Source: This is the preferred method of cooling.
SETUP, ADJUSTMENT and OPERATION 4 MK-101 PRO SERIES Setup for Operation: 1. Before powering or starting, check for damage that could prevent this equipment from proper operation or performing it’s intended function. Check for binding and alignment of moving parts. Check for damaged, broken, or missing parts. 2. Verify the On/Off switch is in the OFF position. 3.
SETUP, ADJUSTMENT and OPERATION ADJUSTMENT and OPERATION: 1. Cutting Straight Edges: DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.
SETUP, ADJUSTMENT and OPERATION 2. Diagonal Cutting: NOTE: To cut diagonal, the Dual 45º Flat Angle Guide (MK Diamond Part No. 134557-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.
SETUP, ADJUSTMENT and OPERATION 3. 45º Miter Cutting: NOTE: To cut 45º Miters, the 45º Bullnose Miter Guide (MK Diamond Part No. 134585-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.
SETUP, ADJUSTMENT and OPERATION 4. 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. DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.
SETUP, ADJUSTMENT and OPERATION 5. Adjusting the Cutting Head: The Cutting Head is heavy! Care must be used when changing the position of the Cutting Head.
SETUP, ADJUSTMENT and OPERATION 6. Adjusting the Post for Maximum Cutting Length: The Cutting Head and Post are heavy! Use care when changing the position of the Cutting Head. ON/OFF Switch Off Position Slide Water Basin out of the front of the Saw Unplug (A) Ensure the ON/OFF Switch is in the OFF position (B) Unplug the GFCI from the power source* (C) Remove Water Basin Hold the Post when removing the Post Support Plate.
SETUP, ADJUSTMENT and OPERATION 7. Cleanup: NOTES: 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. Water Pump In container External Container Pump Suction (A) Clean the Water Pump suction of all debris (B) Place the Water Pump In an external container Cooling Flow Points (C) Run the MK-101 until clear water is seen at the blade cooling ports (Approx.
SETUP, ADJUSTMENT and OPERATION Ensure water is not forced into the motor casing when cleaning.
MAINTENANCE AND TROUBLESHOOTING MAINTENANCE: 1. New Maintenance: Perform the following after initial purchase and operation of the MK-101. Inspect V-belt (A) Check and adjust V-belt tension Following 1st 48 hours of operation (See V-belt Inspection) 2. 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.
MAINTENANCE AND TROUBLESHOOTING 3. Monthly Maintenance: The following maintenance should be performed Monthly.
MAINTENANCE AND TROUBLESHOOTING Cutting Head Adjustment Knob (I) Remove the Cutting Head (See Adjusting the Cutting Head) (J) Lubricate the Cutting Head Adjustment Knob Retaining Holes (K) Lubricate the Cutting Head Adjustment Knob retaining holes Pivot Shaft (L) Lubricate the Cutting Head Pivot Shaft 4. Flow Adjustment: NOTE: If flow to the diamond blade requires adjustment, perform the following actions.
MAINTENANCE AND TROUBLESHOOTING 1. 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.
MAINTENANCE AND TROUBLESHOOTING 2. Diamond Blade Change-out: NOTE: When installing the Retaining Screw, do not “cross-thread" and DO NOT over tighten the screw.
MAINTENANCE AND TROUBLESHOOTING 4. V-Belt Inspection, Adjustment and Replacement: The 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 changed 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.
MAINTENANCE AND TROUBLESHOOTING Old V-belt New V-belt Direction of push (J) Push the motor toward the front of the Cutting Head to loosen the V-belt (K) Remove the V-belt Belt Seated 9/16-inch Wrench Pulley (M) Verify the V-belt is seated in the grooves of both pulleys (N) Tighten the Motor Adjustment Strap to remove slack Retaining Bolts Rotate clockwise to tighten (P) Repeat steps N and O until proper V-belt tension is achieved Check Tension 1/2-way between pulleys Rotate clockwise to tighte
MAINTENANCE AND TROUBLESHOOTING TROUBLESHOOTING: 1.
MAINTENANCE AND TROUBLESHOOTING 3.
MAINTENANCE AND TROUBLESHOOTING NOTE: “Rodding” cooling channels is performed by inserting a small wire rod through the cooling inlet on top of the Blade Guard and directing the rod out through each of the cooling flow tubes located on the underside o the Blade Guard. The cooling channels should be “rodded” until all ports are free of foreign debris.
MAINTENANCE AND TROUBLESHOOTING ° 4.
EXPLODED VIEW AND PARTS LIST EXPLODED VIEW: MK-101 PRO 24 SAW W/STAND MK-101 PRO/PRO 24 Revision 07/05, Effective Date August 22, 2005 Page 37
EXPLODED VIEW AND PARTS LIST MK-101 PRO W/STAND MK-101 PRO/PRO 24 Revision 07/05, Effective Date August 22, 2005 Page 38
EXPLODED VIEW AND PARTS LIST BLADE GUARD CASTING, MK-101 PRO CUTTING HEAD ASSEMBLY, MK-101 PRO MK-101 PRO/PRO 24 Revision 07/05, Effective Date August 22, 2005 Page 39
EXPLODED VIEW AND PARTS LIST TABLE ASSEMBLY, MK-101 PRO MK-101 PRO/PRO 24 Revision 07/05, Effective Date August 22, 2005 Page 40
EXPLODED VIEW AND PARTS LIST TABLE ASSEMBLY, MK-101 PRO 24 MK-101 PRO/PRO 24 Revision 07/05, Effective Date August 22, 2005 Page 41
EXPLODED VIEW AND PARTS LIST MOTOR ASSEMBLY / 2HP, 120V, 60 Hz MK-101 PRO/PRO 24 Revision 07/05, Effective Date August 22, 2005 Page 42
EXPLODED VIEW AND PARTS LIST PARTS LIST: Item Description A A1 A1A A2 A3 A4 A5 A6 A7 A8 A8A A9 A10 A11 A13 A14 A15 A16 A17 A18 A19 A20 A20A A20B A20C A21 A21A A22 A23 A24 A24A A24B A25 A25A A25B A25C A25D A26 A26A A26B A26C A26D A26E A27 A28 A29 A30 A31 A32 A33 A33A A34 Accessories Carton, Accessory Pack, 101 Carton, Accessory Pack, PL-101 Foam, Accessory Pack Carton Wrench, 15/16 Closed End Guard, Splash Wing screw, 1/4-20 X 1/2 Washer, 1/4 SAE Flat Pump, Water, G-150A Pump, Water, G-300V, 230V Fitting,
EXPLODED VIEW AND PARTS LIST A35 A36 A37 A38 Lid, Acc Holder Manual-Clear Clamp, Holding, Pump Screw, Wing, 1/4-20x1/2 Nut, Hex, 1/4x20 1 1 2 2 150512 162054 151888 151893 C C1 C1A C2 C2A C2B C3 C4 C5 C7 C8 Frames Frame, 101 Frame, Pro-24 Pan, Plastic, 101 Pan, Plastic, Pro-24 Pan, Stainless Steel Pin, 3/16 X 3/8 Roll Plate, Adjustment Plug, Rubber Drain Drain Plug, HD Rental Strap, 9” Drain Plug 1 1 1 1 1 2 2 1 1 1 153003 153209 150634 153262 150634S 151783 151758 153439 159529 159530 D D1 D1A D1B
EXPLODED VIEW AND PARTS LIST F4 F5 F6 F7 Screw, 1/4-20 x 1 Hex Head Cap Washer, 1/4 Split Lock Washer, 1/4 SAE Flat Belt, 260J6 Micro-V 1 4 4 1 152676 152591 151915 158194 G G1 G1A G1B G1C G1D G1E G2 G3 G4 Blade Guard Assemblies Blade Guard, 101/115 Blade Guard, BD-101 Blade Guard, DT-101 Blade Guard, MK-101Rental, Orange Blade Guard, PL-101 Rental, Blue Blade Guard, 101/115Pro Tube, Water Screw, 5/16-18 X 1/2 Socket Head Set Elbow, 1/8 MNPT X 1/4 BARB 90° Brass 1 1 1 1 1 1 2 3 1 153659 153659-BD 153
EXPLODED VIEW AND PARTS LIST H31 H32 H33 H34 H35 H36 H37 H38 Screw, 10-24 X 5/16 Slotted Hex Washer Head Grounding Washer, #10 SAE Flat Washer, #10 Lock, Internal Teeth Terminal, 16-14 X #10 Ring, Non-insulated Receptacle, Pump Cord, Power Wire, MK-100/101 Jumper Label, Home Depot Tool Rental 1 1 2 1 1 1 2 1 159597 154369 158336 154540 159828 159829 160519 160602 J J1 J1A J1B J1C J2 J3 J4 J5 J6 J7 J8 J9 J10 J11 J12 J13 J14 J15 J16 J17 J18 J18A J19 J20 J21 J22 J23 Cutting Head Subassemblies Cutting Head
EXPLODED VIEW AND PARTS LIST L4 Washer, 5/16 SAE Flat 2 151754 M M1 M1A M2 M3 M4 M5 M6 M7 M8 M9 MA Tables Table, 100/101 Table, 1-Slot, 101Pro24 Table Extension, 101Pro Screw, 1/4-20 X 1/2 Socket Head Set Shim, .
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.
ACCESSORIES ACCESSORIES: ITEM 1. NUMBER DESCRIPTION 137166 MK-200, 10 x 5/8 Arbor 128074 MK-215, 10 x 5/8 Arbor 153252 MK-315, 10 x 5/8 Arbor 134577 Dual 45° Flat Angle Guide 134569 90° Protractor 152792 Dressing Stone 152610 Ground Fault Circuit Interrupter 151889 Universal Stand 2. 3. 4. 6. 7. 8. 9.
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. NOTE: There is a $25.00 minimum order when ordering direct from MK Diamond. All purchases must be made using VISA or MasterCard.
MK-101 Pro MK-101 Pro 24 TILE SAW OWNER’S MANUAL & OPERATING INSTRUCTIONS 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.
