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

Mk diamond mk-101 pro24 jcs tile saw
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MK-101 Pro24 JCS
OWNER'S MANUAL

OPERATING INSTRUCTIONS

U.S. Patent No. 7,419,538
Revision 201
06.2013
Manual Part #162059
Caution: Read all safety and operating instructions
before using this equipment. This parts list MUST
accompany the equipment at all times.

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Summary of Contents for MK Diamond Products MK-101 Pro24 JCS

  • Page 1: Operating Instructions

    MK-101 Pro24 JCS OWNER'S MANUAL OPERATING INSTRUCTIONS U.S. Patent No. 7,419,538 Revision 201 06.2013 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 Electrical Requirement & Grounding Instructions 9-10 Electric Motor Safety Safety Label Locations Lockout Product Specifications UNPACKING, TRANSPORT and ASSEMBLY Unpacking Contents Transport JCS Stand Setup 16-18...

  • 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 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.
  • Page 6 MK-101 Pro24 JCS SAFETY USE RECOMMENDED ACCESSORIES Consult the owner’s manual for recommended accessories. Using improper accessories may increase the risk of personal or by-stander injury. Unauthorized equipment modifications will void all warranties. Manufacturer does not assume responsibility for any accident due to equipment modifications.
  • Page 7 MK-101 Pro24 JCS SAFETY WARNING 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 ELECTRICAL SHOCK NEVER touch electrical wires or components while the engine is running.

  • 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: Electrical Requirement & Grounding Instructions

    MK-101 Pro24 JCS 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! WARNING In case of a malfunction or breakdown, grounding provides a path of least resistance for electric cur- rent to reduce the risk of electric shock.
  • Page 10 MK-101 Pro24 JCS SAFETY WARNING The “drip loop” is that part of the cord below the level of the receptacle, or the connector, if an extension cord is used. This method of position- ing the cord prevents the travel of water along the power cord and coming in contact with the receptacle.

  • Page 11: Electric Motor Safety

    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 12: 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 13: Product Specifications

    MK-101 Pro24 JCS SAFETY PRODUCT SPECIFICATIONS • Integrated stand allows operator to set up or transport in a matter of seconds • Solid rubber heavy-duty wheels won't scuff floors • Designed for easy transport, loading and storage by one person •...

  • Page 14: 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 15: 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 16: 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 17 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 18 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 19: 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 20 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 21 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 22: 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 23 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 24: 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 25 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 26 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 27 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 28: 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 29: 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 30 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 31: 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 32: 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 33: 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 34 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 35 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 36 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 37 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 38: 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 39: 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 40 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 41 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 42 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 43: 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 44 MK-101 Pro24 JCS EXPLODED VIEW MK-101 Pro24 JCS Part # 153243-JCS...
  • Page 45 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 46 MK-101 Pro24 JCS EXPLODED VIEW JCS Portable Stand Part # 169218...
  • Page 47 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 48 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 49 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 50 MK-101 Pro24 JCS EXPLODED VIEW & PARTS LIST MK-101 Pro24 Part # 160486 Part# Item Description TERMINAL, 16 -14 AWG x #10 RING 154540 MTR, 1- 1/2 HP 120V 60Hz 160484 ASSY, SWITCH BOx, 30AMP, LIF11 161101...
  • Page 51 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 52 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 53: Cutting Head

    MK-101 Pro24 JCS EXPLODED VIEW & PARTS LIST Cutting Head Part # 158191 Item Description Part# NUT, HEx, 5/16 - 18 101196 FLANGE, OUTER 2-3/8 135830 NUT, HEx, 5/8 - 18 135848 BEARING, BALL, 17 x 40 x 12MM 137711...
  • Page 54 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 55: 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 56: 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 57: Contact

    © COPYRIGHT 2012, 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 58 NOTES...
  • Page 59 NOTES...
  • Page 60 MK-101 Pro24 JCS OWNERS MANUAL & OPERATING INSTRUCTIONS MK Diamond Products, Inc. 1315 Storm Parkway Torrance, CA 90501 Toll-Free: (800) 421-5830 Phone: (310) 539-5221 Fax: (310) 539-5158 www.mkdiamond.com...

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