MK Diamond Products MK-660 SERIES, Owner'S Manual & Operating Instructions

Page 1: ...R S MANUAL OPERATING INSTRUCTIONS Enter the Serial Number of your new saw in the space below The Serial Number is located on the rear of the Cutting Head 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 SERIAL NUMBER ...

Page 2: ...ed correctly your MK 660 should provide you with years of quality service In order to help you we have included this manual This owners manual contains information necessary to operate and maintain your MK 660 safely and correctly Please take a few minutes to familiarize yourself with the MK 660 by reading and reviewing this manual If you should have questions concerning your MK 660 please feel fr...

Page 3: ...ACKING TRANSPORT UNIVERSAL STAND and ASSEMBLY Unpacking 11 Contents 11 Transport 12 Universal Stand 12 Assembly 13 SETUP ADJUSTMENT AND OPERATION Setup 16 Adjustment and Operation 19 Cleanup 23 MAINTENANCE AND TROUBLESHOOTING Maintenance 25 Troubleshooting 30 EXPLODED VIEW AND PARTS LIST Exploded View 34 Parts List 35 THEORY Theory of Diamond Saws 37 ACCESSORIES Accessories 38 ORDERING and RETURN ...

Page 4: ...ng 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 REMOVE ADJUSTING KEYS AND WRENCHES Form a h...

Page 5: ... 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 Make sure the ON OFF Switch is in the OFF position before plugging in a power tool USE RECOMMENDED ACCE...

Page 6: ...mond 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 activi...

Page 7: ... 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 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 F...

Page 8: ... 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 k...

Page 9: ...m Location Description Part No 1A Cutting Head Front Caution Operating Instructions 155214 1B Cutting Head Rear Serial Number and Specifications 156561 1C Cutting Head Front Motor Reset 154409 2A Pump Left Side Warning Connect to Grounded Receptacle N A 2B Pump Right Side Pump Specifications N A TILE SAW SPECIFIC WARNINGS Wear eye protection Use splash hood for every operation for which it can be ...

Page 10: ...s The saw can cut an object one and one half 1 1 4 inches thick in one pass Motor Specifications Motor specifications for the MK 660 are listed in Table 2 below Voltage 115 v Motor Amperage 8 8 a Frequency 60 Hz RPM 3500 rpm Horse Power 3 4 hp Weight 53 lbs Table 2 Thermal Overload Protection The motor is protected by a thermal overload equipped with a manual reset Blade Capacity The MK 660 uses a...

Page 11: ...usting knob flat washer one 1 7 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 inner flange wrench 1 splash guard one 1 owners manual one 1 pump manual and one 1 warranty card MK 660 Frame and Water Pan MK 660 Cutting ...

Page 12: ...3 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 Lift Point Lift Point A Open the Universal Stand and place on flat surface B Remove Water Pan C Orient the Saw to the Stand D Seat Left Post Side of saw onto stand between stand Orientation Pin E Seat Right Side of saw onto stand...

Page 13: ...d is completely installed and seated on the Pivot Shaft Pivot Hole Pivot Shaft Post Turn Clockwise to tighten A Loosen the Blade Guard Retaining Screw C Using the Blade Nut Wrench loosen and then remove the Retaining Nut and Outer Flange Turn counter clockwise to loosen Retaining Nut and Outer Flange B Open the Outer Blade Guard to expose the Retaining Nut and Flanges Outer Blade Guard Blade Wrenc...

Page 14: ...uide retaining thumbscrew and place it over the Movable Cutting Table Ruler Stop B Place the Adjustable Cutting Guide onto the Movable Cutting Table Ruler Stop and tighten the retaining thumbscrew Retaining Holes Rotation Direction Retaining Nut and Outer Flange Turn counter clockwise to loosen Adjustable Cutting Guide Turn clockwise to tighten Adjustable Cutting Guide E Install Diamond Blade onto...

Page 15: ... washer and Splash Guard then align to the hole found on back of the Blade Guard B Install the Splash Guard onto the Blade Guard Retaining Hole Thumbscrew Splash Guard Turn clockwise To tighten B Press one end of the Cooling Transfer Tube onto the Water Pump Discharge Fitting Turn clockwise to tighten C Slide Cooling Flow Adjusting Clamp onto the Cooling Transfer Tube Discharge Fitting Press on Fl...

Page 16: ...is in the OFF position B Verify the Movable Cutting Table moves freely C Inspect the Diamond Blade for damage verify the blade is correct for the material being cut D Inspect the Pump Assembly for damage ensure the cord is free of cracks or cuts E Inspect the MK 660 for damage ensure the cord is free of cracks or cuts Press together Verify ease of movement See Maintenance section if problems exist...

Page 17: ...ation method the water should be changed often for longer pump life 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 D Place an external catch Basin below the Water Pan drain hole A Ensure the Drain Plug is installed in the Water Pan C Fill the Water Pan until water completely covers the Water...

Page 18: ...power cord make sure the length and wire gauge correspond to he requirements listed in TABLE 1 on page 8 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 ...

Page 19: ...red cut length indicated inside the diamond C Tighten the retaining thumbscrew D Place the tile against the Ruler Stop and Cutting Guide E Turn the motor ON F Verify cooling flow on both sides of the blade See Maintenance Section to adjust flow G Perform the cut H Turn the motor OFF when work is complete Desired Cut length indicated here Turn Clockwise to tighten Adjustable Cutting Guide Ruler Sto...

Page 20: ... 45º Flat Angle Guide on the Ruler Stop C Position the Dual 45º Flat Angle Guide and tighten the retaining thumbscrew D Position the tile against the Dual 45º Flat Angle Guide and the Ruler Stop G Perform the cut Ruler Stop Turn counter clockwise to loosen Align Guide to Ruler Stop Turn Clockwise to tighten 45º Flat Angle Guide Ruler Stop Hold Work in Position Direction of Cut Turn counter clockwi...

Page 21: ...en the retaining thumbscrew D Position the tile on the 45º Bullnose Miter Guide and the Ruler Stop G Perform the cut Align Guide to Ruler Stop Turn counter clockwise to loosen Turn Clockwise to tighten Ruler Stop Bull Nose Miter Hold Work in Position Direction of Cut A Remove the Adjustable Cutting Guide Turn counter clockwise to loosen Adjustable Cutting Guide Ruler Stop E Turn the motor ON F Ver...

Page 22: ...e thumbscrew I Perform the cut Turn counter clockwise to loosen Align Guide to Ruler Stop Ruler Stop Set Angle Ruler Stop Hold Work in Position Direction of Cut A Remove the Adjustable Cutting Guide Turn counter clockwise to loosen Adjustable Cutting Guide Ruler Stop Turn Clockwise to tighten D Position the Protractor Cutting Guide to the desired cut length indicated inside the diamond Desired Cut...

Page 23: ... front of Saw GFCI Off Position ON OFF Switch D Ensure the ON OFF Switch is in the OFF position F Unplug MK 660 from the GFCI E Unplug the GFCI from the Power source B Place the Water Pump in an external container A Clean the Water Pump suction of all debris C Run the MK 660 until clear water is seen at the blade cooling ports Approx 1 minute H Remove the Water Pan from the MK 660 I Clean the Wate...

Page 24: ...DJUSTMENT and OPERATION Ensure water is not forced into the motor casing when cleaning K Clean the Movable Cutting Table Roller Wheel Frame Support J Clean the Movable Cutting Table Guide Bar L Clean the remainder of the MK 660 Clean Guide Bar Roller Wheel Frame Support ...

Page 25: ...Maintenance The following maintenance should be performed Monthly A Ensure the ON OFF Switch is in the OFF position B Unplug MK 660 C Lubricate the Guide Bar D Lubricate the Roller Wheel Assembly A Remove the Diamond Blade Retaining Screw and Outer Flange Rotate Blade Wrench counter clockwise to loosen B Lubricate the Outer Flange and Retaining nut C Remove the Outer Blade Guard GFCI Guide Bar Rol...

Page 26: ...ange H Align the Alignment Slot of the Inner Flange to the Motor Shaft Alignment Pin and Install the Inner Flange Inner Flange Alignment Pin Motor Shaft Inner Flange D Remove the Inner Flange Inner Flange I Lubricate the Outer Blade Guard Pivot Shaft Pivot Shaft J Install the Outer Blade Guard Outer Blade Guard Rotate clockwise to tighten K Remove the Cutting Head Cutting Head L Lubricate the Cutt...

Page 27: ...ad Adjustment Knob N Lubricate the Cutting Head Adjustment Knob retaining holes A Increase cooling flow by releasing the Flow Adjusting Clamp B Reduce cooling flow by Pressing down on the Flow Adjusting Clamp Adjustment Knob Pull Tab to loosen Press Tab to Restrict Flow Retaining Hole O Lubricate the Cutting Head Pivot Hole Pivot Hole P Verify the Cutting Table Roller Wheel Assembly is tight Rotat...

Page 28: ...nd blade can be dressed using the MK Dressing Stick part number 152972 and by following the steps below Off Position ON OFF Switch C Position the Dressing Stick F Cut the Dressing Stick 7 or 8 times to dress the Blade B Set the Adjustable Cutting Guide to cut a 1 16 strip D Turn the motor ON G Ensure the ON OFF Switch is in the OFF position Setup for Operation Set Adjustable Cutting Guide A Setup ...

Page 29: ...e Outer Blade Rotate counter clockwise to loosen Pivot Up to Open Hold in position Rotate counter clockwise to loosen C Remove Diamond Blade from Blade Shaft Diamond Blade Blade Shaft Diamond Blade Blade Shaft F Install the Retaining Nut and Outer Flange Hold the Shaft using the Inner Flange Retaining Wrench and tighten using the Blade Wrench Retaining Nut and Outer Flange Hold in position Rotate ...

Page 30: ...erial being used Return to MK Diamond for Repair E Return to MK Diamond A Check that the Guide Bar are clean clean if dirty B Check the Movable Cutting Table Roller Wheels for wear replace if necessary Return to MK Diamond for Repair C Return to MK Diamond If not Glazed go to Step B Contact place of purchase or MK Diamond 800 421 5830 to verify blade If Glazed Dress Blade See Blade Dressing If not...

Page 31: ...heck for restriction check Impeller damage G Remove the 3 Pump Casing Retaining Screws F Remove the Pump Intake Screen and check for debris Go to Step C Check Impeller for damage If flow exists go to Step E If flow exists go to Step D Pull Tab to loosen If flow exists go to Step A Pull to remove Cover Pump suction with water Pull to remove If flow exists go to Step F Remove Discharge Fitting Pull ...

Page 32: ...de 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 J Clean the Blade Guard Intake Fitting K Rod Cooling Channels and recheck flow Return to MK Diamond for Repair L Return to MK Diamond Intake Fitting Rod Channels If cooling channels clear go to Step L G...

Page 33: ...ify circuit breaker not tripped If tripped reset once G Return to MK Diamond If less than 20 Amps move saw to 20 Amp circuit Overload Reset Switch If motor does not start go to Step B Verify all plugs connected If all plugs connected go to Step C If not tripped or If re trip occurs Go to Step D Reset once if tripped If circuit 20 Amp or greater go to Step E Check Breaker 20 Amps or greater If trip...

Page 34: ...MK 660 Revision 01 02 Effective Date January 10 2002 EXPLODED VIEW AND PARTS LIST EXPLODED VIEW ...

Page 35: ...ass 1 154652 B3 Knob Davies 1 151681 B4 Washer 5 16 SAE Flat 2 151754 B5 Wing nut 5 16 18 Nylock 1 151746 D Cutting Head less blade guard 1 n a D1 Cutting Head 660 1 154291 D2 Cover Cutting Head 660 1 154293 D3 Gasket Cover 660 1 154381 D4 Screw 10 24 x 5 8 Pan Head Phillips Self Tapping Machine 8 153681 D5 Screw 5 16 18 x 2 1 2 Hex Head Cap Fully Threaded 1 151748 D6 Washer 5 16 Split Lock 1 1517...

Page 36: ...18 x 1 Hex Head Cap 2 151743 F5 Washer 5 16 Split Lock 2 151747 F6 Washer 5 16 SAE Flat 2 151754 G Linear Bearing 1 151737 MK G1 Casting Bearing Linear 1 151737 G1a Bearing Multi Lube 2 157126 G2 Screw 5 16 18 x 1 Hex Head Cap 2 151743 G3 Washer 5 16 Split Lock 2 151747 G4 Washer 5 16 SAE Flat 2 151754 H Post 1 n a H1 Post Rear 660 Shaft 5 8 Pivot 660 1 1 153451 153452 H2 Screw 3 8 16 x 2 Hex Head...

Page 37: ...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 ...

Page 38: ...DESCRIPTION 1 139292 MK 200 7 x 5 8 Arbor 2 139311 MK 215 7 x 5 8 Arbor 3 153293 MK 315 10 x 5 8 Arbor 4 134577 Dual 45 Flat Angle Guide 5 134585 small or 153201 large 45 Bullnose Miter 6 134569 90 Protractor 7 152792 Dressing Stone 8 152610 Ground Fault Circuit Interrupter 9 151889 Universal Stand ...

Page 39: ... 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...

Page 40: ...e 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 ...