MK Diamond Products MK-101 Pro24 JCS Owner's Manual
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MK Diamond Products MK-101 Pro24 JCS Owner's Manual

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Revision 204
Manual Part #162059
Caution: Read all safety and operating instructions
before using this equipment. This parts list MUST
accompany the equipment at all times.
MK-101 Pro24 JCS
Part # 153243-JCS
02.2015
OWNER'S MANUAL

OPERATING INSTRUCTIONS

MK-101 Pro24 JCS
U.S. Patent No. 7,419,538

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  • Page 1: Operating Instructions

    MK-101 Pro24 JCS OWNER'S MANUAL OPERATING INSTRUCTIONS MK-101 Pro24 JCS U.S. Patent No. 7,419,538 Part # 153243-JCS Revision 204 02.2015 Manual Part #162059 Caution: Read all safety and operating instructions before using this equipment. This parts list MUST accompany the equipment at all times.
  • Page 2 INTRODUCTION Congratulations on your purchase of a MK-101 Pro24 JCS. We are certain that you will be pleased with your purchase. MK Diamond takes pride in producing the finest construction power tools and diamond blades in the industry. Operated correctly, your MK-101 Pro24 JCS should provide you with years of service. In order to help you, we have included this manual.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY Safety Messages Damage Prevention Message General Safety Precautions and Hazard Symbols California Proposition 65 Message Candian French Safety Translation 9-14 Electrical Requirement 15-18 Safety Label Locations Lockout Product Specifications UNPACKING, TRANSPORT and ASSEMBLY Unpacking Contents Transport JCS Stand Setup 23-25 Assembly...

  • Page 4: Safety

    MK-101 Pro24 JCS SAFETY Read and follow all safety, operating and maintenance instructions. Failure to read and follow these instructions could result in injury or death to you or others. Failure to read and follow these instructions could also result in damage and/or reduced equipment life. Safety warnings and guidelines do not by themselves eliminate danger.
  • Page 5 MK-101 Pro24 JCS SAFETY PERSONAL PROTECTIVE EQUIPMENT ALWAYS wear approved respiratory, head, ear and eye protection when operating this machine. ACCIDENTAL STARTS! Before starting the engine/motor, be sure the ON/OFF switch is in the OFF position to pre- vent accidental starting. Place the ON/OFF switch in the OFF position before performing any service operation.
  • Page 6 MK-101 Pro24 JCS SAFETY USE PROPER APPAREL DO NOT wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry that may be caught in moving parts. Non-slip footwear is recommended. Wear protective hair cover- ing to contain long hair. SECURE WORK Clamps or a vise should be used to hold work whenever practical.
  • Page 7 MK-101 Pro24 JCS SAFETY CHECK FOR DAMAGED PARTS Before using a power tool, check for damaged parts. A guard or any other part that is damaged should be carefully checked to determine if it would operate properly and perform its intended function. Always check moving parts for proper alignment or binding.

  • Page 8: California Proposition 65 Message

    MK-101 Pro24 JCS SAFETY SILICA DUST WARNING Grinding/cutting/drilling of masonry, concrete, metal and other materials with silica in their composition may give off dust or mists containing crystalline silica. Silica is a basic component of sand, quartz, brick clay, granite and numerous other minerals and rocks. Repeated and/or substantial inhalation of airborne crystalline silica can cause serious or fatal respiratory diseases, including silicosis.

  • Page 9: Candian French Safety Translation

    MK-101 Pro24 JCS DE SéCURITé Lisez et suivez toutes les consignes de sécurité, d'utilisation et d'entretien. Ne pas lire et suivre ces consignes pourrait entraîner des blessures, voire la mort, pour vous ou d'autres personnes. Ne pas lire et suivre ces consignes pourrait aussi endommager et/ou raccourcir la durée de vie de l'équipement.
  • Page 10 MK-101 Pro24 JCS DE SéCURITé ÉQUIPEMENT DE PROTECTION INDIVIDUELLE Portez TOUJOURS l'équipement de protection respiratoire, auriculaire et oculaire homologué lors de l'utilisation de cet outil. DÉMARRAGES ACCIDENTELS! Avant de démarrer le moteur, vérifiez que le commutateur MARCHE-ARRÊT est en position ARRÊT (OFF) pour empêcher tout démarrage accidentel.
  • Page 11 MK-101 Pro24 JCS DE SéCURITé UTILISER DES VÊTEMENTS APPROPRIÉS NE PAS porter de vêtements amples, gants, cravates, bagues, bracelets ou autres bijoux susceptibles de se prendre dans les pièces mobiles. Le port de chaussures antidérapantes est recommandé. Les cheveux longs doivent être ramassés sous un couvre-chef.
  • Page 12 MK-101 Pro24 JCS DE SéCURITé VÉRIFICATION DES PIÈCES ENDOMMAGÉES Avant d'utiliser un outil électrique, vérifier s'il y a des pièces endommagées. Examiner soigneusement les pièces et dispositifs de protection qui semblent endommagés afin de déterminer s'ils fonctionnent correctement et remplissent les fonctions prévues. Vérifier toujours l'alignement et le réglage corrects des pièces mobiles.
  • Page 13 MK-101 Pro24 JCS DE SéCURITé AVERTISSEMENT SUR LA POUSSIÈRE DE SILICE La rectification/la coupe/le perçage de la maçonnerie, du béton, du métal et d'autres matériaux contenant de la silice dans leur composition peut dégager de la poussière ou des nuages contenant de la silice cristalline.
  • Page 14 MK-101 Pro24 JCS DE SéCURITé SÉCURITÉ DU MOTEUR ÉLECTRIQUE Pour les soins et les interventions d'entretien du moteur électrique, reportez-vous au 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.
  • Page 15 MK-101 Pro24 JCS SAFETY ELECTRIC MOTOR SAFETY For maintenance care and operation of the electric motor, refer 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.

  • Page 16: Electrical Requirement

    MK-101 Pro24 JCS SAFETY ELECTRICAL REQUIREMENTS AND GROUNDING INSTRUCTIONS In order to prevent electrical shock and injury, the following electrical safety precautions and symbols should be followed at all times! WARNING In case of a malfunction or breakdown, grounding provides a path of least resistance for electrical current to reduce the risk of electric shock.
  • Page 17 MK-101 Pro24 JCS SAFETY WARNING To avoid the possibility of the appliance or plug receptacle getting wet, position the machine to one side of a wall mounted receptacle. This will prevent water from dripping into the receptacle or plug. A "drip loop,"...
  • Page 18 MK-101 Pro24 JCS SAFETY WARNING Use of undersized extension cords result in low voltage to the motor that can result in motor burnout and premature failure. MK Diamond warns that equipment returned to us showing signs of being run in a low voltage condition, through the use of undersized extension cords,will be repaired or replaced totally at the customer’s expense.

  • Page 19: Safety Label Locations

    MK-101 Pro24 JCS SAFETY SAFETY LABEL LOCATIONS The warning 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.

  • Page 20: Lockout

    MK-101 Pro24 JCS SAFETY LOCK OUT METHOD In order to help prevent accidental starting and to help make your work area “kidproof,” this machine is provided with a means to deactivate the functioning of the motor switch. The switch is equipped with a lockout tab that can be used with a lock to prevent movement of the switch.

  • Page 21: Unpacking

    MK-101 Pro24 JCS SAFETY UNPACKING Your saw has been shipped from the factory thoroughly inspected. Only minimal assembly is required. CAUTION Use proper lifting techniques when lifting the Saw. CONTENTS In your container, you will find one (1) MK-101 frame and water basin, one (1) MK-101 Cutting Head, one (1) 10-inch wet cutting continuous rim diamond blade, one (1) adjustable cutting guide, one (1) water pump clamp and wing nuts, one (1) electric water pump, one (1) protractor, one (1) dual flat 45°...

  • Page 22: Transport

    MK-101 Pro24 JCS TRANSPORT TRANSPORT CAUTION 1. The MK-101 weighs approximately two hundred and two (202) pounds. 2. Never transport the MK-101 with water in the Water Basin. Lift the saw using the handle. Cutting Head Wheels Handle Casters...

  • Page 23: Jcs Stand Setup

    MK-101 Pro24 JCS STAND SET-UP JCS STAND: Key Components for Set Up NOTE: Familiarize with the following components before proceeding to SET UP. Handle Red Leg Lock Green Blue Knob Knob Wheel Lock Cross Member Front Leg Springs Safety Cutting Head...
  • Page 24 MK-101 Pro24 JCS STAND SET-UP JCS STAND: Key Components for Set Up THE MK-101 w/JCS stand weighs approximately two hundred and two pounds CAUTION (202 pds). Read and understand all instructions. Failure to follow all instructions in SEQUENCE could result in serious injury.
  • Page 25 MK-101 Pro24 JCS STAND TAKE-DOWN JCS STAND - Take Down Instructions Move table forward toward Pull and hold Green Knob. Lift Release Green Knob to operator. Safety Arm until it hits bottom secure Safety Arm. of Frame. Move Table back and...

  • Page 26: Assembly

    MK-101 Pro24 JCS ASSEMBLY ASSEMBLY Follow the assembly instructions to prepare your MK-101 for operation. Cutting Head Installation NOTE: If the cutting head is installed, go to the next step. Align Cutting Head rear Pivot Ensure Cutting Head stop is in...
  • Page 27 MK-101 Pro24 JCS ASSEMBLY DIAMOND BLADE INSTALLATION NOTE: When installing the Retaining Screw, do not “cross-thread” and DO NOT over tighten the screw. Shaft Lock Pushbutton Position Movable Cutting Table Locate the Shaft Lock push Depress and hold the Shaft...
  • Page 28 MK-101 Pro24 JCS ASSEMBLY ADJUSTABLE CUTTING GUIDE INSTALLATION NOTE: The Adjustable Cutting Guide can be used on either side of the Diamond Blade. Place the Adjustable Cutting Guide onto the Movable Cutting Table Ruler/Stop and tighten the retaining thumbscrew. SPLASH GUARD INSTALLATION...

  • Page 29: Setup

    – verify the blade is correct for the material being cut. Inspect for damage Inspect the Pump Assembly Inspect the MK-101 Pro24 JCS for damage – ensure the cord for damage – ensure the cord is free of cracks or cuts.
  • Page 30 MK-101 Pro24 JCS SETUP 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. External Water Source This is the preferred method of cooling.

  • Page 31: Operation

    MK-101 Pro24 JCS OPERATION MK-101 PRO Series Setup for Operation CAUTION 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.
  • Page 32 MK-101 Pro24 JCS OPERATION Set Cutting Depth CAUTION When loosing the Cutting Head Adjusting Knob, the Cutting Head will pivot down unless held. Loosen Cutting Head Set cutting depth approximately Tighten the Adjusting Knob. Adjusting Knob. 1/4 to 1/2 inch below the surface of the Movable Cutting Table.
  • Page 33 MK-101 Pro24 JCS OPERATION 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 CAUTION it was designed.
  • Page 34 MK-101 Pro24 JCS OPERATION 45° Miter Cutting NOTE: To cut 45° Miters, the 45° Bullnose Miter Guide (MK Diamond Part No. 153201- MK) should be used. CAUTION DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.

  • Page 35: Operation

    MK-101 Pro24 JCS OPERATION 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 CAUTION it was designed.

  • Page 36: Adjustment

    MK-101 Pro24 JCS ADJUSTMENT Adjusting the Cutting Head NOTE: For larger tiles and maximum cutting length, the cutting head should be in the front pivot hole. The Cutting Head is heavy! Care must be used when changing the position of the CAUTION Cutting Head.
  • Page 37 MK-101 Pro24 JCS ADJUSTMENT Adjusting the Post for Maximum Cutting Length The Cutting Head and Post are heavy! Use care when changing the position of the CAUTION Cutting Head. Ensure the ON/OFF Switch Remove Water Basin. Remove the Cutting Head (See is in the OFF position.

  • Page 38: Cleanup

    MK-101 Pro24 JCS CLEANUP Cleanup NOTE: 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. Run the MK-101 until clear...

  • Page 39: Maintenance

    MK-101 Pro24 JCS MAINTENANCE NEW MAINTENANCE Perform the following after initial purchase and operation of the MK-101. Check and adjust V-belt tension following first 48 hours of operation (See V-belt Inspection). Maintenance Following Use To extend the life of the MK-101 Pro24, the following procedure should be performed after each use.

  • Page 40: Monthly Maintenance

    MK-101 Pro24 JCS MAINTENANCE Monthly Maintenance The following maintenance should be performed Monthly. Lubricate the Arbor Shaft. Remove the Diamond Blade. Lubricate the Outer Flange and Retaining-nut. Verify the Motor Adjustment Verify all motor mounting Verify the Roller Wheel Strap is tight.
  • Page 41 MK-101 Pro24 JCS MAINTENANCE Flow Adjustment NOTE: If flow to the diamond blade requires adjustment, perform the following actions. Increase cooling flow by releas- Reduce cooling flow by ing the Flow Adjusting Clamp. Pressing down on the Flow Adjusting Clamp.
  • Page 42 MK-101 Pro24 JCS MAINTENANCE Diamond Blade change-out NOTE: When installing the Retaining Screw, do not “cross-thread” and DO NOT over tighten the screw. Locate the Shaft Lock pushbutton Remove Retaining Nut and Remove the Diamond Blade. on the underside of the Cutting Outer Flange, depress and hold Head.
  • Page 43 MK-101 Pro24 JCS MAINTENANCE Belt Inspection, Adjustment and Replacement The MK-101 is designed with a power transmission belt. In order to ensure the MK-101 operates at peak efficiency, the belt should be inspected monthly, and changed if the belt shows damage and/or excessive wear.
  • Page 44 MK-101 Pro24 JCS MAINTENANCE Remove the belt. Install the new belt Verify the belt is seated in the (MK Diamond Part No. 158194). grooves of both pulleys. Tighten the Motor Adjustment Check belt tension Repeat steps N and O until Strap to remove slack.

  • Page 45: Troubleshooting

    MK-101 Pro24 JCS TROUBLESHOOTING Blade will not cut properly Check for Smoothness Check for proper blade rotation. Ensure the Blade Core or “Glazing” (Dress blade is not bent. if needed). Verify the blade is correct for the material being used.

  • Page 46: Cooling Flow

    MK-101 Pro24 JCS TROUBLESHOOTING Cooling Flow Verify the cooling flow Remove the Cooling Transfer Place Pump into a bucket of Adjusting Clamp is open. If flow Tube from the Blade Guard water and check flow. If flow exists, go to Step A.
  • Page 47 MK-101 Pro24 JCS TROUBLESHOOTING BLADE STOPS TURNING Allow the motor to cool and Verify all plugs fully installed. depress motor Overload Check Ground Fault Circuit Reset Switch. If motor does not Interrupter start, go to Step B. NOTE: Verify circuit breaker at least 20 amps - if not, move to 20-amp circuit.
  • Page 48 MK-101 Pro24 JCS TROUBLESHOOTING Movable Cutting Table Misaligned The Movable Cutting Table of the MK-101 may become misaligned with the Cutting Head of the Tile Saw over time. Should misalignment occur, perform the following steps to realign the Tile Saw.
  • Page 49 MK-101 Pro24 JCS TROUBLESHOOTING HORIzONTAL ALIGNMENT PROCEDURE The Horizontal alignment will ensure that straight cuts (or Rip Cuts) are made. Pull Movable Cutting Table Position Cutting Head Move Guide Bar until Blade is to front of Tile Saw. to normal Cut Depth.

  • Page 50: Troubleshooting

    MK-101 Pro24 JCS TROUBLESHOOTING 90° ALIGNMENT VERIFICATION 90º-alignment verification ensures the blade cuts tile straight up and down and not at an angle. The Diamond blade must be removed and reinstalled when removing the blade guard. NOTE: If the blade is misaligned following 90º-alignment verification, return the saw to MK Diamond for repair.
  • Page 51 NOTES...
  • Page 52 MK-101 Pro24 JCS EXPLODED VIEW MK-101 Pro24 JCS Part # 153243-JCS...
  • Page 53 MK-101 Pro24 JCS PARTS LIST Part# Item Description FITTING, PLASTIC, 1/4 FNPT x 1/4 BARB 128397 HOSE, VINYL, 1/4 x 3/8 TSAW 132951 CASTING, ACC DUAL FLAT-COMP 134577 WRENCH, TILESAW, 15/16 CSD END 134684 WASHER, FLAT, SAE, 3/8 150923 WASHER, LOCK, SPLIT, 3/8...
  • Page 54 MK-101 Pro24 JCS EXPLODED VIEW JCS Portable Stand Part # 169218...
  • Page 55 MK-101 PRO24 JCS PARTS LIST Part# Item Description WASHER, FLAT, SAE, 3/8 150923 WASHER, FLAT, SAE, 5/16 151754 NUT, 3/8 16 NYLOK HEx 152505 SCREW, 5/16 - 18 x 1 HEx HEAD MACHINE 152520 NUT, HEx, 8 -32 153549 SCREW, 5/16 -1 8 x 2 HEx HEAD 155494 WHEEL, REAR 8"...
  • Page 56 MK-101 Pro24 JCS EXPLODED VIEW & PARTS LIST MK-101 Pro24 JCS Part # 169220 Part# Item Description CASTING, 101/990 LNR BRG MT-COM 135855 SCREW, HEx HD, 5/16 - 18 x 1 151743 WASHER, LOCK, SPLIT, 5/16 151747 WASHER, FLAT, SAE, 5/16...
  • Page 57 MK-101 Pro24 JCS EXPLODED VIEW & PARTS LIST MK-101 Pro24 INCLUDED WITH ITEM 8 Part # 158478 INCLUDED WITH ITEM 8 QTY. Item Description PART # KEY, 3/16 SQ x 1 - 1/8 150344 WASHER, FLAT, SAE, 1/4 151915 SCREW, HEx HD, 1/4 - 20 x 3/4...
  • Page 58 MK-101 Pro24 JCS EXPLODED VIEW & PARTS LIST MK-101 Pro24 Part # 160486 ITEM DESCRIPTION Part # TERMINAL, 16 - 14 AWG x #10 RING 154540 ASSY, SWITCH BOx, 30AMP, LTF11 161101 MTR, 1-1/2HP, 115V, SBOx, GRN 169223G...
  • Page 59 MK-101 Pro24 JCS EXPLODED VIEW & PARTS LIST Switch Box Part # 161101 Part# Item Description WASHER, #10 SAE FLAT 154369 SCREW, PAN HD PHIL 6 - 32 x 5/8 157393 WASHER #10, INTERNAL TEETH 158336 BUSHING, SWITCH, 30 AMP...
  • Page 60 MK-101 Pro24 JCS EXPLODED VIEW & PARTS LIST Roller Wheel Part # 151756 Part# Item Description WHEEL, ROLLER 151799 NUT, 1/4 - 20 HEx 151893 BELT, MICRO-V, 260J6 151914 WASHER, 1/4 SAE FLAT 151915 BRACKET, ROLLER WHEEL 154021...
  • Page 61 MK-101 Pro24 JCS EXPLODED VIEW & PARTS LIST Cutting Head Part # 158191 ITEM # DESCRIPTION PART # QTY. NUT, HEx, 5/16 - 18 101196 FLANGE, OUTER, 2 - 3/8 135830 NUT, HEx, 5/8-18 135848 BEARING, BALL, 17x40x12MM 137711 KEY, 3/16 SQ x 1-1/8...
  • Page 62 MK-101 Pro24 JCS EXPLODED VIEW & PARTS LIST Part# Item Description SCREW, 5/16 - 18 x 1/2 SOCKET HEAD SET 152607 ELBOW, 1/8 MNPT x 1/4 BARB 90DEG 154652 TUBE, WATER 155389 CASTING, 101 BLD GUARD-DC-COMP 162481...

  • Page 63: Accessories

    MK-101 Pro24 JCS ACCESSORIES ACCESSORIES ITEM NUMBER DESCRIPTION MK-200 10” x .060 x 5/8” 137166 Premium grade tile blades for fast, smooth, chip-free MK-215 18” x .060 x 5/8” 128074 Supreme grade diamond blade for hard materials MK-315 10” x .080 x 5/8”...

  • Page 64: Ordering Information

    MK-101 Pro24 JCS ORDERING & RETURN ORDERING INFORMATION You may order MK Diamond products through your local MK Diamond distributor or, you may order direct from MK Diamond. When ordering direct from MK Diamond, please have the following information ready before calling: •...

  • Page 65: Contact

    © COPYRIGHT 2014, MK DIAMOND PRODUCTS, INC. ALL RIGHTS RESERVED. The MK Diamond logo is a registered trademark of MK Diamond Products, Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their re- spective owners and used with permission.
  • Page 66 NOTES...
  • Page 67 NOTES...
  • Page 68 MK-101 Pro24 JCS OWNER'S MANUAL & OPERATING INSTRUCTIONS MK Diamond Products, Inc. 1315 Storm Parkway Torrance, CA 90501 Toll-Free: (800) 421-5830 Phone: (310) 539-5221 Fax: (310) 539-5158 www.mkdiamond.com...

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