MK Diamond Products MK-100 TRACKER Owner`s manual

MK-100 TRACKER
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-100 TRACKER 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-100 TRACKER should provide you with years of quality service. In order to help
you, we have included this manual. This owner’s manual contains information necessary to operate and
maintain your MK-100 TRACKER safely and correctly. Please take a few minutes to familiarize yourself with
the MK-100 TRACKER by reading and reviewing this manual.
If you should have questions concerning your MK-100 TRACKER, please feel free to call our friendly customer
service department at: 800 421-5830
Regards,
MK Diamond
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 2
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
16
19
26
MAINTENANCE AND TROUBLESHOOTING
Maintenance
Troubleshooting
27
38
EXPLODED VIEW AND PARTS LIST
Exploded View
Parts List
39
40
THEORY
Theory of Diamond Saws
43
ACCESSORIES
Accessories
44
ORDERING and RETURN INSTRUCTIONS
Ordering Information
Return Material Policy
Packaging Instructions
Authorized Service Centers
45
45
45
45
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 3
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. Each safety message will be preceded by one of the following (3) three words that identify the
severity of the message.
Not following instructions WILL lead to DEATH or SERIOUS INJURY
Not following instructions COULD lead to DEATH or SERIOUS INJURY
Not following instructions CAN lead to injury
DAMAGE PREVENTION AND INFORMATION MESSAGES:
A Damage Prevention Message is to inform the user of important information and/or instructions that could
lead to equipment or other property damage if not followed. Information Messages convey information that
pertains to the equipment being used. Each message will be preceded by the word NOTE, as in the example
below.
NOTE:
Equipment and/or property damage may result if these instructions are not followed.
GENERAL SAFETY PRECAUTIONS AND HAZARD SYMBOLS:
In order to prevent injury, the following safety precautions and symbols should be followed at all times!
Safety Precautions:
KEEP GUARDS IN PLACE.
In order to prevent injury, keep guards in place and in working order at all times.
REMOVE ADJUSTING KEYS AND WRENCHES.
Form a habit of checking to see that keys and adjusting wrenches are removed from the power tool before it
is turned on.
KEEP WORK AREA CLEAN.
Cluttered work areas and benches invite accidents.
DO NOT USE IN DANGEROUS ENVIRONMENTS.
Do not use power tools in damp or wet locations nor expose them to rain. Always keep the work area well
lighted.
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-100 TRACKER
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Page 4
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 7 shows the correct AWG
size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage.
The smaller the gage number, the heavier the cord.
WEAR 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.
ALWAYS USE SAFETY GLASSES.
Safety glasses should always be worn when working around power tools. In addition, a face,
dust mask or respirator should be worn if a cutting operation is dusty. Everyday eyeglasses only
have impact resistant lenses and may not prevent eye injury-they are NOT safety glasses.
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.
DO NOT OVERREACH.
Keep proper footing and balance at all times by not overreaching.
MAINTAIN TOOLS WITH CARE.
Keep tools clean for the best and safest performance. Always follow maintenance instructions for
lubricating, and when changing accessories.
DISCONNECT TOOLS.
Power tools should always be disconnected before servicing or when changing accessories, such as blades,
bits, cutters, and the like.
REDUCE THE RISK OF UNINTENTIONAL STARTING.
on
Make sure the trigger switch; locking button is in the RELEASE position before plugging in a power
tool.
USE RECOMMENDED ACCESSORIES.
Consult the owner's manual for recommended accessories. Using improper accessories may increase the
risk of personal or by-stander injury.
NEVER STAND ON THE TOOL.
Serious injury could occur if a power tool is tipped, or if a cutting tool is unintentionally contacted.
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 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.
DIRECTION OF FEED.
Always feed work into a blade or cutter against the direction of rotation. A blade or cutter should always be
installed such that rotation is in the direction of the arrow imprinted on the side of the blade or cutter.
NEVER LEAVE A TOOL RUNNING UNATTENDED – TURN POWER OFF.
Do not leave a tool until it comes to a complete stop. Always turn a power tool OFF when leaving the work
area, or, when a cut is finished.
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 5
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
Before plugging the equipment into an electrical outlet, be sure the trigger switch, locking button is in
the "RELEASE" position to prevent accidental starting. Unplug the power tool 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 covers, shrouds, or guards removed.
Sawing and drilling generates dust. Excessive airborne particles may cause irritation to eyes, skin and
respiratory tract. To avoid breathing impairment, always employ dust controls and protection suitable to the
material being sawed or drilled; See OSHA (29 CFR Part 1910.1200). 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.
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. Some
examples of these chemicals are:
• Lead, from lead-based paints
• Crystalline silica, from bricks and cement and other masonry products and
• Arsenic and chromium, from chemically treated lumber
For further information, consult the following sources:
http://www.osha-slc.gov/sltc/silicarystalline/index.html
http://www.oehha.org/prop65/out_of_date/6022kLstA.html
Your risk from these exposures varies depending on how often you do this type of work. To reduce your
exposure to these chemicals, work in a well-ventilated area, and work with approved safety equipment, such
as those dust masks that are specially designed to filter out microscopic particles.
MK-100 TRACKER
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Page 6
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. The plug must be plugged into a matching
outlet that is properly installed and grounded in accordance with all local codes and ordinances.
• Do not modify the plug provided – if it will not fit the outlet; have the proper outlet installed by a
qualified electrician
• Improper connections of the equipment-grounding conductor can result in a risk of electric shock.
The equipment-grounding conductor is the insulated conductor that has an outer surface that is
green, with or without yellow stripes. If repair or replacement of the electric cord or plug is
necessary, 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 cord immediately
Grounding
Pin
This tool is intended for use on a circuit that has an outlet that looks like the one shown in Sketch A
of Figure 1. The tool has a grounding plug that looks like the plug illustrated in Sketch A of FIGURE
1. A temporary adapter, which looks like the adapter illustrated in sketches B and C, may be used to
Connect this plug to a 2-pole receptacle as shown in Sketch B, if a
properly grounded outlet is not available. The temporary adapter
should be used only until a properly grounded outlet can be
Metal Screw
installed by a qualified electrician. The green-colored rigid ear,
Cover of Grounded
Outlet Box
lug, and the like, extending from the adapter, must be connected
(A)
(B)
to a permanent ground such as a properly grounded outlet box.
ADAPTER
(C)
Grounding
Means
Grounding
Pin
NOTE: Use of a temporary adapter is not permitted in Canada.
(D)
FIGURE 1
To reduce the risk of electrocution, keep all connections dry and off the ground.
A Ground Fault Circuit Interrupter (GFCI) should be provided on the circuit(s) or outlet(s) to be used
for the Tile Saw. Receptacles are available having built-in GFCI protections and may be used for
this measure of safety.
When using an extension cord, the GFCI should be installed closest to the power source, followed
by the extension cord and lastly, the saw.
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 7
SAFETY
Power
Cord
To avoid the possibility of the appliance plug or receptacle getting wet, position the saw to one side
of a wall mounted receptacle. This will prevent water from dripping onto the receptacle or plug. A
"drip loop," shown in FIGURE 2, should be arranged by the user to properly position the power cord
relative to the power source.
The "drip loop" is that part of the cord below the level of the receptacle, or
Power
Tool
the connector, if an extension cord is used. This method of positioning the
Supporting
Surface
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.
Drip Loop
FIGURE 2
Use only extensions 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 extension cords before using and replace if damaged. Do not
abuse extension cords and do not yank on any cord to disconnect. Keep cords away from heat and
sharp edges. Always disconnect the extension cord from the receptacle before disconnection the
product form the extension cord.
To reduce the risk of electrocution, keep all connections dry and off the ground. Do not touch the
plug with wet hands.
Use of undersize 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.
To choose the proper extension cord,
• Locate the length of extension cord needed in TABLE 1 below.
• Once the proper length is found, move down the column to obtain the correct AWG size required
for that length of extension cord.
As an example, a fifty (50) foot extension cord would require an AWG size of 16.
Extension Cord Minimum Gage for Length
Volts
120V
MK-100 TRACKER
25 ft.
AWG
14
Total Length of Cord in Feet
50 ft.
100 ft
150 ft.
AWG
AWG
AWG
12
Not Recommended
TABLE 1
Revision 02/03, Effective Date February 12, 2003
Page 8
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
1A.
1B.
1C.
2.
3A
3B
4A
4B
Location
Motor Rear
Motor Rear
Motor Rear
Blade Guard
Motor Front
Motor Front
Pump Left Side
Pump Right Side
A
Description
Caution Use Ground Fault Interrupt
Caution Receptacle for Pump Only
Service or Warranty Information
Serial Number
Warning Read and Follow Operating Instructions
Motor Specifications
Warning Connect to Grounded Receptacle
Pump Specifications
Part No.
155678
154822
155038
157249-01
155806
N/A
N/A
N/A
B
C
1
A
2
B
A
B
4
3
TILE SAW SPECIFIC WARNINGS:
Wear eye protection.
Use splash hood for every operation for which it can be used.
Disconnect saw before servicing, when changing cutting blades, and cleaning.
Use tool only with smooth edge cutting blades free of openings and grooves.
Replace damaged cutting blade before operating.
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 9
SAFETY
PRODUCT SPECIFICATIONS:
The MK-100 TRACKER is a versatile Tile Saw. Operated and used according to this manual, the MK-100
TRACKER will provide years of dependable service.
General Description:
The MK-100 TRACKER Tile Saw is engineered as a tabletop or stand mounted wet tile saw. The saw
includes a powerful 115v totally enclosed capacitor start GE 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. The saw can cut an object three and one-half (3-1/2) inches thick in one pass.
Motor Specifications:
Motor specifications for the MK-100 TRACKER are listed in Table 2 below.
Voltage
Overall Amperage
Motor Only Amperage
Frequency
RPM
Horse Power
Weight
115 v
13.4 a
12.8 a
60 Hz
3450 rpm
1.5 hp
97 lbs
Table 2
Thermal Overload Protection:
The motor is protected by a thermal overload equipped with a manual reset.
Blade Capacity:
The MK-100 TRACKER uses a ten (10) inch (254mm) diameter, wet cutting continuous rim, MK Diamond
blade with a one-sixteenth 1/16 inch (15.875 mm) cutting width and a five-eighths (5/8) inch (15.875 mm)
arbor.
Tile Types:
The MK-100 TRACKER can cut a variety of tile types including Porcelain, Terracotta, Marble, Quarry and
Slate, or almost any other non-ferrous material.
NOTE:
The MK-100 TRACKER is not designed to cut plastic or ferrous (metals) material.
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 10
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
UNPACKING:
Your MK-100 TRACKER has been shipped from the factory thoroughly inspected. Only minimal assembly is
required
Use proper lifting techniques when lifting the MK-100 TRACKER.
CONTENTS:
In your container, you will find one (1) MK-100 TRACKER frame and water basin, one (1) MK-100 TRACKER
Cutting, one (1) 10-inch wet cutting continuous rim diamond blade, one (1) adjustable cutting guide, one (1)
electric water pump, one (1) pump discharge fitting, one (1) cooling transfer tube, one (1) flow adjusting
clamp, one (1) drain plug, one (1) blade wrench, one (1) Table Clip, one (1) splash guard, one (1) owners
manual, one (1) pump manual and one (1) warranty card.
MK-100 TRACKER
Frame
and Water Basin
MK-100 TRACKER
Cutting Head
Removable Cutting
Table
Diamond Blade
Adjustable
Cutting Guide
Electric
Water Pump
Pump
Discharge Fitting
Cooling
Transfer Tube
Flow
Adjusting Clamp
Drain Plug
Wrench
Splash
Guard
Owners
Manual
Pump
Manual
Warranty
Card
TRANSPORT:
1. The MK-100 TRACKER weighs approximately ninety-seven (97) pounds.
2. Never transport the MK-100 TRACKER with water in the Water Basin.
The MK-100 TRACKER is designed with a rigid frame and removable Cutting Head. Two people are required
to transport the MK-100 TRACKER 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).
Lift the saw using the
lift points shown.
Cutting Head
Cutting Table
Lift Point
Lift Point
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 11
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
UNIVERSAL STAND:
The MK-100 TRACKER weighs ninety-seven (97) 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.
Slide Water Basin out
of the front of the Saw
(A)
Open the Universal Stand
and place on flat surface
Right Side
of Stand
Orientation
Pin
Left Side
of Stand
(B)
Remove Water Basin
Seat Left (Post)
Side of Saw
(D)
Seat Left (Post) Side of saw
onto stand between stand
Orientation Pin
Right Side
of Saw
Left Side
of Saw
Right Side
of Saw
Left side
of stand
Right Side
of Stand
(C)
Orient the Saw
to the Stand
Slide Water Basin
back in the Saw
Register
Angle
(E)
Seat Right Side of saw onto
stand between stand and
Register Angle
(F)
Reinstall the Water Basin
Cutting
Table
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 12
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
ASSEMBLY:
Follow the assembly instructions to prepare your MK-100 TRACKER for operation.
1. Cutting Head Installation:
NOTE: If the Cutting Head is installed, go to step 2.
Turn Counterclockwise to remove
Post
Rear Pivot
Hole
Turn Clockwise
to tighten
Pivot Shaft
(A)
Remove Adjusting Knob
(B)
Align Cutting Head rear Pivot
Hole to the Post, Pivot Shaft
(C)
Install the Cutting Head onto the
Post, Pivot Shaft and Install
The Adjusting Knob
2. Diamond Blade Installation:
NOTE: When installing the Retaining Screw, do not “cross-thread" and DO NOT over tighten the screw.
Pivot Blade
Guard up
Tighten
Wing-nut
Movable
Cutting Table
(A)
Position Movable Cutting Table
to the front of the saw and
raise the Blade Guard
Diamond
Blade
Cutting
Head
Press and
Hold
Shaft Lock
Pushbutton
(B)
Locate the Shaft Lock
pushbutton on the underside
of the Cutting Head
Rotation Direction
MK-100 TRACKER
Retaining Screw
and Outer Flange
(C)
Depress and hold the Shaft Lock
pushbutton and remove Retaining
Screw and Outer Flange using
the Blade Wrench
Rotate Blade
Wrench clockwise
to tighten
Retaining
Nut and
Outer Flange
Blade
Shaft
(D)
Install Diamond Blade
onto Blade Shaft
Blade
Wrench
Turn counterclockwise to
loosen
(E)
Verify the Blade is seated on
the Blade Shaft and direction
of rotation is correct
Revision 02/03, Effective Date February 12, 2003
(F)
Install Retaining Nut and Outer
Flange, depress and hold the
Shaft Lock pushbutton
and Tighten
Page 13
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
3. . Movable Cutting Table Installation:
Guide
Rail
Guide
Rail
Wheel
(A)
Align the four (4) wheels of the
Movable Cutting Table to the
saw Guide Rails
Verify
movement
Wheel
(B)
Seat all four (4) wheels onto the
Guide Rails
(C)
Verify movement of the Movable
Cutting Table
4. Adjustable Cutting Guide Installation:
NOTE: The Adjustable Cutting Guide can be used on either side of the Diamond Blade.
Turn counterclockwise to loosen
Adjustable
Cutting Guide
Turn clockwise
to tighten
Ruler/Stop
(A)
Loosen Adjustable Cutting
Guide retaining thumbscrew
and place it over the Movable
Cutting Table Ruler/Stop
Adjustable
Cutting Guide
Ruler/Stop
(B)
Place the Adjustable Cutting
Guide onto the Movable Cutting
Table Ruler/Stop and tighten
the retaining thumbscrew
5. 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
MK-100 TRACKER
(B)
Install the Splash Guard
onto the Blade Guard
Revision 02/03, Effective Date February 12, 2003
Page 14
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
5. Water Pump Preparation:
Cooling
Transfer
Tube
Turn clockwise
to tighten
Discharge
Fitting
(A)
Install Water Pump
Discharge Fitting
MK-100 TRACKER
Press on
(B)
Press one end of the Cooling
Transfer Tube onto the Water
Pump Discharge Fitting
Revision 02/03, Effective Date February 12, 2003
Flow Adjusting
Clamp
Press on
(C)
Slide Cooling Flow Adjusting
Clamp onto the Cooling
Transfer Tube
Page 15
SETUP, ADJUSTMENT and OPERATION
SETUP:
1. Pre-start Inspection:
Prior to beginning work, a pre-start inspection of the saw should be preformed.
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.
(C)
Inspect the Diamond Blade for
damage – verify the blade is
correct for the material being cut
Inspect for
damage
Inspect for
cracks or cuts
Inspect for
damage
(D)
Inspect the Pump Assembly
for damage – ensure the cord
is free of cracks or cuts
(E)
Inspect the MK-100 TRACKER
for damage – ensure the cord
is free of cracks or cuts
2. Connecting the Water Pump:
1.
2.
To prevent the possibility electrical shock, the MK-100 TRACKER 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 if cutting with a Dry Blade.
Cooling
Transfer
Tube
Inlet
connection
Press
together
Press on
(A)
Connect the Cooling Transfer
Tube to the inlet connection
of the Blade Guard
MK-100 TRACKER
Pump
Connection
(B)
Connect the Water Pump power
cord to the connection found on
the back of the motor
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Page 16
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.
I. External Water Source:
This is the preferred method of cooling.
Drain Plug
Cover Pump
Suction
Water Pump
In container
External
Container
(A)
Remove the Drain plug
(B)
Place the Water Pump
In an external container
(C)
Fill the external container until
water completely covers the
Water Pump suction
Catch
Basin
(D)
Place an external catch
basin below the Water
Basin drain hole
II. Re-circulation:
NOTE: When using the re-circulation method, the water should be changed often for longer pump life.
Drain Plug
Installed
Cover Pump
Suction
Water
Pump
(A)
Ensure the Drain Plug is
Installed in the Water Basin
MK-100 TRACKER
(B)
Place the Water Pump in the
back of the Water Basin
Revision 02/03, Effective Date February 12, 2003
(C)
Fill the Water Basin until water
completely covers the
Water Pump suction
Page 17
SETUP, ADJUSTMENT and OPERATION
4 MK-100 TRACKER Setup for Operation:
1. Before powering or starting, check for damage that could prevent this equipment from proper
operation or performing its 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. Before connecting the MK-100 to a power supply, be sure the voltage, cycle and phase of the
job site power source meet the requirements of TABLE 3
VOLTAGE:
CYCLE:
PHASE:
115v
60hz
1-phase
TABLE 3
4. If using an extension power cord, make sure the length and wire gauge correspond to the
requirements listed in TABLE 1 on page 9. 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.
NOTE: In order to avoid breaker tripping, a 20-amp circuit breaker should be used.
Portable Generator:
If using a portable generator to provide power, ensure the generator meets the following minimum
requirements:
8 KW
120/240 volts
66.7/33.3 amps
Single Phase
ON/OFF
Switch
Off
Position
GFCI
GFCI Plugged
Into Power
Source
(A)
Ensure the ON/OFF Switch
is in the OFF position
(B)
Plug MK-100 into the GFCI
(C)
Plug the GFCI into the
Power source
5. Set Cutting Depth:
When loosing the Cutting Head Adjusting Knob, the Cutting Head will pivot down unless held.
Turn Counterclockwise to loosen
(A)
Loosen Cutting Head
Adjusting Knob
MK-100 TRACKER
Adjust Cutting
Head to Cut Depth
of Approx ¼” to ½”
(B)
Set cutting depth approximately
1/4 to 1/2 inch below the surface
of the Movable Cutting Table
Revision 02/03, Effective Date February 12, 2003
Turn Clockwise
to tighten
(C)
Ensure the Adjusting Knob
is tight
Page 18
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.
Turn Clockwise
to tighten
Desired Cut length
indicated here
Turn Counterclockwise to loosen
(A)
Loosen the Adjustable Cutting
Guide retaining thumbscrew
Adjustable
Cutting Guide
(B)
Position the Adjustable Cutting
Guide to desired cut length
indicated inside the diamond
ON/OFF
Switch
On
Position
Cooling Flow
Points
Ruler/Stop
(D)
Place the tile against the
Ruler/Stop and Cutting Guide
Hold Work
in Position
(C)
Tighten the retaining
thumbscrew
(E)
Turn the motor ON
ON/OFF
Switch
(F)
Verify proper cooling flow on
both sides of the blade (See
Maintenance Section to
increase/decrease flow)
Off
Position
Direction
of Cut
(G)
Perform the cut
MK-100 TRACKER
(H)
Turn the motor OFF when
work is complete
Revision 02/03, Effective Date February 12, 2003
Page 19
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.
Turn counterclockwise to loosen
Adjustable
Cutting Guide
Turn counterclockwise to loosen
Ruler/Stop
(A)
Remove the Adjustable Cutting
Guide
NOTE:
Turn Clockwise
to tighten
Align Guide
to Ruler/Stop
Ruler/Stop
(B)
Place the Dual 45º Flat Angle
Guide on the Ruler/Stop
(C)
Position the Dual 45º Flat Angle
Guide and tighten the
retaining thumbscrew
If cutting the tile in two equal halves, align the tile in the V-notch of the Movable Cutting Table
Ruler/Stop.
45º Flat
Angle Guide
ON/OFF
Switch
On
Position
Cooling Flow
Points
Ruler/Stop
(D)
Position the tile against the Dual
45º Flat Angle Guide and the
Ruler/Stop
Hold Work
in Position
(E)
Turn the motor ON
ON/OFF
Switch
(F)
Verify proper cooling flow on
both sides of the blade (See
Maintenance Section to
increase/decrease flow)
Off
Position
Direction
of Cut
(G)
Perform the cut
MK-100 TRACKER
(H)
Turn the motor OFF when
work is complete
Revision 02/03, Effective Date February 12, 2003
Page 20
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.
Turn counterclockwise to loosen
Adjustable
Cutting Guide
Ruler/Stop
(A)
Remove the Adjustable Cutting
Guide
Bull Nose
Miter
Ruler/Stop
Turn Clockwise
to tighten
Turn counterclockwise to loosen
Align Guide
to Ruler/Stop
(B)
Place the 45º Bullnose Miter
Guide on the Ruler/Stop
ON/OFF
Switch
(C)
Position the 45º Bullnose Miter
Guide and tighten the
retaining thumbscrew
On
Position
Cooling Flow
Points
Ruler/Stop
(D)
Position the tile on the 45º
Bullnose Miter Guide and the
Ruler/Stop
(E)
Turn the motor ON
ON/OFF
Switch
Hold Work
in Position
(F)
Verify proper cooling flow on
both sides of the blade (See
Maintenance Section to
increase/decrease flow)
Off
Position
Direction
of Cut
(G)
Perform the cut
MK-100 TRACKER
(H)
Turn the motor OFF when
work is complete
Revision 02/03, Effective Date February 12, 2003
Page 21
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.
Turn counterclockwise to loosen
Adjustable
Cutting Guide
Turn counterclockwise to loosen
Ruler/Stop
(A)
Remove the Adjustable Cutting
Guide
Ruler/Stop
(B)
Place the 90º Protractor on
the Ruler/Stop
Turn Clockwise
to tighten
Turn Clockwise
to tighten
Align Guide
to Ruler/Stop
Protractor
Set Angle
(C)
Set the desired angle and
tighten the thumbscrew
ON/OFF
Switch
On
Position
Ruler/Stop
(D)
Position the 90º Protractor
and tighten the
retaining thumbscrew
(D)
Position the tile against the 90º
Protractor and the Ruler/Stop
Hold Work
in Position
Cooling Flow
Points
ON/OFF
Switch
Off
Position
Direction
of Cut
(F)
Verify proper cooling flow on
both sides of the blade (See
Maintenance Section to
increase/decrease flow)
MK-100 TRACKER
(E)
Turn the motor ON
(G)
Perform the cut
Revision 02/03, Effective Date February 12, 2003
(H)
Turn the motor OFF when
work is complete
Page 22
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.
ON/OFF
Switch
Turn Counterclockwise to remove
Off
Position
Unplug
(A)
Ensure the ON/OFF Switch
is in the OFF position
(B)
Unplug the GFCI from the
power source
Remove
Cutting Head
(C)
Remove Adjusting Knob
Turn Clockwise
to tighten
Front Pivot
Hole
Rear Pivot
Hole
(D)
Remove the Cutting Head from
The rear pivot hole
(E)
Install the Cutting Head onto
the front pivot hole
(F)
Install the Adjusting Knob
Adjust Cutting
Head to Cut Depth
of Approx ¼” to ½”
GFCI Plugged
Into Power
Source
(G)
Set cutting depth approximately
1/4 to 1/2 inch below the surface
of the Movable Cutting Table
MK-100 TRACKER
(H)
Plug the GFCI into the
power source
Revision 02/03, Effective Date February 12, 2003
Page 23
SETUP, ADJUSTMENT and OPERATION
6. Adjusting the Post for Maximum Cutting Length:
The Cutting Head and Post are heavy! Care must be used when changing the position of the
Cutting Head.
ON/OFF
Switch
Off
Position
Slide Water Basin
out front of 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.
Cutting
Head
Turn counterclockwise to loosen
(D)
Remove the Cutting Head (See
Adjusting the Cutting Head
Post
Rear
Holes
(G)
Relocate the Post to the rear
Post retaining holes
9/16-inch
Wrench
(E)
Loosen the Post Support Plate
and retaining bolts
Turn Clockwise
to tighten
9/16-inch
Wrench
(H)
Install and tighten the Post
Support Plate and retaining bolts
Post Support
Plate
(F)
Remove the Post Support Plate
and retaining bolts
Cutting
Head
(I)
Install the Cutting Head (See
Adjusting the Cutting Head
Slide Water Basin
in back of Saw
GFCI Plugged
Into Power
Source
(J)
Install the Water Basin
MK-100 TRACKER
(K)
Plug the GFCI into the
power source
Revision 02/03, Effective Date February 12, 2003
Page 24
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-100 TRACKER
until clear water is seen
at the blade
Ensure the saw is disconnected before completing the remainder of the cleanup process.
ON/OFF
Switch
Off
Position
GFCI
Unplug
(D)
Ensure the ON/OFF Switch
is in the OFF position
(E)
Unplug the GFCI from the
Power source
(F)
Unplug MK-100 TRACKER
from the GFCI
Clean Water
Basin
Soap and
Fresh Water
Slide Water Basin
out front of Saw
(G)
Clean the MK-100 TRACKER
with soap and clean water
(H)
Remove the Water Basin
from the MK-100 TRACKER
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
(I)
Clean the Water Basin
Page 25
SETUP, ADJUSTMENT and OPERATION
Ensure water is not forced into the motor casing when cleaning.
Clean
Guide Bar
(J)
Clean the Movable Cutting
Table Guide Bar
Roller Wheel
Frame Support
(K)
Clean the Movable Cutting
Table Roller Wheel Frame
Support
(L)
Clean the remainder of the
MK-100 TRACKER
Guide Wheel
Roller
Wheels
(M)
Clean the Movable Cutting
Table Roller Wheels
MK-100 TRACKER
(N)
Clean the Movable Cutting
Table Guide Wheels
Revision 02/03, Effective Date February 12, 2003
Page 26
MAINTENANCE AND TROUBLESHOOTING
MAINTENANCE:
1. New Maintenance:
Perform the following after initial purchase and operation of the MK-100.
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-100 TRACKER, 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.
ON/OFF
Switch
Off
Position
(A)
Ensure the ON/OFF Switch
is in the OFF position
GFCI
(B)
Unplug MK-100 TRACKER
Guide Bar
(C)
Lubricate the Guide Bar
Roller Wheel
Assembly
(A)
Lubricate the Roller
Wheel Assembly
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 27
MAINTENANCE AND TROUBLESHOOTING
3. Monthly Maintenance:
The following maintenance should be performed monthly.
Rotate Blade Wrench
counter-clockwise
to loosen
Outer
Flange
Retaining
Screw and
Outer Flange
(A)
Remove the Diamond Blade
Verify
Tight
(D)
Verify the Roller Wheel
Assembly is tight and in
good condition
(B)
Lubricate the Outer Flange
and Retaining-nut
Verify Four
Bolts Tight
(E)
Verify all motor mounting
Bolts are tight
Turn Counterclockwise to remove
(G)
Remove the Blade Guard
MK-100 TRACKER
Outer
Flange
(C)
Lubricate the Inner Flange
Verify Bolt
Tight
(F)
Verify the Motor Adjustment
Strap is tight
Blade Guard
Pivot Shaft
(H)
Lubricate the Blade Guard
Pivot Shaft
Revision 02/03, Effective Date February 12, 2003
Page 28
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.
Press Tab
to Restrict
Flow
Pull Tab
to loosen
(D)
Increase cooling flow by
releasing the Flow Adjusting
Clamp
MK-100 TRACKER
(E)
Reduce cooling flow by
Pressing down on the Flow
Adjusting Clamp
Revision 02/03, Effective Date February 12, 2003
Page 29
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. The diamond blade can be dressed using the MK Dressing
Stick (part number 152972) and by following the steps below.
Adjustable
Cutting Guide
Setup for
Operation
Set Adjustable
Cutting Guide
(A)
Setup the MK100 for operation
(See Setup, Adjustment
and Operation)
ON/OFF
Switch
(B)
Set the Adjustable Cutting Guide
to cut a 1/16-strip
Cooling Flow
Points
ON/OFF
Switch
(C)
Position the Dressing Stick
Hold Work
in Position
On
Position
(D)
Turn the motor ON
Ruler/Stop
(E)
Verify proper cooling flow on
both sides of the blade (See
Maintenance Section to
increase/decrease flow)
Direction
of Cut
(F)
Cut the Dressing Stick 7 or 8
times to dress the Blade
Off
Position
(G)
Ensure the ON/OFF Switch
is in the OFF position
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 30
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.
Cutting
Head
Diamond
Blade
Rotate Blade
Wrench counterclockwise to loosen
Retaining
Nut and
Outer Flange
Shaft Lock
Pushbutton
(A)
Locate the Shaft Lock
pushbutton on the underside
of the Cutting Head
(B)
Remove Retaining Nut and Outer
Flange, depress and hold the
Shaft Lock pushbutton and loosen
Diamond
Blade
Rotation Direction
(C)
Remove the Diamond Blade
Rotate Blade
Wrench clockwise
to tighten
Retaining
Nut and
Outer Flange
Blade
Shaft
(D)
Install the Diamond Blade
onto Blade Shaft
(E)
Verify the Blade is seated on
the Blade Shaft and direction
of rotation is correct
(F)
Install Retaining Nut and Outer
Flange, depress and hold the Shaft
Lock pushbutton and tighten
3. Cutting Head Stop Installation:
Blade
Stop Up
Rear
Pivot Hole
(A)
Remove the Cutting Head
(See Adjusting the Cutting Head)
(B)
Install Head Stop UP, when the
Cutting Head is installed on the
rear Pivot Hole
Blade
Stop Down
Front
Pivot Hole
(C)
Install Head Stop DOWN, when
the Cutting Head is installed on
the forward Pivot Hole
(D)
Reinstall the Cutting Head
(See Adjusting the Cutting Head)
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 31
MAINTENANCE AND TROUBLESHOOTING
3. V-Belt Inspection, Adjustment and Replacement:
The MK-100 TRACKER is designed with a power transmission v-belt. In order to ensure the MK-100
TRACKER 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.
ON/OFF
Switch
Diamond
Blade
Off
Position
Unplug
(A)
Ensure the ON/OFF Switch
is in the OFF position
(B)
Unplug the GFCI from the
Power source
7/16-inch
Wrench
Cutting
Head
(C)
Remove the Diamond Blade
Rotate Counterclockwise to
loosen
Inspect
V-belt
Three
Bolts
(D)
Remove the Cutting Head (See
Adjusting the Cutting Head
Check Tension
1/2-way
between pulleys
(E)
Remove the Belt Guard
Rotate Counterclockwise to
loosen
Retaining
Bolts
1/2-inch
Wrench
(G)
Check belt for proper tension
if tension correct, go to step R
(proper tension 1/8-inch)
MK-100 TRACKER
(H)
Loosen motor mounting bolts
If re-tensioning only, go
to step N
Revision 02/03, Effective Date February 12, 2003
(F)
Inspect the V-belt for cracks,
Fraying, separation and wear. Go
to step H if replacement required
Rotate Counterclockwise to
loosen
Adjustment
Strap Bolt
9/16-inch
Wrench
(I)
Loosen the Motor Adjustment
Strap
Page 32
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
Continue Adjustment
Until Correct
(N)
Tighten the Motor Adjustment
Strap to remove slack
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 tighten
Retaining
Bolts
1/2-inch
Wrench
MK-100 TRACKER
(L)
Install the new V-belt
(MK Diamond Part No. 158194)
(Q)
Tighten the motor
mounting bolts
Revision 02/03, Effective Date February 12, 2003
(O)
Check V-belt tension
(proper tension 1/8-inch)
7/16-inch
Wrench
Rotate clockwise
to tighten
Three
Bolts
(R)
Install the Belt Guard
Page 33
MAINTENANCE AND TROUBLESHOOTING
TROUBLESHOOTING:
4. Blade will not cut properly:
If Rotation incorrect,
reverse Blade
If “Glazed”, Dress Blade
(See Blade Dressing)
If not “Glazed”,
go to Step B
(A)
Check for Smoothness
or “Glazing” (Dress blade
if needed)
If Rotation Correct,
go to Step C
(B)
Check for proper rotation
If Blade Core is Bent,
Change Blade
If not “Glazed”, go
to Step D
(C)
Ensure the Blade Core
is not bent
Contact place of purchase or
MK Diamond (800 421-5830)
to verify blade
If Blade Correct,
go to Step E
(D)
Verify the blade is correct for
the material being used
Return to
MK Diamond
for Repair
(E)
Return to MK Diamond
5.1 Movable Cutting Table Does Not Move Correctly:
Clean Guide Bar
and Frame if dirty
If clean,
go to Step B
Check Roller
Wheel for wear
If Wheel not worn,
go to Step C
(A)
Check the Guide Bar and
Frame for cleanliness –
clean if dirty
MK-100 TRACKER
(B)
Check the Movable Cutting Table
Roller Wheels for wear –
replace if necessary
Revision 02/03, Effective Date February 12, 2003
Return to
MK Diamond
for Repair
(C)
Return to MK Diamond
Page 34
MAINTENANCE AND TROUBLESHOOTING
5.2 Cutting Table Alignment:
Allen
Screw
7/16-inch
wrench
(A)
Locate the Frame Retaining
Screws and Allen screw
Cutting
Table
Rotate counterclockwise to loosen
Frame
7/16-inch
wrench
Retaining
Screw
(G)
Tighten the back Frame
Retaining Screws
(C)
Loosen the back Frame Retaining
Screw
Blade
7/16-inch
wrench
Cutting
Groove
Retaining
Screw
(E)
Adjust the Frame until the
Movable Cutting Table, Cutting
Groove is centered with the
Blade
Allen
Screw
7/16-inch
wrench
Retaining
Screw
(B)
Loosen the front Frame
Retaining Screw
Allen
Wrench
(D)
Loosen the front Frame Allen
Screw
MK-100 TRACKER
Rotate counterclockwise to loosen
Retaining
Screw
Retaining
Screw
Allen
Screw
Rotate counterclockwise to loosen
Rotate clockwise
to loosen
(F)
Tighten the front Frame Retaining
Screws
Allen
Wrench
Rotate clockwise
to loosen
(H)
Tighten the front and back
Frame Allen Screws
Revision 02/03, Effective Date February 12, 2003
Page 35
MAINTENANCE AND TROUBLESHOOTING
6. Cooling Flow:
Cover Pump suction
with water
Pull to
Remove
If flow exists,
go to Step A
Go to
Step C
Pull Tab
to loosen
(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
Remove
Discharge Fitting
Pull to
Remove
Pull Intake Screen
to remove
If flow exist,
go to Step F
If flow exist,
go to Step E
(D)
Remove the Cooling Transfer
Tube and check flow
(E)
Remove the Pump Discharge
Fitting and check
Phillips
Screwdriver
Check Impeller
for damage
Once Screws
removed, go
to Step H
(G)
Remove the 3 Pump Casing
Retaining Screws
MK-100 TRACKER
If flow exist, go
to Step D
Check for
restriction
If Screen clean,
go to Step G
(F)
Remove the Pump Intake
Screen and check for debris
Intake Fitting
If no damage
or restrictions,
go to Step I
(H)
Remove the Pump Casing
and check for restriction;
check Impeller damage
Revision 02/03, Effective Date February 12, 2003
Turn counterClockwise
to loosen
Go to
Step J
(I)
Remove the Blade Guard
Intake Fitting
Page 36
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.
Allan Wrench
Cover
screws
Go to
Step K
(J)
Remove the Cooling Channel
cover screws
MK-100 TRACKER
Rod
Channels
Turn counterClockwise
to loosen
If cooling channels
clear, go to Step L
(K)
Rod Cooling Channels
and recheck flow
Revision 02/03, Effective Date February 12, 2003
Return to
MK Diamond
for Repair
(L)
Return to MK Diamond
Page 37
MAINTENANCE AND TROUBLESHOOTING
°
7. Blade Stops Turning:
Overload
Reset Switch
Verify all plugs
connected
If motor does not
start, go to Step B
If all plugs connected,
go to Step C
(A)
Allow motor to cool and
depress motor Overload
Reset Switch
(B)
Verify all plugs are fully
Installed*
If tripped, reset
once if trips again,
go to step F
If less than 20
Amps move saw
to 20 Amp circuit
Check Breaker
20 Amps
or greater
If circuit 20 Amp
or greater
go to Step E
(D)
Verify the circuit breaker is at
least 20 amps – if not, move to
20-amp circuit
Check Breaker
tripped
If circuit breaker
not tripped
go to Step F
(E)
Verify circuit breaker is not
tripped, if it is tripped – reset the
circuit breaker once
Reset once
if tripped
If not tripped, or
If a re-trip occurs,
Go to Step D
(C)
Check to see if the Ground
Fault Circuit Interrupter (GFCI)
is tripped*
Check for
correct circuit
voltage
If voltage is
115V go to Step G
(F)
Check power source voltage is
115V, if it is not 115v – move
to another circuit
Return to
MK Diamond
for Repair
(G)
Return to MK Diamond
* A GFCI wall socket is the preferred protective device.
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 38
EXPLODED VIEW AND PARTS LIST
EXPLODED VIEW:
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 39
EXPLODED VIEW AND PARTS LIST
PARTS LIST:
Item
A
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A11a
A12
A13
A14
A15
A16
A17
A18
Description
Accessory Pack
Wrench, 15/16 Closed End
Curtain, Splash
Bracket, Splash Curtain
Wingscrew, 1/4-20 X 1/2
Washer, 1/4 SAE Flat
Pump, 115v Water
Fitting, Plastic, 1/4 FNPT X 1/4 BARB
Hose, Vinyl, 1/4 ID
Clamp, Flow, 1/4-1/2
Owner’s Manual, Water Pump
Rip Guide (comp)
Screw, 1/4-20 X 3/4 Thumb
Blade, MK-100, 10 X 060 X 5/8
Owner’s Manual, MK-100 TRACKER
Carton, Accessory Pack, 101
Foam, Accessory Pack Carton
Card, MK Warranty Registration
Label, Do Not Return
Sell Sheet, Tile Accessory
Qty
1
1
1
1
1
1
1
2’
1
1
1
1
1
1
1
1
1
1
1
Part #
n/a
134684
134841
152571
151888
151915
151271
128397
132951
154394
155745
134551
150991
154380
153366
154022
155037
157063
156915
B
B1
B2
B3
B4
Carton
Carton, 100
Insert, Carton, Cutting Head
Insert, Carton, Accessory Pack
Pallet, 101, Plastic
1
2
1
1
n/a
158541
158542-1
158542-2
158767
C-E
Assembly, Frame
-
n/a
C
C1
C2
C3
C4
C5
Frame
Frame, 101
Pan, Plastic, 101
Pin, 3/16 X 3/8 Roll
Plate, Adjustment
Plug, Rubber Drain
1
1
2
2
1
n/a
153003
150634
151783
151758
153439
D
D1
D3
D4
D5
D6
Post
Post, DC, 101, MK Red (comp)
Post, DC, 101 (raw)
Shaft, 10.63” Pivot, 101
Steel, 1 Dia C1045 CDS
Screw, 3/8-16 X 1/2 Socket Head Set
Plate, Support
Screw, 3/8-16 X 2 1/2
Washer, 3/8 Split Lock
1
1
1
.92’
1
1
2
2
n/a
158438
158437
153254
156193
153710
155671
156030
150925
E
E1
E2
E3
Stop, Cutting Head
Kit, Stop, 10” Cutting Head
Stop, 10” Cutting Head
Screw, 1/4-20 X 1 1/4 Hex Head Cap
Washer, 1/4 Split Lock
1
1
1
1
157728-MK
157728
157145
152591
D2
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 40
EXPLODED VIEW AND PARTS LIST
Item
F-J
F
F1
F2
F3
F4
F5
F6
F7
F8
F9
G
G1
G2
G3
G4
G5A
H
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10
H11
H12
H13
H14
H15
H16
H17
H18
H19
H20
H21
H22
H23
Description
Assembly, 115V Cutting Head, MK-100
Qty
1
Part #
158225
Belt Guard
Belt Guard, MK-100 (comp)
Belt Guard, MK-100 logo (raw)
Insert, 3/8-16 AVK
Bracket, Inner Belt Guard, 100/101/101Pro
Screw, 1/4-20 x 3/4 Hex Head Cap
Screw, 1/4-20 x 1 Hex Head Cap
Washer, 1/4 Split Lock
Washer, 1/4 SAE Flat
Belt, 260J6 Micro-V
Knob, 3/8-16 X 1.5 MK Adjustment
Washer, 3/8 SAE Flat
1
1
2
1
3
1
4
4
1
1
1
n/a
158319-00
158318-00
158193
158611
152370
152676
152591
151915
158194
156770-2
150923
Blade Guard
Blade Guard, 101/115 (comp)
Blade Guard, MK logo (raw)
Elbow, 1/8 MNPT X 1/4 BARB 90° Brass
Tube, Water
Tubing, Stainless Steel 1/4 OD X .028 wall
Screw, 5/16-18 X 1/2 Socket Head Set
Label, Tile saw Serial #, No Mark
1
1
1
1
2
.75‘
3
1
n/a
153659
152508
154652
155389
152579
152607
157249-01
Subassembly, 115V Cutting Head, MK-100
Head, 10” Cutting (comp)
Head, 10” Cutting (raw)
Pin, Blade Shaft Lock
Spring, Blade Guard Lock
E-Ring, 1/4 Retaining
Bearing, 17mm X 40mm X 12mm Ball (6203-2NSE)
Shaft, Blade 880/101/1080
Steel, 3/4 Dia C12L14
Flange, 2-3/8 Inner
Steel, 2-3/8 Dia C12L14
Flange, 2-3/8 Outer
Nut, 5/8-18 Hex
Pulley, 6J19 X 5/8 Bore
Steel, 2.0 Dia C1215 CD
Key, 3/16 x 3/16 x 1 1/8 Square
Screw, 5/16-18 X 3/8 Socket Head Set, Cup Point
Bumper, 1/2 Dia Rubber
Screw, 5/16-18 X 1 Hex Head Cap
Washer, 5/16 SAE Flat
Washer, 5/16 Split Lock
Nut, 5/16-18 Hex
Screw, 5/16-18 x 2 1/2 Hex Head Cap, Full Thread
Pivot, Blade Guard
Washer, 3/8 SAE Flat
Wingnut, 5/16-18 Nylock
Strap, Motor Adjustment
Screw, 3/8-16 X 3 1/2 Hex Head Full Thread
1
1
1
1
1
1
2
1
1’
1
.09’
1
1
1
1.5”
1
2
1
4
4
4
4
1
1
2
1
1
1
158191
158224
158223
158200
158201
158202
137711
158222
154188
137737
154196
135830
135848
158199
154723
150344
157083
152674
151743
151754
151747
101196
151748
153208
150923
151746
152673
153147
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 41
EXPLODED VIEW AND PARTS LIST
Item
J
J1
J2
J11
J12
J13
J14
J15
J16
J17
J18
J19
J20
J21
J22
J23
J24
J25
J26
Description
Assembly, 1.5hp/115V/60Hz GE Motor
Motor, 1.5HP\115V\60Hz GE
Casting, Conduit Box (comp)
Casting, Conduit Box (raw)
Gasket, Conduit Box / Motor
Screw, #12 X 5/8 Indented Hex Washer Slotted B
Cord, 14/3 SJTW X 5-15P X Power
Cord, 18/3 SJTW X 5-15R Pump
Switch, 20A DPST Toggle, w/ QD Terminals
Plate, Toggle Switch Lockout
Boot, Toggle Switch
Pulley, 6J17 X 5/8 Bore
Steel, 1.75 Dia C1215 CD
Key, 3/16 x 3/16 x 1-1/8 Square
Screw, 5/16-18 X 3/8 Socket Head Set, Cup Point
Label, Warning, Read Owner’s Manual, 1-3/4 X 3-3/8
Label, Caution, GFCI, 1 X 2 1/8
Label, Caution, 5 Amp Max., 1 X 2-1/8
Label, MK Service Info., 2 1/8 X 1-13/16
Screw, 10-32 X 3/8 Hex Washer Head Grounding
Washer, #10 Internal Tooth Lock
Tie, 12 X #10 Clamp
Screw, 10-32 X 1 Socket Head Set, Cup Point
Nut, 10-32 Hex
Washer, 1/2 Internal Tooth Lock
Capacitor, 50mF Run, w/ QD Terminals
Terminal, 16-14 X .250 90° Female Spade
Capacitor, 270-324mF Start, w/ QD Terminals
Switch, Overload Protection
K-M
Assembly, Tracker Wheel Table, MK
1
159554
KA
KA1
KA2
KA3
KA4
KA5
KA6
KA7
KA8
KA9
Table, Tracker Wheel
Assembly, Tracker Wheel Table
Table, Tracker Wheel (comp)
Table, 100/101 (raw)
Wheel, Conveyor Cart
Nut, Hex w/ WSHR 5/16-18
Frame, Tracker Wheel
Stop, MK Tracker Wheel Table
Screw, 10/24 x 1/4 Socket Set – Cup Point
Screw, 5/16-18 x 3/4 Hex Head Cap
Washer, 5/16 Split Lock
Washer, 5/16 SAE Flat
1
1
1
2
2
1
1
2
4
4
4
159554
158962
157597
133090
153942
158937
159652
157522
151369
151747
151754
MA
MA1
MA2
MA3
MA4
MA5
MA6
MA7
Dual Roller Wheel
Assembly, Dual Roller Wheel
Bracket, Dual Roller Wheel
Wheel, Roller
Screw, 1/4-20 X 1 1/2 Hex Head Cap
Washer, 1/4 SAE Flat
Nut, 1/4-20 Hex
Shim, .004 X 5/16 ID X 1/2 OD
1
1
2
2
2
2
~4
159549
159548
151799
151914
151915
151893
152519
J3
J4
J5
J6
J7
J8
J9
J10
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Qty
1
1
1
1
1
2
1
1
1
1
1
1
1.5”
1
2
1
1
1
1
1
2
1
1
2
1
1
1
1
1
Part #
158297
157980
157971
158077
158213
158335
158205
158253
154310
158211
154301
158214
155342
150344
157083
155806
155678
154822
155038
158209
158336
158210
158254
156269
158337
158242
158798
158206
158207
Page 42
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. As a result, a diamond blade
for cutting soft, abrasive material must have a hard metal matrix composition to resist this erosion long
enough for the exposed diamonds to be properly utilized. Conversely, a blade for cutting a hard, nonabrasive material must have a soft bond to ensure that it will erode and expose the diamonds embedded in
the matrix. These simple principles are the foundation of “controlled bond erosion”.
Types of Cutting:
There are two basic types of cutting-Dry or Wet. The choice of which type of blade to use depends on:
• The requirements of the job
• The machine/tool utilizing the diamond blade
• The preference of the operator
In the case of DRY cutting, the overwhelming popularity and quantity of hand-held saws and the flexible
nature of MK Diamond blades to professionally handle most ceramic, masonry, stone and concrete materials,
make the DRY cutting blade a very attractive tool. When using a DRY blade, the user must be aware of
distinct operating practices to ensure optimum performance. DRY cutting blades require sufficient airflow
about the blade to prevent overheating of the steel core. This is best accomplished by shallow, intermittent
cuts of the material with periods of “free-spinning” (for several seconds) between each cut, to maximize the
cooling process.
For WET cutting applications, MK has the exact blade to compliment both the material to be cut and the wet
cutting machine to be used. 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
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 43
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
134585
(small)
or
153201
(large)
45° Bullnose Miter
134569
90° Protractor
152792
Dressing Stone
152610
Ground Fault Circuit Interrupter
151889
Universal Stand
2.
3.
4.
5.
6.
7.
8.
9.
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 44
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.
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
All parts may be ordered by calling toll free to – 800 421-5830 or 310 539-5221 and asking for Customer
Service. For technical questions, call – 800 474-5594.
RETURN MATERIALS POLICY:
To expedite the service relative to the return of a product purchased through MK Diamond, please observe
the following:
NOTE: When returning all items, they must have been purchased within the previous twelve (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 returned items, call toll free to – 800 421-5830 or 310 539-5221 and ask for Customer Service. For
technical questions, call – 800 474-5594 or 310 257-2845.
PACKAGING INSTRUCTIONS:
•
•
•
•
•
Remove the Blade guard and Support Angle Assembly
Dry the saw before shipping
When packing, include the following: MK-100, Diamond Blade, Blade guard and Support Angle Assembly
and Adjustable Cutting Guide (Other Accessories are not required)
Package the unit in its original container or one of comparable size (do not ship the unit partially exposed)
Ensure all parts are secured in the packaging to prevent moving
AUTHORIZED SERVICE CENTERS:
For quicker repair time, you may contact MK Diamond Customer Service, toll free, at – 800 421-5830 or 310
539-5221 for the Authorized Service Center closest too you. For technical questions, call – 800 474-5594.
MK-100 TRACKER
Revision 02/03, Effective Date February 12, 2003
Page 45
MK-100 TRACKER
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. Some examples of these
chemicals are:
• Lead, from lead-based paints
• Crystalline silica, from bricks and cement and other masonry products and
• Arsenic and chromium, from chemically treated lumber
Your risk from these exposures varies depending on how often you do this type of
work. To reduce your exposure to these chemicals, work in a well-ventilated area,
and work with approved safety equipment, such as those dust masks that are
specially designed to filter out microscopic particles.
MK DIAMOND PRODUCTS, INC
1315 STORM PARKWAY, TORRANCE, CA 90509-2803
310 539 5158