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MK Diamond Products MK-101-24HD, Owner'S Manual & Operating Instructions

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MK Diamond Products MK-101-24HD Owner'S Manual & Operating Instructions Download Page 40

40

When installing the Retaining Nut, do not "cross-thread" and DO NOT over 

tighten the nut.

Diamond Blade Change-out

(A)  

Locate the Shaft Lock push 

button on the underside of the 

Cutting Head

(B)  

Remove Retaining Nut and Outer 

Flange, depress and hold the Shaft Lock 

hold button and loosen

NOTE: 

(C)  

Remove the Diamond Blade

(D)  

Install the new Diamond Blade 

onto Blade Shaft. Install Outer 

Flange and Retaining Nut

(E)  

Verify the Blade is seated on 

the Blade Shaft and direction  of 

rotation is correct

(F)  

Depress and hold the Shaft Lock but-

ton and tighten Retaining Nut

MK-101-24HD   

MAINTENANCE

Summary of Contents for MK-101-24HD

Page 1: ...PERATING INSTRUCTIONS www mkdiamond com Caution Read all safety and operating instructions before using this equipment This owners manual MUST accompany the equipment at all times Revision 103 Manual Part No 169700 MK 101 24HD Part 169212 ...

Page 2: ... manual contains information necessary to operate and maintain your Tile Saw safely and correctly Please take a few minutes to familiarize yourself with the saw by reading and reviewing this manual If you should have questions concerning your saw please feel free to call our friendly customer service department at 800 421 5830 Regards MK Diamond NOTE For your 1 one year warranty to be effective co...

Page 3: ...ransport 23 Stand Optional 23 Assembly 24 26 SETUP STARTUP ADJUSTMENT OPERATION and SHUTDOWN Setup 27 29 Operation 30 33 Cutting Head Adjustment 34 35 Cleanup 36 MAINTENANCE AND TROUBLESHOOTING Maintenance 37 42 Troubleshooting 43 47 EXPLODED VIEW AND PARTS LIST Exploded View Parts List 48 55 ACCESSORIES ORDERING and RETURN INSTRUCTIONS Theory of Diamond Blade 56 Accessories 57 Ordering Informatio...

Page 4: ...ty 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 ALWAYS read this Owner s Manual before operating the machine DO ...

Page 5: ...er dust removal Use dust collection system when applicable NEVER operate the machine in an explosive atmosphere or near combustible materials Sparks from the cutting action of this machine can ignite flammable materials liquids gases or dust This equipment should not be operated by persons under 18 years of age always wear approved respiratory head ear and eye protection when operating this machin...

Page 6: ...angerous or hazardous environments DO NOT use power tools in damp or wet locations nor expose them to rain Always keep the work area well lighted REMOVE ADJUSTING KEYS AND WRENCHES KEEP WORK AREA CLEAN DO NOT USE IN DANGEROUS PLACES MAINTAIN TOOLS WITH CARE Keep tools clean and maintained for the best and safest performance Always follow maintenance instructions and examine the machine before use ...

Page 7: ...VER 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 modifications will void all warranties Manufacturer does not assume responsibility for any accident due to equipment modifications NEVER op...

Page 8: ...s dust masks that are specially designed to filter out microscopic particles Where use of a dust extraction device is possible it should be used To achieve a high level of dust collec tion use an industrial vacuum cleaner 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 sil...

Page 9: ... sécurité et par l un des trois mots suivants DANGER AVERTISSEMENT ou ATTENTION DANGER LE NON RESPECT des consignes entraînera des BLESSURES GRAVES voire la MORT AVERTISSEMENT LE NON RESPECT des consignes PEUT ENTRAÎNER des BLESSURES GRAVES voire la MORT ATTENTION LE NON RESPECT des consignes PEUT ENTRAÎNER des BLESSURES Il peut également être utilisé pour alerter contre les pratiques dangereuses ...

Page 10: ...de silice Prévoir un système de dépoussiérage adéquat Utiliser un système de captage des poussières le cas échéant NE JAMAIS utiliser l outil dans une atmosphère explosive ou près de matériaux combustibles Les étincelles produites par l action de coupe de cet outil peuvent enflammer les matériaux les liquides les gaz ou les poussières inflammables Cet équipement ne doit pas être utilisé par des pe...

Page 11: ... dans des endroits mouillés ou humides ne pas les exposer à la pluie Toujours garder le lieu de travail bien éclairé RETIRER LES CLÉS ET OUTILS DE RÉGLAGE GARDER LE LIEU DE TRAVAIL PROPRE NE PAS UTILISER DANS DES ENDROITS DANGEREUX ENTRETENIR SOIGNEUSEMENT LES OUTILS Garder les outils propres et bien entretenus pour une performance optimale et sécuritaire Toujours suivre les instructions d entreti...

Page 12: ...N NE JAMAIS débrancher tous les dispositifs d urgence ou de sécurité Ces dispositifs sont prévus pour la sécurité de l opérateur La déconnexion de ces dispositifs peut causer des blessures graves des lésions corporelles voire la mort La déconnexion d un de ces dispositifs annulera toutes les garanties Les modifications non autorisées de l équipement annuleront toutes les garanties Le fabricant déc...

Page 13: ...rable comme une substance connue pour causer le cancer Lors de la découpe de tels matériaux suivez toujours les précautions respiratoires Utiliser une protection respiratoire appropriée et approuvée NIOSH lorsqu il existe un risque de poussière Les masques en papier ou les masques chirurgicaux sans numéro d homologation NIOSH ne sont pas recommandés parce qu ils ne protègent pas suffisamment le tr...

Page 14: ...livret d instructions de votre moteur électrique fourni avec le moteur électrique Protéger le moteur électrique contre la poussière autant que possible et garder les ouvertures de ventilation propres Avant de brancher l outil s assurer que la tension de sortie est dans la plage indiquée sur la plaque signalétique de l outil NE PAS pulvériser de l eau sur le moteur électrique NE PAS toucher la fich...

Page 15: ...fer to your electric motor instruction book let furnished with the electric motor Protect the electric motor from dust as much as possible and keep 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 DO NOT spray water on the electric motor Do not touch the plug with wet hands To reduce the risk of el...

Page 16: ...ry do not connect the equipment grounding conductor to a live terminal Check with a qualified electrician or service personnel if the grounding instructions are not completely understood or if in doubt as to whether the tool is properly grounded Use only 3 wire extension cords that have 3 prong grounding plugs and 3 pole receptacles that accept the tool s plug Repair or replace a damaged or worn c...

Page 17: ...urface Power Tool Drip Loop Power Cord Drip Loop Information WARNING ON WARNING Use only extension cords that are intended for outdoor use These extension cords are identified by a marking Acceptable for use with outdoor appliances store indoors while not in use Use only extension cords having an electrical rating not less than the rating of the product Do not use damaged extension cords Examine e...

Page 18: ... 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 To choose the proper extension cord Locate the length of extension cord needed in the table below Once the proper leng...

Page 19: ...19 NOTES ...

Page 20: ...rooves Replace Damaged Cutting Wheel Before Operating Do Not Fill Water Bath Above Water Fill Line See Manual for Pump Replacement WARNING 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 25 50 75 100 150 250 Max Cord Length Max Cord Length Max Cord Length No 12 Wire ...

Page 21: ...18 Tile LxWxH inches 42 x 21 1 2 x 23 LxWxH mm 1 014 x 546 x 584 Part 169612 MK 101 24HD PRODUCT SPECIFICATION The MK 101 24HD is a versatile Tile Saw Operated and used according to this manual the unit will provide years of dependable service The MK 101 24HD is engineered as a table top or stand mounted wet tile saw The saw include a powerful 120V totally enclosed capacitor start motor with a the...

Page 22: ...nty Card Name address City state zip Code phoNe Fax e mail produCt model part NumBer maChiNe serial MK DiaMonD Warranty CarD q tile distriButor q home CeNter q equipmeNt supply house q tool supply q Bldg material supply q reNtal equipmeNt house are you a do it yourselFer q or CoNtraCtor q IF so what type tile q masoNry q other what Criteria was importaNt iN ChoosiNg this saw rate From 1 to 5 5 Bei...

Page 23: ...ion and Removal in the following section transport Lift Point Lift Point Cutting Head The MK 101 24HD weighs approximately ninety eight 98 pounds follow the guidelines for transport in the TRANSPORT section when placing it on the stand CAUTION Stand Optional MK 101 24HD PRODUCT SPECIFICATION A Open the stand and place on flat surface B Remove Water Basin place saw on stand C Ensure the back of the...

Page 24: ...all tiles 6 tile or smaller the Cutting Head should be in the rear pivot hole and the Post should be in the forward post retaining hole For large tiles and maximum cutting length the Cut ting Head should be in the front pivot hole and the Post should be in the rear post retaining hole Note Move Cutting Head Stop in upward position when using rear pivot hole and in the down position when using fron...

Page 25: ...nd remove Retaining Nut and Outer Flange using the Blade Wrench E Install Diamond Blade onto Blade Shaft F Verify the Blade is seated on the Blade Shaft and direction of rotation is correct G Install Retaining Nut and Outer Flange depress and hold the Shaft Lock pushbutton and tighten Retaining Nut NOTE When installing the Retaining Nut do not cross thread and DO NOT over tighten Diamond Blade Ins...

Page 26: ...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 MK 101 24HD ASSEMBLY Adjustable Cutting Guide Installation Splash Guard Installation Water Pump Preparation A Install Water Pump Discharge Fitting B Press one end of the Cooling Transfer Tube onto the Water Pump Discharge Fitting C Slide Cooling Flow Adjusting...

Page 27: ...ely C Inspect the Diamond Blade for damage verify the blade is correct for the material being cut D Inspect the Pump Assembly for damage ensure the cord is free of cracks or cuts E Inspect the MK 101 24HD for damage ensure the cord is free of cracks or cuts A Connect the Cooling Transfer Tube to the inlet connection of the Blade Guard B Connect the Water Pump power cord to the connection found on ...

Page 28: ... often for longer pump life A Ensure the Drain Plug is installed in the Water Basin CAUTION Water Pump Setup for Operation SETUP for Operation External Water Source Re circulation MK 101 24HD SETUP NOTE If using a dry blade for operation DO NOT connect the water pump 1 Before powering or starting check for damage that could prevent this equipment from proper operation or performing it s intended f...

Page 29: ...cle 4 I f using an extension power cord make sure the length and wire gauge cor respond to the requirements listed in on page 12 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 ov...

Page 30: ...sired cut length B Tighten the retaining thumbscrew C Place the tile against the Ruler Stop and Cutting Guide Turn the motor ON D Verify proper cooling flow on both sides of the blade See Maintenance Section to increase decrease flow E Perform the cut Turn the motor OFF when work is complete CAUTION Cutting Straight Edges MK 101 24HD OPERATION ...

Page 31: ...ing thumbscrew C Position the tile against the Guide and Ruler Stop Turn the motor on D Verify proper cooling flow on both sides of the blade See Maintenance Section to increase decrease flow E Perform the cut Turn the motor OFF when work is complete CAUTION MK 101 24HD OPERATION Diagonal Cutting Optional To cut diagonal the Dual 45º Flat Angle Guide MK Diamond Part No 134577 MK should be used NOT...

Page 32: ... tile on the 45º Bullnose Miter Guide and the Ruler Stop Turn the motor ON C Verify proper cooling flow on both sides of the blade See Maintenance Section to increase decrease flow D Perform the cut Turn the motor OFF when work is complete CAUTION 45 Miter Cutting Optional MK 101 24HD OPERATION To cut 45º Miters the 45º Bullnose Miter Guide MK Diamond Part No 153201 MK should be used NOTE ...

Page 33: ...e retaining thumbscrew D Position the tile against the 90º Protractor and the Ruler Stop Turn the motor ON E Verify proper cooling flow on both sides of the blade See Maintenance Section to increase decrease flow F Perform the cut Turn the motor OFF when work is complete CAUTION Off angle Cutting Optional MK 101 24HD OPERATION To cut angles other than 45º angles or Miters a 90º Protractor MK Diamo...

Page 34: ...pivot hole E Remove the Cutting Head Stop Bolt Rotate Cutting Head Stop to down position and re tighten Cutting Head Stop Bolt F Install the Adjusting Knob G Set cutting depth approximately 1 4 to 1 2 inch below the surface of the Movable Cutting Table NOTE For small tiles 6 tile or smaller the Cutting Head should be in the rear pivot hole and the Post should be in the forward post retaining hole ...

Page 35: ...ing the Cutting Head C Loosen the Post Support and retaining bolts D Remove the Post Support and Retaining Bolts E Remove and relocate the Post to the rear Post retaining holes F Install and tighten the Post Support and retaining bolts G Install the Cutting Head See Adjusting the Cutting Head H Install the Water Basin and Blade CAUTION CAUTION Adjusting the Post for Maximum Cutting Length MK 101 2...

Page 36: ...the cleanup process Ensure water is not forced into the motor casing when cleaning D Clean the Movable Cutting Table Guide Bar E Clean the Movable Cutting Table Roller Wheel Frame Support F Clean the remainder of the saw CAUTION CAUTION MK 101 24HD CLEANUP NOTES CLEANUP A Place the Water Pump in an external container B Run the saw until clear water is seen at the blade cooling ports Approx 1 minut...

Page 37: ... Check and adjust V belt tension following first 48 hours of operation See V belt Inspection A Lubricate the Guide Bar B Lubricate the Roller Wheel Assembly Ensure the saw is off and disconnected before performing any maintenance CAUTION MK 101 24HD MAINTENANCE MAINTENANCE Maintenance Following Use Perform the following after initial purchase and operation of the MK 101 24HD ...

Page 38: ... the Outer Flange and Retaining nut C Lubricate the Arbor Shaft D Verify the Roller Wheel Assembly is tight and in good condition E Verify all motor mounting Bolts are tight F Verify the Motor Adjustment Strap is tight G Remove the Blade Guard H Lubricate the Blade Guard Pivot Shaft I Remove the Cutting Head See Adjusting the Cutting Head ...

Page 39: ...r 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 MK Diamond Part No 152792 and by following the steps below Blade Dressing A Setup the MK100 for operation See Setup Adjustment and Operation B Set the ...

Page 40: ... Remove Retaining Nut and Outer Flange depress and hold the Shaft Lock hold button and loosen NOTE C Remove the Diamond Blade D Install the new Diamond Blade onto Blade Shaft Install Outer Flange and Retaining Nut E Verify the Blade is seated on the Blade Shaft and direction of rotation is correct F Depress and hold the Shaft Lock but ton and tighten Retaining Nut MK 101 24HD MAINTENANCE ...

Page 41: ... eight 48 hours of operation NOTE A Remove the Diamond Blade B Remove the Cutting Head See Adjusting the Cutting Head C Remove the two top Belt Guard Bolts D Remove Belt Guard bottom bolt E Inspect the Micro V Belt for cracks fraying separation and wear Go to step H if replacement is required F Check belt for proper tension If tension correct go to step Q proper tension should be 1 8 inch deflecti...

Page 42: ...mond Part No 158194 M Verify the Micro V Belt is seated in the grooves of both pulleys N Tighten the Motor Adjustment Strap to remove slack O Check Micro V Belt tension proper tension 1 8 inch Repeat steps N and O until proper Micro V Belt tension is achieved P Tighten the four motor mount ing bolts Q Install the Belt Guard MK 101 24HD MAINTENANCE ...

Page 43: ...re is not bent D Verify the blade is correct for the material being used A Check the Guide Bar and Frame for cleanliness clean if dirty B Check the Movable Cutting Table Roller Wheels for wear replace if necessary MK 101 24HD TROUBLESHOOTING Blade will not cut properly Movable Cutting Table Does Not Move Correctly ...

Page 44: ...ke Fitting Go to Step F E Remove the Cooling Channel cover screws Go to step G F Rod the Cooling Channels and then recheck flow 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 of the Blade Guard The cooling chan nels should be rodded unti...

Page 45: ...move to another circuit NOTE If alignment problems are the result of a warped blade a bent frame or bent support arm or if alignment is off by more than 1 8 inch contact the MK Diamond Service Center 800 474 5594 A Combination square square 12 inch or greater 1 2 inch Wrench or MK Triple Hole Box Wrench and MK Open End Wrench Blade Alignment Procedure Tools Needed The Movable Cutting Table of the ...

Page 46: ...ght cuts or Rip Cuts are made A Position Cutting Head to normal Cut Depth B Move Guide Bar until Blade is centered in Cutting Groove Tighten rear guide bar retaining bolt C Pull Movable Cutting Table to front of Tile Saw D Position Square flat on Movable Cutting Table against Ruler Stop Position front of Square against Blade E Move Guide Bar until Square rests evenly across Blade Horizontal Rough ...

Page 47: ... and reinstalled when removing the blade guard A Remove Blade Guard and water pan B Position Square on Movable Cutting Table against the Diamond Blade C Verify the Diamond Blade is Square to the Movable Cutting Table D If not Square loosen Movable Cutting Table Wheel Assembly to adjust Move Wheel Assembly up or down to Square the Movable Cutting Table E After Squaring tighten Movable Cutting Table...

Page 48: ...48 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 24 19 21 23 4 22 MK 101 24HD EXPLODED VIEW Saw Assembly Part 169212 ...

Page 49: ...FLAT SAE 1 4 151915 1 10 WASHER LOCK SPLIT 1 4 152591 1 11 PAN WATER 153262 1 12 CLAMP HOSE 1 4 1 2 FLOW 154394 1 13 KNOB TRI PLASTIC MK 660 1 1 2 156770 02 1 14 SCREW HEX HD 1 4 20 X 1 1 4 157145 1 15 STOP CUTTING HEAD 157728 1 16 DRAIN PLUG W RING 159529 1 17 STRAP 9 DRAIN PLUG 159530 1 18 RIP GUIDE LARGE DIE CAST 159751 1 19 MK 333JB 10 X 080 X 5 8 7MM 160294 HD 1 20 GUARD SPLASH 160310 1 21 as...

Page 50: ...50 1 2 3 4 5 6 7 8 9 11 13 INCLUDED WITH ITEM 8 2 3 5 10 12 Cutting Head Assembly Part 168167 MK 101 24HD EXPLODED VIEW ...

Page 51: ... 1 5 WASHER LOCK SPLIT 1 4 152591 4 6 SCREW HEX HD TAP 1 4 20 X 1 152676 1 7 SCREW 5 16 18 X 3 8 SOCKET HEAD SET 157083 1 8 ASSY SUB CUTTING HEAD MK 101 158191 1 9 BELT 6J260 158194 1 10 PULLEY 6J19 X 5 8 BORE 158199 1 11 CASTING 101 BELT GUARD COMP 158319 01 1 12 BRACKET INNER BELTGUARD 158611 1 13 MTR 1 1 2HP 115V 3400 RPM 168022G 1 MK 101 24HD PARTS LIST ...

Page 52: ...1754 5 11 STRAP 1 INCH MOTOR ADJ 152673 1 12 BUMPER RUBBER 1 2 DIA 152674 1 13 BOT 3 8 16 X 3 1 2 HEX HEAD TAP 153147 1 14 SCREW 5 16 18 X 3 8 SOCKET HEAD SET 157083 1 15 PULLEY 6J19 X 5 8 BORE 158199 1 16 BUTTON SHAFT LOCK 158200 1 17 SPRING BLADE SHAFT LOCK 158201 1 18 RING 1 4 E STYLE RETAINING 158202 1 19 SHAFT BLADE 158222 1 20 CASTING 10 CTTG HEAD COMP 158224 1 21 SCREW HEX HD TAP 5 16 18X3 ...

Page 53: ...W PARTS LIST Item Description Part Qty 1 SCREW 5 16 18 X 1 2 SOCKET HEAD SET 152607 3 2 ELBOW 1 8 MNPT X 1 4 BARB 90DET 154652 1 3 TUBE WATER 155389 2 4 CASTING 101 BLD GUARD DC COMP 162481 1 1 2 3 4 Assy Blade Guard Part 152582 ...

Page 54: ...STING 101 990 LNR BRG MT COM 135855 1 2 SCREW HEX HD 5 16 18 X 1 151743 4 3 WASHER LOCK SPLIT 5 16 151747 4 4 WASHER FLAT SAE 5 16 151754 4 5 ASSY WHEEL BRKT TSAW 151756 1 6 SPACER GUIDE BAR COVER COMMON 152393 2 7 COVER 3 4 X 37 GUIDE BAR 153219 1 8 BAR 3 4 X 37 GUIDE BAR 153492 1 9 CAST TABLE PRO24 OVRMLD COMP 161182 1 ...

Page 55: ...D VIEW PARTS LIST Assy Wheel Brkt Saw Part 151756 Item Description Part Qty 1 WHEEL ROLLER TSAW 151799 1 2 NUT HEX 1 4 20 151893 1 3 SCREW HEX HEAD 1 4 20 X 1 12 151914 1 4 WASHER FLAT SAE 1 4 151915 1 5 BRACKET ROLLER WHEEL 154021 1 ...

Page 56: ...ed During cutting operations liberal amounts of water act as a coolant to support the cutting effectiveness and longevity of the WET blade Additionally using water adds to the overall safety of cutting operations by keeping the dust signature down Know All You Can About the Material You Wish to Cut Diamond blades do not really cut they grind the material through friction Diamond crystals often vis...

Page 57: ...e 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 Miter 6 134569 MK 90 PROTRACTOR 7 152792 DRESSING STONE 8 152610 GROUND FAULT CIRCUIT INTERRUPTER 9 168244 Saw Stand ...

Page 58: ...12 months Have the Model Number of the saw Have the Serial Number of the saw Have the location of where the saw was purchased Have the date when the saw was purchased Contact Customer Service for approval to return the item s Obtain a Returned Goods Number RGA authorizing the return Follow the packaging instructions in the following section Ensure your item s are prepaid to the destination For ret...

Page 59: ...t at the time of approval for printing MK DIAMOND PRODUCTS INC will guarantee every machine they build to be free from defects in material and workmanship for 1 one year from date of purchase The obligation of MK DIAMOND PRODUCTS INC under this warranty is limited to the repair or replacement of any parts which under normal use prove to be defective in material or workmanship The parts involved or...

Page 60: ...MK 101 24HD TILE SAW OWNER S MANUAL OPERATING INSTRUCTION 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 com ...

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