quip
MK- 2005G
GAS POWERED BRICK SAW
OWNER’S MANUAL &
OPERATING INSTRUCTIONS
CAUTION:
Read all safety and
operating instructions
before using this
e
ment
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-2005G Brick 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-2005G 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-2005G safely and correctly. Please take a few minutes to familiarize yourself with the MK-2005G by
reading and reviewing this manual.
If you should have questions concerning your MK-2005G, please feel free to call our friendly customer service
department at: 800 421-5830
Regards,
MK Diamond
MK-2005G Revision 04/2003, Effective Date April 2, 2003
Page 2
TABLE OF CONTENTS
Page
SAFETY:
Safety Messages 4
Damage Prevention Message 4
General Safety Precautions and Hazard Symbols 4
California Proposition 65 Message 6
Safety Label Locations 7
Brick Saw Specific Warnings 7
Product Specifications 8
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
Unpacking 9
Contents 9
Transport 9
Universal Stand 10
Assembly 11
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
Setup 15
Startup 18
Adjustment and Operation 19
Shutdown 25
Cleanup 25
MAINTENANCE AND TROUBLESHOOTING
Maintenance 27
Troubleshooting 44
EXPLODED VIEW AND PARTS LIST
Exploded View 47
Parts List 48
THEORY
Theory Of Diamond Blades 52
ACCESSORIES ORDERING and RETURN INSTRUCTIONS
Accessories 53
Ordering Information 54
Return Material Policy 55
Packaging Instructions 55
Authorized Service Centers 55
Manual Part No. 158320 Revision No. 1
MK-2005G Revision 04/2003, Effective Date April 2, 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.
EXPLOSIVE FUEL!
Gasoline is extremely flammable, its vapors can explode if ignited; store only in approved containers,
in well-ventilated, unoccupied buildings and away from sparks or flames. Do not fill the fuel tank while
the engine is running or hot. Spilled fuel could ignite if it contacts hot parts or sparks from ignition. Do
not start the engine near spilled fuel. Never use gasoline as a cleaning agent.
LETHAL EXHAUST GASES!
Engine exhaust gasses contain poisonous carbon monoxide, an odorless colorless gas that can cause
death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or
confined area.
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.
ENGINE OVER-SPEED.
)
Never tamper with the governor components or settings to increase the maximum speed of the
)
machine. Severe personal injury and/or equipment damage could result if the equipment is operated
(
(
speeds above design maximum.
MK-2005G Revision 04/2003, Effective Date April 2, 2003
Page 4
SAFETY
ACCIDENTAL STARTS!
on
Before starting the engine, be sure the ON/OFF switch is in the "OFF" position to prevent accidental
starting. Place the ON/OFF switch in the OFF position 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 shrouds or guards removed.
HOT PARTS!
Engine components can become extremely hot from operation. To prevent severe burns, do not touch
these areas while the engine is running, or immediately after it is turned off. Never operate the engine
with heat shields removed.
ALWAYS USE SAFETY GLASSES!
Safety glasses should always be worn when working around power tools. Everyday eyeglasses only
have impact resistant lenses and may not prevent eye injury; they are NOT safety glasses.
ALWAYS USE RESPIRATORY PROTECTON!
Exhaust gases may be harmful if inhaled. Do not operate gas-powered equipment in enclosed
spaces. Respiratory protection should be worn when operating gas powered equipment.
ALWAYS USE HEARING PROTECTION!
To reduce the possibility of hearing loss, always use hearing protection when operating equipment.
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 operate equipment in dangerous environments. Always keep the work area well lighte d.
KEEP CHILDREN AWAY.
All visitors and children should be kept a safe distance from work area.
MAKE 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.
WEAR PROPER APPAREL.
Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry that may be caught in moving
parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair.
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.
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 5
SAFETY
DO NOT OVERREACH.
Keep proper footing and balance at all times by not overreaching.
MAINTAIN TOOLS WITH CARE.
Keep tools sharp and clean for the best and safest performance. Always follow maintenance instructions for
lubricating and when changing accessories.
SHUTDOWN TOOL.
The saw should always be shutdown before servicing or whe n changing accessories such as blades, bits,
cutters, and the like.
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.
NEVER LEAVE 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.
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, 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.
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
• 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.
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
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 6
SAFETY
SAFETY LABEL LOCATIONS:
Safety labels are located according to Figures 1 through 6 below. The labels contain important safety
information. Please read the information contained on each safety label. These labels are consid ered 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 Location Description Part No.
1A Motor-tank, front Oil Alert N/A
1B Motor-tank, front Danger-Use in Ventilated Areas 155582
2A Motor-tank, top Warning-Do Not Overfill 155580
2B Motor-tank, top Caution-Hot Surface 155578
2C Motor-tank, top Honda Motor Information N/A
3 Motor-tank, right Danger-California Exhaust Warning 155581
4 Motor-tank, left Read Honda Owner's Manual N/A
5 Motor-air filter Caution-Clean Air Filter N/A
6A Blade Guard Serial Number 157007
6B Blade Guard Caution-Operating Safety Instructions 155040
A
A
B
1
B
C
2
3
4
A
5
6
Brick Saw SPECIFIC WARNINGS:
• Read Owner's Manual
• Keep All Guards In Place
• Always Wear Approved Safety Protection For:
Ear
Eye
Head
B
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 7
SAFETY
PRODUCT SPECIFICATIONS:
The MK-2005G is a versatile gas powered brick saw. Operated and used according to this ma nual, the MK2005G will provide years of dependable service.
General Description:
The MK-2005G Brick Saw is engineered as a portable brick saw powered by a 5.5 horsepower, pull start,
Honda gas engine. The saw is capable of cutting masonry up to five (5) inches (127 mm) in height in a single
pass.
Motor Specifications:
Honda motor specifications for the MK-2005G are listed in Table 1 below.
Blade Capacity:
The MK-2005G is designed for use with a 14-inch diameter segmented wet or dry MK Diamond blade with a
.110 to .375 inch cutting width.
Masonry Types:
The MK-2005G can cut a variety of masonry types including, cinder block, slump stone block, wall brick,
paver brick, concrete block and cylinders, roofing tile, marble, granite, decorative rock or almost any other
non-ferrous material.
NOTE:
The MK-2005G is not designed to cut plastic or ferrous (metals) material.
Spring Assisted Cutting Head:
The MK-2005G is designed with a spring-assisted cutting head to allow for easier step cutting. The Cutting
Head can be locked in the down position when cutting smaller pieces.
Shaft Operated Water Pump:
The MK-2005G has a flexible shaft, belt driven water pump supplying cooling water to the blade for wet
cutting operations.
Design Size:
The MK-2005G is designed to accommodate a piece up to eighteen and one-half (18-1/2) inches (470 mm)
wide, thirty (30) inches (760mm) long and seven and one-half (7-1/2) inches high.
Motor Type 4-stroke, overhead valve, single cylinder
Max Power Output 5.5 Hp
Max RPM 3,600 RPM
Fuel Tank Capacity 0.95 gallons (3.6 liters)
Engine Oil Capacity 0.63 quarts (0.6 liters)
Table 1
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 8
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
UNPACKING:
Your MK-2005G has been shipped from the factory thoroughly inspected. Only minimal assembly is required.
If not done, completely remove the plastic wrapping from the MK-2005G.
Remove the accessories box from the Water Basin and remove the contents from the box.
CONTENTS:
In your container, you will find one (1) MK-2005G, one (1) movable cutting table, one (1) adjustable cutting
guide, one (1) drain plug, one (1) blade wrench, one (1) owner's manual, one (1 ) Honda owner's manual and
one (1) warranty card.
MK-2005G Movable
Owner's Manual Honda
Adjustable
Cutting Table
Owner's Manual
Cutting Guide
Warranty
Card
Drain Plug Blade
Wrench
TRANSPORT:
The MK-2005G weighs approximately 200 pounds; two people should be used when transporting the saw.
1. Never transport the MK-2005G with water in the Cooling Basin.
2. The MK-2005G, Brick Saw weighs approximately 200 pounds; two people are required when
lifting or moving.
NOTE: Lock the Cutting Head in the DOWN position, and remove the Movable Cutting Table when
transporting the MK-2005G.
The MK-2005G is designed with recessed handles in the right and left upright casting s for ea se of transport.
To transport –
• Verify the Movable Cutting Head is locked in the down position and the Movable Cutting Table is removed
• Grasp the saw by the recessed handle in the right and left upright castings
• Grasp the front of the saw
• Lift and transport the saw to the desired work location
Remove Movable
Cutting Table
Lift Point
Cutting Head
Locked Down
Lift Point
MK-2005G Revision 04/2003, Effective Date April 2, 2003
Page 9
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
UNIVERSAL STAND:
Note: If using the MK Diamond, Universal Stand, perform the following steps.
1. Preparing to Seat Saw:
The MK-2000, Brick Saw weighs approximately 200 pounds; two people are required when lifting
or moving.
Loosen Wing Nut
Open the Universal Stand
and place on flat surface
(A)
Pivot Up
(B)
Position Water Pump
clear of Water Basin
Remove Water Basin
Slide Water Basin
out back of Saw
(C)
2. Seating the Saw:
Back of Saw
Back of Stand
(A)
Orient the Saw
to the Stand
Front Brace
(B)
Seat front of Saw
on the front of the Stand
Front of Stand
Rear of Saw
Back of Stand
(C)
Seat rear of Saw
on the back of the Stand
3. Final:
Slide Water Basin
in back of Saw
Reinstall Water Basin
(C)
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 10
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
ASSEMBLY:
Follow the assembly instructions in this section to prepare your MK-2005G for operatio n.
1. Movable Cutting Table Installation:
Cutting Table
Front
Roller Wheels
Position Movable Cutting
Table Roller Wheels
above Saw Guide Rails
(A)
Guide Rail
Roller Wheels Guide Rails
(B)
Seat Movable Cutting Table
Roller Wheels on Saw
Guide Rails
Move back and forth to
verify ease of movement
(C)
Verify Movable Cutting Table
is seated correctly
2. Adjustable Cutting Guide Installation:
NOTE: The Adjustable Cutting Guide can be used on either side of the Diamond Blade.
Turn counter-
clockwise to loosen
Loosen Adjustable Cutting
Guide retaining thumbscrew
(A)
Align
Parallel Slots
Ruler/Stop
(B)
Position Adjustable Cutting
Guide above Movable
Cutting Table
Turn clockwise
to tighten
Seated
(C)
Seat and tighten the
Adjustable Cutting Guide
retaining thumbscrew
3. Releasing Cutting Head:
The following actions will cause the Cutting Head to rotate upward, hold the saw by the handle and
NOTE: The Cutting Head is locked in the down position when shipped from the factory.
Locking Handle
Remove Cutting Head Locking
Handle from shipping location
discard the Shipping Nut
control the upward movement.
Turn counter-
clockwise to
9/16-inch wrench
Shipping Bolt
(A)
9/16-inch
wrench
loosen
(B)
Remove Shipping Bolt from
the Cutting Head – discard
Shipping Bolt
Height
Adjustment
Stud
(C)
Install Cutting Head
Locking Handle into
Height Adjustment Stud
Turn clockwise
to tighten
Locking Handle
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 11
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
4. Diamond Blade Installation:
NOTE: When installing the diamond blade retaining-bolt, ensure the threads of the bolt are aligned with the
threads of the drive shaft so as not to “cross-thread" the bolt.
Loosen Locking
Handle to adjust
Cutting Head
Raise Cutting Head
Seat Blade on
Blade Shaft
Verify Blade is seated on Blade
Shaft in correct rotation direction
Cutting Head
(A)
Rotation Direction
(D)
Blade Wrench
Identify and remove Retaining
Screw and Outer Flange
Rotate Blade
Wrench clockwise
to tighten
Install Retaining Screw and
Outer Flange then tighten
Retaining Screw
and Outer Flange
Turn counter-
clockwise to
(B)
Retaining Screw
and Outer Flange
(E)
Install
Blade
loosen
(C)
Install Diamond Blade
onto Blade Shaft
5. Water Pump Installation:
NOTE: The Belt Driven, Flexible Shaft Water Pump is locked in the shipping position from the factory. It will
need to be removed from between the left Upright Casting and the Cutting Head to allow free movement of
the Cutting Head.
Loosen Wing Nut
Loosen and remove Water
Pump adjustment clamp,
wing nut and bolt
Remove Water Pump
(A)
7/16-inch
Wrench
Remove Water
Pump from Clamp
Loosen Wing Nut
(B)
Loosen and remove Water
Pump retaining clamp,
wing nut and bolt
Cutting
Head
Water
Pump
Upright
Casting
(C)
Remove Water Pump Assembly
from between left Upright
Casting and Cutting Head
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 12
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
7/16-inch
Wrench
Install Water Pump retaining
clamp, wing nut and bolt
Install Water
Pump into Clamp
Tighten Wing Nut
(D)
Tighten Wing Nut
Install Water Pump
(E)
Install Water Pump adjustment
clamp. wing nut and bolt
6. Filling Oil Reservoir:
NOTE: SAE 10W-30 is recommended for general use in temperatures of – 4ºF (20ºC) and above. If you
are operating outside of this range, consult the chart in this manual.
Engine Oil Capacity is 0.63 US qt (0.6l).
Loosen Locking
Handle to adjust
Cutting Head
Level Cutting Head
Cutting Head
(A)
NOTE: When installing the Oil Dipstick, ensure the threads are aligned with the threads of the Oil Reservoir
so as not to “cross-thread" the dipstick.
Bottom Edge
Add Oil until level reaches
the bottom edge of fill hole
(D)
Turn counter-
clockwise to
loosen
Remove Dipstick
Turn clockwise
to tighten
Install Dipstick
(B)
(E)
Dipstick
Dipstick
Fill through
Reservoir fill hole
(C)
Fill Oil Reservoir
Wipe up excess oil
(F)
Clean Up
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 13
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY
7. Filling Fuel Tank:
1. Gasoline is highly flammable and explosive. You can be burned or seriou sly injured when
handling fuel.
2. To fuel, stop engine if running, and allow it to cool.
3. Refuel in a well-ventilated area.
4. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools,
etc.
NOTES: 1. Fuel can damage paint and plastic. Be careful not to spill fuel when filling the fuel tank.
Turn counter-
clockwise to
loosen
Turn clockwise
to tighten
5. Wipe up spills immediately.
Damage caused by spilled fuel IS NOT covered under the warranty.
2. DO NOT use stale or contaminated gasoline, or an oil/gasoline mixture.
3. If using the Universal Stand with the MK-2005G, a ladder meeting OSHA specification is
recommended.
4. Use unleaded gasoline with a pump octane rating of 86 or higher.
Fill Throat
(A)
Remove Fuel Cap
Fuel Cap
(B)
Fill Fuel Tank
Upper Limit
(C)
Verify fuel level is below
the throat of the Fuel Tank
Fuel Cap
(D)
Install Fuel Cap
Fill Throat
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 14
r
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
SETUP:
1. Pre-start Inspection:
The pre-start inspection should be performed before beginning any job.
Inspect Blade for damage –
Verify Blade correct for material
Inspect Engine for leaks
Upper Limit
Check for proper fuel level
(See Maintenance section if low)
If the Diamond Blade shows signs of fatigue cracking, replace the blade before starting work.
Cracks
(A)
Replace if Excessively Grooved
(See Maintenance Section)
(B)
Inspect Wooden Strip for
excessive grooves
Verify Ease of Movement
(See Maintenance Section)
(C)
Verify Movable Cutting Table
moves freely
being cut
Proper Oil Level
Low Level
(F)
Look for leaks
(D)
Inspect for
damage
(E)
Inspect MK-2005G for general
damage, loose connections
Check for proper oil level
(See Maintenance section if low)
and hardware
Fill Throat Air Filte
(G)
(H)
Check Air Filter for cleanliness
(See Maintenance section
if dirty)
MK-2005G Revision 04/2003, Effective Date April 2, 2003
Page 15
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
2. Water Pump Setup:
The Water Pump can be setup in three ways, External Water Source, Re-circulation or Un-coupled for dry
blade operation.
NOTE: To extend the life of the Diamond Blade and Water Pump, MK Diamond recommends a clean cooling
water source when using a Wet Diamond Blade.
I. External Water Source:
This is the preferred method of cooling when using a "wet" diamond blade.
Drain Plug
Verify Water Basin is inserted
into the MK-2005G and
remove the Drain Plug
Fill the External Water Source
Container and place a Catch
Basin below the Drain Hole
(A)
(D)
Water Basin
Clean Water
Loosen Wing Nut
Remove Water Pump
(B)
Loosen and remove Water
Pump adjustment clamp,
wing nut and bolt
Water Pump
Water Container
(C)
Place the Water Pump
Assembly into an External
Water Source Container
II. Re-circulation:
NOTE: 1. Water Pump could interfere with masonry being cut.
2. Water should be periodically replaced when using this method.
Drain Plug
Verify Water Basin is inserted
into the MK-2005G and
install the Drain Plug
(A)
Water Basin
Loosen Wing Nut
(B)
Loosen Water Pump adjustment
clamp wing nut and bolt
Water Pump
Molded Stand
(C)
Place Water Pump on Pump
Stand molded into Water Basin
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 16
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
Fill the Water Basin
with clean water
(D)
Clean Water
III. Dry Blade Operation:
NOTE: Failure to perform the following steps will lead to premature pump failure.
Identify Water Pump Drive
Curtain Rod
Remove the Splash Curtain
Remove Water Basin
(A)
End Pivot Plate
(D)
(G)
Pivot Plate
Splash Curtain
Slide Water Basin
out back Of Saw
9/16-inch
Wrench
Retaining Bolts
(B)
Loosen Water Pump Drive End
Pivot Plate front and rear
retaining bolts
Loosen Wing Nut
Remove Water Pump
(E)
Loosen and remove Water
Pump adjustment clamp,
wing nut and bolt
Pivot Up
(C)
Pivot front of Water Pump Drive
End Pivot Plate up and tighten
the retaining bolts
(F)
Move Water Pump Assembly
to the outside of the
Water Basin
9/16-inch
Wrench
Water Pump
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 17
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
STARTUP:
1. Engine Start:
1. Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and/or death.
NOTE: If restarting a warm engine leave the Choke Lever in the OPEN position.
Direction of
Movement
Engine Switch
Direction of
Movement
Choke Lever
Place Choke Lever in the OPEN
position when engine is warm
2. Avoid any areas or actions that expose you to carbon monoxide.
Fuel Valve
(A)
Place Fuel Valve in the
ON position
Direction of
Movement
(D)
Place Engine Switch
in the ON position
Choke Lever
(B)
Place Choke Lever in the
CLOSED position
Direction of
Movement
(E)
Pull Starter Cord slowly, until
slack is removed and
Direction of
Movement
Starter Cord
resistance is felt
(G)
Direction of
Movement
Throttle Lever
(C)
Move the Throttle Lever
Direction of
Movement
to 1/3
rd
Open
Starter Cord
(F)
Pull Starter Cord straight back
in a smooth fast motion
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 18
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
ADJUSTMENT AND OPERATION:
NOTE: 1. Step Cutting is the preferred cutting method for all cuts.
2. When cutting hard material Step Cutting should always be used.
3. Step Cutting will extend the life of the Diamond Blade.
1. Step Cuts:
A Step Cut is performed when a series of small cuts of increasing depth are used to complete a single cut.
Step Cuts are used for large objects or for hard objects such as Firebri ck and Pavers.
Note: Skip steps C and D, if cutting dry.
Ruler Markings
Set the Adjustable Cutting Guide
Cooling Flow
Points
Verify cooling flow exists on
both sides of the blade
Push Direction
DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed.
Set Edge of Cutting
Guide to Desired Cut
Length on Ruler/Stop
Ruler/Stop
(A)
Adjustable
Cutting Guide
Set against Adjustable
Cutting Guide and
Ruler/Stop
Ruler/Stop
(B)
Position the masonry piece
Direction of
Movement
(C)
Open the Cooling Flow Control
Valve and adjust flow
Direction of
Movement
Throttle Lever
(D)
Move the Throttle Lever to
(E)
(F)
Setup to Cut
adjust blade speed (faster blade
speed for smoother cuts)
Lower Cutting
Head 1/4 -1/2
Inch During
Push Stroke
(G)
Step Cut "Push" stroke
Step Cut "Pull" stroke
Lower Cutting
Head Additional
1/4 -1/2 Inch During
Pull Stroke
Pull Direction
(H)
Repeat steps G and H until
cutting is complete
Control Valve
Hold Work
in Position
Repeat “Push”
and “Pull” Strokes
Until Cut Complete
(I)
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 19
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
Direction of
Movement
Move the Throttle Lever to lower
blade speed
Throttle Lever
(K)
Raise Cutting Head once
cut is complete
Raise Cutting
Head
(J)
2. Chop Cutting:
A Chop Cut is performed by cutting completely through an object in one pass.
Note: Skip steps C and D, if cutting dry.
Ruler Markings
Set the Adjustable Cutting Guide
Cooling Flow
Points
Verify cooling flow exists on
both sides of the blade
DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed.
Set Edge of Cutting
Guide to Desired Cut
Length on Ruler/Stop
Ruler/Stop
(A)
(D)
Adjustable
Cutting Guide
Set against Adjustable
Cutting Guide and
Ruler/Stop
Ruler/Stop
(B)
Position the masonry piece
Direction of
Movement
Throttle Lever
(E)
Move the Throttle Lever to
Direction of
Movement
Control Valve
(C)
Open the Cooling Flow Control
Valve and adjust flow
Position
Work Below
Cutting Head
(F)
Setup to Cut
adjust blade speed (faster blade
speed for smoother cuts)
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 20
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
Hold Cutting
Table Stationery
Lower Cutting Head
to begin the cut
Raise Cutting Head once
cut is complete
Lower Cutting
Head Smoothly
(G)
(J)
to Cut
Raise Cutting
Head
Continue to Lower
Cutting Head until
Cut Complete
(H)
Continue lowering the
Cutting Head until the
cut is complete
Direction of
Movement
Throttle Lever
(J)
Move the Throttle Lever to lower
blade speed
3. Cutting with the Cutting Head Locked Down:
This method is preferred when cutting small objects.
Note: Skip steps D and E, if cutting dry.
Ruler Markings
Set the Adjustable Cutting Guide
DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed.
Set Edge of Cutting
Guide to Desired Cut
Length on Ruler/Stop
Ruler/Stop
(A)
Adjustable
Cutting Guide
Set against Adjustable
Cutting Guide and
Ruler/Stop
Ruler/Stop
(B)
Position the masonry piece
Loosen Locking
Handle to adjust
Cutting Head
Lock Cutting
Head in down
position
(C)
Lock Cutting Head in
the down position
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 21
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
Direction of
Movement
Open the Cooling Flow Control
Valve and adjust flow
Unlock Cutting
Setup to Cut
Head
Unlock Cutting Head
Control Valve
(D)
Hold Work
in Position
(G)
Loosen Locking
Handle to adjust
Cutting Head
(J)
Cooling Flow
Points
(E)
Verify cooling flow exists on
both sides of the blade
Push Slowly to Cut
(H)
Slowly push piece toward the
blade – continue until the
cut Is complete
Raise Cutting
Head
(K)
Raise Cutting Head once
cut is complete
Direction of
Movement
(F)
Move the Throttle Lever to
adjust blade speed (faster blade
speed for smoother cuts)
Direction of
Movement
(I)
Move the Throttle Lever to lower
blade speed
Throttle Lever
Throttle Lever
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 22
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SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
4. Angle Cuts:
Angle Cuts may be performed using the Step Cut, Chop Cut or the Locked Cutting Head cutting methods.
The following is utilizing the Locked Cutting Head method.
NOTE: Care must be used when cutting angles so as not to damage the Adjustable Cutting Guide.
Skip steps F and G, if cutting dry.
Turn counterclockwise
Remove Adjustable
Cuttin
Lock Cutting
Head in down
position
Cooling Flow
Points
Verify cooling flow exists on
both sides of the blade
DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed.
to loosen
Guide
(A)
Remove Adjustable
Cutting Guide
Align 45° Slots
to Ruler/Stop
Ruler/Stop
(B)
Reposition Adjustable
Cutting Guide
Adjustable
Cutting Guide
(C)
Position masonry piece
against the Adjustable
Cutting Guide
Loosen Locking
Handle to adjust
Cutting Head
(D)
Lock Cutting Head in
the down position
Turn clockwise
hten
to ti
Align work
with Blade
(E)
Position Adjustable Cutting
Guide and masonry piece to
Direction of
Movement
(F)
Open the Cooling Flow Control
Valve and adjust flow
required cut position
Direction of
Movement
Throttle Lever
(G)
Move the Throttle Lever to
(H)
(I)
Setup to Cut
adjust blade speed (faster blade
speed for smoother cuts)
Place Work
in Position
Control Valve
Hold Work
in Position
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 23
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
Push Slowly to Cut
Slowly push piece toward the
blade – continue until the
Raise Cutting Head once
(J)
cut Is complete
Raise Cutting
Head
(M)
cut is complete
Direction of
Movement
Throttle Lever
(K)
Move the Throttle Lever to
lower blade speed
Unlock Cutting
Head
(L)
Unlock Cutting Head
Loosen Locking
Handle to adjust
Cutting Head
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 24
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
SHUTDOWN:
1. Normal Engine Shutdown:
Direction of
Movement
Move the Throttle Lever to lower
blade speed
Throttle Lever
(A)
Engine Switch
(B)
Place Engine Switch
in the OFF position
Direction of
Movement
Direction of
Movement
(C)
Place Fuel Valve in the
OFF position
Fuel Valve
2. Emergency Engine Shutdown:
Engine Switch
Place Engine Switch
in the OFF position
(A)
Direction of
Movement
Direction of
Movement
Throttle Lever
(B)
Move the Throttle Lever to lower
blade speed
Direction of
Movement
(C)
Place Fuel Valve in the
OFF position
Fuel Valve
3. Cleanup:
Engine parts are extremely hot following use, allow engine to cool 1/2-hour before cleaning. Use
NOTE: If a clean external water source was used, steps A to C may be skipped.
care during cleanup to avoid injury.
Pump Suction
(A)
Clean Water Pump
suction of all debris
Water Pump
Water Container
(B)
Place Water Pump in a
container of clean water
Cooling Flow
Points
(C)
Run MK-2005G until clear water
is seen at blade cooling ports
(Approx. 1 minute)
MK-2005G Revision 12/00, Effective Date December 26, 2000
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SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN
Engine Switch
Place Engine Switch
in the OFF position
(D)
Direction of
Movement
Drain Plug
(E)
Remove Drain Plug and dispose
of water (conform to Federal,
State and local laws for disposal)
Clean Water Basin
(F)
Clean Water Basin with soap
and clean water
NOTE: 1. To extend operating life, the MK-2005G should be cleaned following every use.
2. Using a garden hose or pressure washer can force water into the air cleaner or muffler opening.
3. Use care when cleaning around electrical components.
Clean Movable Cutting Table
Guide Rails with soap and
Mounting Plates
Clean between engine
(G)
clean water
(J)
mounting plates
Guide Rail
Roller Wheel
(H)
Clean Movable Cutting Table
Roller Wheels
Air Filte
(K)
Clean Air Filter
(See Maintenance section)
(I)
Clean exterior surface of
MK-2005G (except engine)
with soap and clean water
(L)
Clean engine throttle linkage
with a dry cloth
Clean Exterior
Throttle Linkage
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 26
MAINTENANCE AND TROUBLESHOOTING
MAINTENANCE:
1. Initial Maintenance:
Perform the following after initial purchase and operation of the MK-2005G.
Change Oil
Change engine oil after 1
month or 1
(See Engine Oil Change)
(A)
st
20 operating hours
st
Check and adjust V-belt tension
Following 1
st
48 hours of operation
See V-belt Inspection
Inspect V-Belts
(B)
2. Maintenance Following Use:
To extend the life of the MK-2005G, the following procedure should be performed after each use. Lubricate
all points listed below with light oil such as, 3 in 1, WD-40, etc.
Engine Switch
Place Engine Switch
in the OFF position
Pivot Point
Lubricate Blade Guard Pivot
Points and Adjustment Bar
(A)
(D)
Direction of
Movement
Adjustment Bar
Lubricate Roller Wheels
(B)
Lubricate the Movable Cutting
Table Roller Wheels
Throttle Linkage
(E)
Lubricate engine throttle linkage
Torsion Spring
(C)
Lubricate Torsion Spring
MK-2005G Revision 04/2003, Effective Date April 2, 2003
Page 27
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MAINTENANCE AND TROUBLESHOOTING
3. Monthly Maintenance:
The following should be performed monthly. Items should be lubricated as di rected.
Outer Flange
Remove and clean Diamond
Blade Outer Flange and
Check Movable Cutting Table
Roller Wheels for wear
(A)
Retaining Bolt
Roller Wheels
(D)
Retaining
Bolt
1/2-inch
Wrench
(B)
Verify all engine mounting
bolts are tight
Air Filte
(E)
Clean engine Air Filter
(See Engine Air Filter Inspection
Cleaning and Replacement)
1/2-inch
Wrench
9/16-inch
Wrench
(C)
Verify engine Adjustment
Straps are tight
4. Six (6) Month Maintenance:
Perform the following maintenance every six months.
Change Oil
Change engine oil
(See Engine Oil Change)
(A)
Clean Fuel Sediment Cup
(See Fuel Sediment
Cup Cleaning)
Fuel Sediment Cup
(B)
Spark Plug
(C)
Clean and Readjust engine
Spark Plug (See Spark Plug
Adjustment and Replacement)
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 28
MAINTENANCE AND TROUBLESHOOTING
5. Yearly Maintenance:
Perform the following maintenance every year.
Replace engine Air Filter
(See Engine Air Filter Inspection
Cleaning and Replacement)
(See V-Belt Inspection,
Adjustment and Replacement)
(A)
(D)
Inspect V-belts
Air Filter
Inspect V-Belts
Spark Plug
(B)
Replace Spark Plug
(See Spark Plug
Adjustment and Replacement)
(C)
Check/Adjust Idle Speed
Check/Adjust Valve Clearance
(Shop Maintenance Required)
6. Two Year Maintenance:
(Shop Maintenance Required)
(A)
Check Fuel Line
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 29
MAINTENANCE AND TROUBLESHOOTING
7. Blade Dressing:
Like most cutting instruments, a diamond blade performs best when it is dressed. Over time and use,
diamonds on the outer edge 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
152792) and by following the steps below.
NOTE: Skip Steps D and E if cutting dry.
Setup MK-2005G for operation
(See Setup, Startup, Adjustment
Operation and Shutdown)
Direction of
Movement
Open the Cooling Flow Control
Valve and adjust flow
Push Slowly to Cut
Cut the Dressing Stick 7 or 8
times to dress the Blade
(A)
Control Valve
(D)
(F)
Set Edge of Cutting
Guide to desired Cut
Length on Ruler/Stop
Ruler Markings
Ruler/Stop
(B)
Set the Adjustable Cutting Guide
to cut 1/16-inch strips
Cooling Flow
Points
(E)
Verify cooling flow exists on
both sides of the blade
Direction of
Movement
Throttle Lever
(G)
Move the Throttle Lever to lower
blade speed
Set against Adjustable
Cutting Guide and
Ruler/Stop
Adjustable
Cutting Guide
Ruler/Stop
(C)
Position the Dressing Stick
Direction of
Movement
Throttle Lever
(E)
Move the Throttle Lever to
adjust blade speed (faster blade
speed for smoother cuts)
Raise Cutting
Head
(H)
Raise Cutting Head once
cut is complete
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 30
MAINTENANCE AND TROUBLESHOOTING
8. Diamond Blade Change-out:
Engine Switch
Place Engine Switch
in the OFF position
Remove
Blade
Remove old Diamond Blade
(A)
(D)
NOTE: When installing the diamond blade retaining-bolt, ensure the threads of the bolt are aligned with the
threads of the drive shaft so as not to “cross-thread" the bolt.
Rotate Blade
Wrench clockwise
to tighten
Install Retaining Screw and
Outer Flange then tighten
(G)
Direction of
Movement
Retaining Screw
and Outer Flange
Cutting Head
Loosen Locking
Handle to adjust
Cutting Head
(B)
Raise Cutting Head
Install
Blade
(E)
Install new Diamond Blade
onto Blade Shaft
Blade Wrench
Retaining Screw
and Outer Flange
Turn counter-
clockwise to
loosen
(C)
Identify and remove Retaining
Screw and Outer Flange
Seat Blade on
Blade Shaft
Rotation Direction
(F)
Verify Blade is seated on Blade
Shaft in correct rotation direction
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 31
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MAINTENANCE AND TROUBLESHOOTING
9. Movable Cutting Table Wheel Change Out:
NOTE: All four (4) Movable Cutting Table, Roller Wheels should be replaced at the same time (MK Diamond
Part No. – 133090)
Movable
Cutting Table
(A)
Remove the Movable
Cutting Table
Clean Holes
(D)
Prepare for Installation
Of New Roller Wheels
Lubricate with
Light Oil (WD-40,
3 in 1, etc)
(F)
Lubricate Roller Wheels
Roller Wheels
(B)
Place Movable Cutting
Table On Work Bench
with Roller Wheels Up
Washe
Roller Wheel
(E)
Install Wheel/Washer Assembly
Into Movable Cutting Table
Movable
Cutting Table
(H)
Install the Movable
Cutting Table
Rotate Wrench
Counte
1/2-Inch Wrench
(C)
Remove Roller Wheels
Rotate Wrench
Counte
1/2-Inch Wrench
(G)
Install Roller Wheel
Retaining Nut – Tighten
-clockwise
-clockwise
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 32
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MAINTENANCE AND TROUBLESHOOTING
10. Protective Wooden Strip Replacement:
The protective wooden strip is to protect the Movable Cutting Table from damage during operation. Over
time, the wooden strip will become grooved from use. A grooved wooden strip will not support masonry
during cutting causing the blade to "break through" the piece instead of performing a smooth cut (MK
Diamond Part No. – 156427).
Remove the Movable
Worn Wooden
Strip
New Wooden
Strip
Protective Wooden Strip
(A)
Cutting Table
(D)
Replace Worn
Movable
Cutting Table
Roller Wheels
(B)
Place Movable Cutting
Table On Work Bench
with Roller Wheels Up
Phillips
Screwdrive
Retaining Screw
(F)
Place Movable Cutting Table on
Work Bench – Wheels Up,
Reinstall Retaining Screws
Retaining Screw
(C)
Remove the two Protective
Wooden Strip Retaining Screws
(G)
Install the Movable
Cutting Table
Phillips
Screwdrive
Movable
Cutting Table
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 33
MAINTENANCE AND TROUBLESHOOTING
11. Check Fuel Level:
1. Gasoline is highly flammable and explosive. You can be burned or seriously injured when
handling fuel.
2. To fuel, stop engine if running and allow it to cool.
3. Refuel in a well-ventilated area.
4. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, powe r tools,
etc.
NOTES: 1. Fuel can damage paint and plastic. Be careful not to spill fuel when filling the fuel tank.
Turn counter-
clockwise to
loosen
Turn clockwise
to tighten
5. Wipe up spills immediately.
Damage caused by spilled fuel IS NOT covered under the warranty.
2. DO NOT use stale or contaminated gasoline or an oil/gasoline mixture.
3. If using the Universal Stand with the MK-2005G, a ladder meeting OSHA specification is
recommended.
4. Use unleaded gasoline with a pump octane rating of 86 or higher.
Fill Throat
Fuel Cap
(A)
Remove Fuel Cap
Upper Limit
(B)
Check Fuel Level
(If level is 1/2 full or
Fill Fuel Tank until level is
below throat
greater, go to step D
Fuel Cap
(D)
Install Fuel Cap
DO NOT over-tighten
Fill Throat
(C)
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 34
MAINTENANCE AND TROUBLESHOOTING
12. Checking Oil Level:
NOTES: 1. Engine Oil Capacity is 0.63 US qt (0.6 l).
2. When installing the Oil Dipstick, ensure the threads are aligned with the threads of the Oil
Reservoir so as not to “cross-thread."
Loosen Locking
Handle to adjust
Cutting Head
Level Cutting Head
Fill through
Reservoir fill hole
Wipe up excess oil
Fill Oil Reservoir
Clean Up
(A)
(D)
(G)
Cutting Head
Turn counter-
clockwise to
loosen
(B)
Remove Dipstick
Bottom Edge
(E)
Add Oil until level reaches
The bottom edge of fill hole
Dipstick
Check Oil Level
If level is normal go to step F
Turn clockwise
to tighten
Install the Dipstick
1/2-way up Dipstick
Bottom of Dipstick
(C)
Dipstick
(F)
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 35
MAINTENANCE AND TROUBLESHOOTING
13. Changing Oil:
Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil.
SAE 10W-30 is recommended for general use. Other viscosity oil shown in the chart below may be used
when the average temperature in your area is within the recommended range.
5W-30
-20ºC -10ºC 0ºC 10ºC 20ºC 30ºC 40ºC -30ºC
10W-30
NOTES: 1. Drain used oil while the engine is warm.
2. Conform to Federal, State and Local laws, codes and ordinances relative to environmental
protection for oil disposal.
Loosen Locking
Handle to adjust
Cutting Head
Raise Cutting Head
Install Oil Drain
(A)
(D)
Cutting Head
5/8-inch
Wrench
3/4-inch
Wrench
(B)
Place container below Oil Drain
Open Oil Drain
Fill through
Reservoir fill hole
(E)
Fill Oil Reservoir
(See Checking Oil Level)
30
5/8-inch
Wrench
3/4-inch
Wrench
100ºF-20ºF 0ºF 20ºF 40ºF 60ºF 80ºF
Drain Completely
(C)
Drain Oil
(conform to Federal, State and
Local laws for disposal)
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 36
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MAINTENANCE AND TROUBLESHOOTING
14. Engine Air Filter Inspection Cleaning and Replacement:
Air Filter Cover
Remove Air Filter Cover
Clean Foam Filter with warm
soapy water – allow to air dry
Retaining Screw
Remove the 3 Cyclone
Carburetor
Air Filter Base
Filter Assembly
retaining screws
Intake
Clean the Air Filter Base
DO NOT allow dirt to enter
Turn counter-
clockwise to
loosen
Dual Air Filter
(A)
Remove Dual Air Filter
Clean Foam Filter
(D)
Dip Foam Filter in clean
engine oil – Squeeze out
excess oil
Turn counter-
clockwise to
loosen
Cyclone Filter
Assembly
(G)
Remove the Cyclone Filter
Assembly from the Air
Filter Cover
Paper Filter
(J)
Install Foam Filter over
Paper Filter
the carburetor intake
MK-2005G Revision 12/00, Effective Date December 26, 2000
(B)
(E)
(H)
(K)
Turn counter-
clockwise to
loosen
Submerge
with Oil
Cyclone Filter
Assembly
Foam Filter
Paper Filter
Foam Filter
(C)
Separate outer Foam Filter
from inner Paper Filter
Paper Filte
Tap to Clean
or use
compressed air
(F)
Inspect Paper Filter, tap on hard
surface to clean or use 30psi air
(direct air inside filter to clean)
Air Guide
Cyclone Housing
(I)
Separate the Air Guide from
the Cyclone Housing and
clean using soap and water
Turn clockwise
to tighten
Dual Air Filter
(L)
Install Dual Air Filter
Page 37
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MAINTENANCE AND TROUBLESHOOTING
Install the Air Guide into
the Cyclone Housing
Air Filter Cover
Install Air Filter Cover
(M)
(P)
Air Guide
Cyclone Housing
Turn clockwise
to tighten
Cyclone Filter
Assembl
(N)
Install the Cyclone Filter
Assembly into the Air
Filter Cover
Retaining Screw
(O)
Install the 3 Cyclone
Filter Assembly
retaining screws
Turn clockwise
to tighten
Cyclone Filter
Assembl
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 38
MAINTENANCE AND TROUBLESHOOTING
15. Fuel Sediment Cup Cleaning:
1. Gasoline is highly flammable and explosive. You can be burned or seriously injured when
handling fuel.
2. To fuel, stop engine if running and allow it to cool.
3. Refuel in a well-ventilated area
4. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, powe r tools,
etc.
NOTES: 1. Conform to Federal, State and Local laws for the proper disposal of fuel
Direction of
Movement
Fuel Sediment
Cup
Remove Fuel Sediment Cub
5. Wipe up spills immediately.
2. Fuel can damage paint and plastic. Be careful not to spill fuel when filling the fuel tank.
Damage caused by spilled fuel IS NOT covered under the warranty.
3. DO NOT use stale or contaminated gasoline or an oil/gasoline mixture.
4. If using the Universal Stand with the MK-2005G, an OSHA approved ladder is recommended
when fueling.
5. When installing the Sediment Cup retaining bolt, ensure the threads of the bolt are aligned
with the threads on the Fuel Valve so as not to “cross-thread the nut."
Fuel Valve
(A)
Place Fuel Valve in
the OFF position
Turn counter-
clockwise to
loosen
10mm Wrench
Fuel Drain
Screw
(B)
Drain the Fuel Sediment Cup
by removing the angled
Turn counter-
clockwise to
loosen
(C)
Remove Sediment Cup
Retaining Screw
Fuel Drain screw
Clean Cup
(D)
(E)
Clean Fuel Sediment Cup using
a nonflammable solvent – allow
Install Fuel Sediment Cup and
Sediment Cup Drain Screw
(F)
Sediment Cup to dry
Retaining
Screw
Turn clockwise
to tighten
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 39
MAINTENANCE AND TROUBLESHOOTING
16. Spark Plug Adjustment and Replacement:
DO NOT work around the engine while hot.
NOTE: 1. Recommended spark plugs are: NGK – BPR6ES or DENSO – W20 EPR-U
2. When installing the Spark Plug, ensure the threads of the are aligned with the threads in the
Pull back to
remove
Clean
Remove Spark Plug Cap
Clean with a wire brush and
Push onto
Spark Plug
Install the Spark Plug Cap
verify the Spark Plug Cap
engine so as not to “cross-thread" the plug.
Spark Plug
Cap
Turn counter-
clockwise to
(A)
clean cap and around
spark plug
Set Gap
Gap Setting
0.028 – 0.031 in
(0.70 – 0.80 mm
(D)
Install the Spark Plug by Hand
re-gap the Spark Plug
Spark Plug
Cap
(G)
is seated
loosen
(B)
Remove Spark Plug
Seat by Hand
(E)
DO NOT cross-thread
the Spark Plug
13/16-inch
Socket
Electrode
not worn
No chips
or cracks
(C)
Inspect Spark Plug
if worn replace Spark Plug
and go to step E
Turn clockwise
to tighten
13/16-inch
Socket
(F)
Tighten the Spark Plug
If new, tighten 1/2-turn
If old, tighten 1/8-1/4 turn
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 40
MAINTENANCE AND TROUBLESHOOTING
17. V-Belt Inspection, Adjustment and Replacement:
The MK-2005G is designed with two power transmission v-belts. The two belts are a matched set and should
be inspected, adjusted and/or replaced at the same time.
NOTES: 1. When new belts are installed, they should be inspected and re-tensioned after the first forty-
eight (48) hours of operation.
2. When performing any maintenance on the power transmission V-belts, always start with the
belt on the Blade Guard side.
I. Blade Side V-belt:
Remove Blade
Remove Diamond Blade
(See Diamond Blade
Pivot Up
Pivot front of Water Pump Drive
End Pivot Plate up and tighten
the retaining bolts
(A)
Change-out)
(D)
(B)
Identify the Water Pump
Pivot Plate
9/16–inch
Wrench
9/16-inch
Wrench
(E)
Disconnect the Blade Guard
Adjustment Bar
NOTE: The Step G may require the pump discharge line to be repositioned.
Retaining Bolts
1/2-inch
Wrench
Remove the Belt Guard
Retaining Bolts
(G)
Turn counter-
clockwise to
loosen
(H)
Inspect the V-belt for cracks,
fraying, separation and wear. Go
to step J if replacement required
Pivot Plate
Turn counter-
clockwise to
loosen
V-belt
9/16-inch
Wrench
Retaining Bolts
(C)
Loosen Water Pump Drive End
Pivot Plate front and rear
retaining bolts
Blade Guard
Pivot Down
(F)
Pivot Blade Guard to expose
Belt Guard retaining bolts
Check Tension
1/2-way
between pulleys
(I)
Check Belt for proper tension
If tension correct, go to step U
(proper tension 1/8-inch)
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 41
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MAINTENANCE AND TROUBLESHOOTING
Turn counter-
clockwise to
loosen
1/2-inch
Wrench
Loosen engine mounting plate
If re-tensioning, go to step S
Retaining Bolts
(J)
Turn counter-
clockwise to
loosen
(K)
Loosen Engine Adjustment
Strap Lock-nut then loosen
the Engine Adjustment Strap
NOTE: DO NOT use a screwdriver when installing new belts.
V-belt V-belt
tension is correct then tighten the
Engine Adjustment Strap Lock-nut
Remove the V-belt
Verify the Engine Adjustment
Strap Lock-nut is loose then
tighten the Adjustment Strap
Continue adjusting V-belt until
(M)
(P)
(S)
Turn clockwise
to tighten
1/2-inch
Wrench
Turn clockwise
to tighten
1/2-inch
Wrench
(N)
Install the new V-belt
(MK Diamond Part No. 156294)
Remove Slack
(Q)
Tighten the Engine Adjustment
Strap to remove slack
Check Tension
between pulleys
(T)
Check V-belt tension
(proper tension 1/8-inch)
1/2-inch
Wrench
Adjustment
Strap Bolt
1/2-way
Direction of Push
(L)
Push the Engine Mounting Plate
toward the front of the unit to
loosen the V-belt
Pulley
(O)
Verify the V-belt is seated in
The grooves of both pulleys
Check Tension
1/2-way
between pulleys
(R)
Check V-belt tension
(proper tension 1/8-inch)
Retaining Bolts
1/2-inch
Wrench
Turn clockwise
hten
to ti
(U)
Install the Belt Guard
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 42
MAINTENANCE AND TROUBLESHOOTING
9/16-inch
Wrench
Locate Water Pump Pivot Plate
Loosen retaining bolts
Install Blade
Install the Diamond Blade
Retaining Bolts
(V)
(Y)
(W)
Relocate Water Pump Pivot
Plate and retighten
retaining bolts
9/16-inch
Wrench
Retaining Bolts
9/16–inch
Wrench
Turn counter-
clockwise to
loosen
(X)
Install the Blade Guard
Adjustment Bar
II. Engine Side V-belt:
Retaining Bolts
1/2-inch
Wrench
Remove the Belt Guard
1/2-inch
Wrench
Loosen engine mounting plate
MK-2005G Revision 12/00, Effective Date December 26, 2000
Retaining Bolts
If re-tensioning, go to step J
(A)
(D)
Turn counter-
clockwise to
loosen
Turn counter-
clockwise to
loosen
V-belt
(B)
Inspect the V-belt for cracks,
fraying, separation and wear. Go
to step D if replacement required
Turn counter-
clockwise to
loosen
1/2-inch
Wrench
(E)
Loosen Engine Adjustment
Strap Lock-nut then loosen
the Engine Adjustment Strap
Check Tension
1/2-way
between pulleys
(C)
Check Belt for proper tension
If tension correct, go to step O
(proper tension 1/8-inch)
Direction of Push
(F)
Push the Engine Mounting Plate
toward the front of the unit to
loosen the V-belt
Page 43
MAINTENANCE AND TROUBLESHOOTING
NOTE: DO NOT use a screwdriver when installing new belts.
V-belt
Remove the V-belt
Verify the Engine Adjustment
Strap Lock-nut is loose then
tighten the Adjustment Strap
Check V-belt tension
(proper tension 1/8-inch)
(G)
Turn clockwise
to tighten
(J)
Check Tension
1/2-way
between pulleys
(M)
V-belt
(H)
Install the new V-belt
(MK Diamond Part No. 156294)
Check Tension
1/2-way
between pulleys
(K)
Check V-belt tension
(proper tension 1/8-inch)
1/2-inch
Wrench
Turn clockwise
to tighten
(N)
Tighten Base Plate
Pulley
(I)
Verify the V-belt is seated in
The grooves of both pulleys
Turn clockwise
to tighten
(L)
Continue adjusting V-belt until
tension is correct then tighten the
Engine Adjustment Strap Lock-nut
Retaining Bolts
1/2-inch
Wrench
Turn clockwise
to tighten
(O)
Install the Belt Guard
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 44
MAINTENANCE AND TROUBLESHOOTING
TROUBLESHOOTING:
Turn the ON/OFF switch to the OFF position and place the Fuel Valve in the CLOSED position
before performing the following.
1. Blade Will Not Cut Properly:
If “Glazed,” Dress
(See Blade Dressing)
Check for Smoothness
Contact Place of Purchase or
MK Diamond (800 421-5830)
or “Glazing”
To Verify Blade
Verify Blade Correct for
Material Being Used
If not “Glazed,
(A)
(D)
go to Step B
If Blade
Correct, go
to Step E
(B)
Check for Proper Rotation
Return to
MK Diamond
for Repair
(E)
Return to MK Diamond
If Rotation
Correct, go
to Step C
Rotation Direction
If Core Bent,
Change Blade
Ensure Blade
Core Not Bent
If Core Not
Bent, go to
Step D
(C)
2. Movable Cutting Table Does Not Move Correctly:
Check that the Guide
Rails are clean and
clean if dirty
(A)
Guide Rail
Roller Wheels
(B)
Check the Movable Cutting Table
Roller Wheels and replace if
necessary
Return to
MK Diamond
for Repair
(E)
Return to MK Diamond
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 45
MAINTENANCE AND TROUBLESHOOTING
3. Cooling Flow:
Direction of
Movement
Check Cooling Flow
Control Valve is open
(A)
Control Valve
Transfer Tube
(B)
Remove Transfer Tube from
Blade Guard
NOTE: “Rodding” cooling channels is performed by removing the flow control valve and then inserting a
small wire rod through the cooling channel inlet, on the top of the Blade Guard and directing the rod out
through each of the diamond blade cooling flow outlet ports, located on the underside of the Blade Gu ard.
The cooling channels should be “rodded” until each of the outlet ports are open and free of foreign debris.
Control Valve
Cooling Valve
Part No. 152597
Verify Cooling Valve operation
by removing the valve from the
Pump
Suction
Pump Impeller is
inside suction
Verify Water Pump suction is
clean and pump impeller is
turning – if not turning, replace
(D)
Blade Guard
(G)
3/4-inch
Wrench
Water Pump
Part No. 157082
Water Pump
Water Container
(E)
Attach the Cooling Valve to the
Transfer Tube to verify flow –
if no flow, replace valve
Drive End in
operating position
(H)
Verify Water Pump drive end is
in the operating position – if in
operating position go to step I
Water Pump
Water Container
(C)
Place Water Pump in clean
water source and check for
flow (if no flow go to step G)
Cooling Flow
Points
(F)
Rod Cooling Channels and
recheck flow
If no flow go to step I
Return to
MK Diamond
for Repair
(I)
Return to MK Diamond
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 46
MAINTENANCE AND TROUBLESHOOTING
4. Blade Stops Turning:
Check engine operating if not restart
(See Setup, Startup, Adjustment,
Operation and Shutdown
Verify Operation
(A)
(B)
Check V-belts
(See V-belt Inspection,
Adjustment and Replacement)
V-belt
Return to
MK Diamond
for Repair
(C)
Return to MK Diamond
5. Engine Stops:
NOTE: The Honda Engine is equipped with an oil level sensor that will stop the engine on a low oil level
Direction of
Movement
Pull Starter Cord straight back
in a smooth fast motion
Clean and Readjust engine
Spark Plug (See Spark Plug
Adjustment and Replacement)
(A)
(D)
Starter Cord
Spark Plug
Upper Limit
(B)
Verify fuel level is below
the throat of the Fuel Tank
Return to
MK Diamond
for Repair
(E)
Return to MK Diamond
Fill Throat
Check for proper oil level
(See Maintenance section if low)
Proper Oil Level
Low level
(C)
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 47
EXPLODED VIEW AND PARTS LIST
EXPLODED VIEW:
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 48
ENGINE GUARD INSTALLATION INSTRUCTION
PARTS LIST:
Item Description Qty MK p/n
A Assembly, Frame, MK2000 Brick saw 1 -
A1 Frame, MK-2000 1 150595
A2 Crossbar, Support 1 150594
A3 Screw, 5/16-18 x 1 Hex Head Cap 1 151743
A4 Washer, 5/16 Split Lock 4 151747
A5 Washer, 5/16 SAE Flat 4 151754
A6 Label, MK Brick saw 12 – 1/2 x 1-3/4 1 155230
B Assembly, Upright Left 1 -
B1 Casting, Upright Left 1 150592
B2 Screw, 5/16-18 x 3/4, Hex Head 6 151369
B3 Washer, 5/16 Split Lock 6 151747
B4 Washer, 5/16 SAE Flat 6 151754
C Assembly, Upright Right 1 -
C1 Casting, Upright Right 1 150593
C2 Screw, 5/16-18 x 3/4, Hex Head 6 151369
C3 Washer, 5/16 Split Lock 10 151747
C4 Washer, 5/16 SAE Flat 10 151754
C5 Bracket, Blade Guard (Stay Level) 1 150582
C6 Clip, Hairpin 1/4 Shaft 1 153953
C7 Screw, 5/16 x 1 Hex Head Cap 4 151743
D Assembly, Cutting Head 1 -
D1 Casting, Cutting Head 1 150583
D2 Shaft, Pivot 1 154147
D3 Stud, Height Adjustment 1 150585
D4 Bearing, Pivot Shaft 2 140004
D5 Collar, Pivot Shaft 2 140012
D6 Screw, 5/16-8 x 3/16 Socket Head Set 2 151167
D7 Strap, Motor Adjustment 1 150584
D8 Bolt, 3/8-16 x 3 1/2 Hex Head Cap 1 153147
D9 Bracket, Cutting Head Height Adjustment 1 156839
D10 Screw, 3/8-16 x 1 1/2 1 153528
D11 Washer, 3/8 SAE Flat 3 150923
D2 Washer, 3/8 Split Lock 1 150925
D13 Nut, T Plan Slab Weld 1 153945
D14 Handle, Cutting Head Height Adjustment Lock Nut, 1 151140
D15 Stud, 5/16-18 x 2 6 156959
D16 Handle 1 139931
D17 Grip, Handle 1 139949
D18 Screw, 3/8-16 x 1 Flat Head Screw Cap 2 154019
D19 Pin, Split Wrist 1 151358
E Assembly, Pivot Spring 1 -
E1 Spring, Torsion Pivot 1 150587
E2 Bracket, Spring Adjustment 1 150589
E3 Screw, 5/16-18 x 1 Hex Head 2 151743
E4 Washer, 5/16 Split Lock 3 151747
E5 Washer, 5/16 SAE Flat 3 151754
E6 Stud, Retaining Spring 1 153788
E7 Screw, 5/16-18 x 3/4 Hex Head 1 151369
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 49
EXPLODED VIEW AND PARTS LIST
Item Description Qty MK p/n
F Assembly, Blade Shaft 1 154636
F1 Casting, Blade Shaft-Arbor 1 153791
F2 Bearing, Blade Shaft 2 154594
F3 Shaft, Blade 1 154639
F4 Flange, Inner 1 154640
F5 Pin, Arbor Alignment 2 153946
F6 Flange, Outer 14 Inch M-Saw 1 132290
F7 Screw, 1/2-20 x 1 1/4, Hex Head (Blade Bolt) 1 152122
F8 Screw, 5/16-18 x 2 –1/4 4 153951
F9 Washer, 5/16 Split Lock 4 151747
F10 Washer, 5/16 SAE Flat 4 150923
G Assembly, Blade Guard 1 -
G1 Casting, Blade Guard 1 150579
G2 Tag, Serial Number MK-20 00 1 157007
G3 Shaft, Blade Guard Bolt 1 150581
G4 Nut, 1/2-13 Hex Lock, Top 1 153943
G5 Bar, Adjustm ent Blade Guard (Stay Level) 1 150580
G6 Screw, 3/8-16 x 1 Hex Head 1 152507
G7 Washer, 3/8 Split Lock 1 150925
G8 Washer, 3/8 SAE Flat 1 150923
H Assembly, Water Control Valve 1 -
H1 Elbow, Street 45 1/4 MNPT 1 153869
H2 Nipple, 1/4 MNPT x Close 1 152598
H3 Valve, Female Ball – 1/4 Pipe 1 152597
H4 Fitting, 1/4 MNPT x 1/2 Barb 1 152704
J Assembly, Splash Guard 1 -
J1 Curtain, Blade Guard 1 152417
J2 Bracket, Water Curtain 1 152723
J3 Screw, 1/4-20 x 1/2, Wing Screw 1 151888
J4 Washer, 1/4 SAE Flat 1 151915
K Assembly, Belt Guard MK-2005 (Arbor Side) 1 -
K1 Casting, Belt Guard Inner 1 1566 69
K2 Screw, 5/16-18 x 1 3/4 Hex Head 2 151919
K3 Washer, 5/16 Split Lock 3 151747
K4 Washer, 5/16 SAE Flat 3 151754
K5 Pulley, Micro-V, 2.0 Diameter 1 156291
K6 Pulley, Micro-V 2 3/8 Diameter 1 156292
K7 Screw, 5/16-18 x 1/2, Socket Head Set (Cup Point) 4 157084
K8 Key, 1-1/8 x 3/16 2 150344
K9 Belt, Micro-V (Gates 220J-10) 1 156294
K10 Casting, Belt Guard Outer 1 156670
K11 Screw, 5/16-18 x 2 1/2 Hex Head 2 101675
L Assembly, Belt Guard MK-2005 (Engine Side) 1 -
L1 Casting, Belt Guard Inner 1 156671
L2 Screw, 5/16-16 x 1 Hex Head 3 151743
L3 Washer, 5/16 Split Lock 5 151747
L4 Washer, 5/16 SAE Flat 5 151754
L5 Pulley, Micro-V, 2.0 Diameter 1 156291
L6 Pulley, Micro-V 2 3/8 Diameter 1 156292
L7 Screw, 5/16-18 x 1/2, Socket Head Set (Cup Point) 4 157084
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 50
EXPLODED VIEW AND PARTS LIST
Item Description Qty MK p/n
L8 Key, 1-1/8 x 3/16 2 150344
L9 Belt, Micro-V (Gates 220J-10) 1 156294
L10 Casting, Belt Guard Outer 1 156672
L11 Screw, 5/16-18 x 2 1/2 Hex Head 2 101675
M Assembly, Table 1 133082
M1 Casting, Table 1 153790
M2 Stop-Rule, Table 1 134387
M3 Screw, 1/4-20 x 3/4 Hex Head 4 152370
M4 Nut, 1/4-20, Keps 4 153941
M5 Wheel, Roller 4 133090
M6 Nut, 5/16-18 Keps 4 153942
M7 Wood Strip, Table Insert 1 156427
M8 Screw, Pan HD Phil. #8 x 1 2 151047
M9 Casting, Squaring Arm 1 132332
M10 Screw, 15/16-18 x 1 1/2, Thumb 1 151155
M11 Nut, 5/16-18 Square 1 151156
N Assembly, Curtain MK Logo 1 -
N1 Rod, Splash Curtain 1 153956
N2 Curtain, Rear 1 150613
N/A Assembly, Curtain Plain 1 -
N/A1 Rod, Splash Curtain 1 153956
N/A2 Curtain, Rear Plain 1 134841
P Assembly, Pan MK Logo
P1 Pan, Plastic 1 150308
P2 Plug, Rubber Drain Without Hole 1 153439
R Assembly, Water Pump, Mechanical 1 -
R1 Pump, Water Centrifugal 1 157082
R2 Mount, Water Pump 1 156108
R3 Screw, 5/16-18 x 1/2 Socket Head Cap 2 152473
R4 Screw, 3/8-16 x 1 Hex Head 2 152507
R5 Washer, 3/8 Split Lock 2 150925
R6 Washer, 5/16 Flat Cut 2 101352
R7 Pulley, 2.69 Diameter 1 157048
R8 Screw, 5/16-18 x 1/2 Socket Head Set (Cup Point) 2 157084
R9 Hose, Vinyl 1/2 x .748 3 ft 152410
R10 Clamp, 7/8 Hose 2 154173
S Assembly, Accessory Pack 1 -
S1 Wrench, Masonry Saw 1 134056
S2 Insert, Accessory 1 153576
S3 Blade, MK-BX30 1 157944
S4 Owner’s Manual 1 158320
T Assembly, Engine Base 1 -
T1 Casting, Engine Base 1 156673
T2 Shaft, Arbor 1 156295
T3 Bearing, Jack Shaft 2 139956
T4 Strap, Engine Belt Tensioning 1 156955
T5 Screw, 5/16-18 x 1 Socket Head Cap 1 151743
T6 Nut, 5/16-18 Hex 6 101196
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 51
EXPLODED VIEW AND PARTS LIST
Item Description Qty MK p/n
T7 Washer, 5/16 Split Lock 5 151747
T8 Washer, 5/16 SAE Flat 5 151754
T9 Washer, 7/16 Flat Cut 5 101352
U Assembly, Plates, Engine Mounting (Top & Bottom) 1 -
U1 Plate, Lower Engine Mounting 1 156296
U2 Screw, 5/16-18 x 1, Socket Head Cap 1 151743
U3 Washer, 5/16 Split Lock 8 151747
U4 Washer, 5/16 SAE Flat 8 151754
U5 Washer, 5/16 Flat Cut 4 151050
U6 Plate, Engine Mounting, Upper 1 156297
U7 Screw, 5/16-18 x 2, Socket Head Cap 4 155494
U8 Washer, Fender, 5/16 ID x 1.0 OD 4 151053
U9 Shock Mount, Upper 4 156961
U10 Shock Mount, Lower 8 156962
U11 Bushing, Stand Off, Shock Mount 4 156104
U12 Nut, 5/16-18 Hex 4 101196
V Assembly, Engine, Honda 5.5 hp 1 -
V1 Engine, Honda 5.5 hp W/Cyclone Filter 1 156282
V2 Deflector, Honda 1 156710
V3 Screw, 6-32 x 3/8 Pan Head Phillips Self-Tapping Cap 2 153466
V4 Screw, 5/16-18 x 1 1/2, Hex Head Cap 4 152467
V5 Washer, 5/16 Split Lock 7 150747
V6 Washer, 5/16 SAE Flat 6 150754
V7 Nut, 5/16-18, Hex 6 101196
V8 Label, Hot Surface, Caution 1 155578
V9 Label, Refueling Warning 1 155580
V10 Label, California, Danger 1 155581
V11 Label, Lethal Exhaust, Danger 1 155582
V12 Oil Drain, M10 x 3/8 Push 1 157577-01
V13 Guard, Engine 1 159562
V14 Arm, Support 1 159563
V15 Screw, 5/16-18x3/4 Hex Head Cap 2 151369
V16 Screw, 3/8-16x1 Hex Head Cap 1 152507
V17 Washer, 3/8 SAE Flat 2 150923
V18 Washer, 3/8 Split Lock 1 150925
V19 Bolt, 5/16-24x1 Hex Head Tap 1 157646
V20 Nut, 3/8-16 Hex 1 101188
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 52
EXPLODED VIEW AND PARTS LIST
1. Remove P#155494(5/16-18x2 screw), P#156961(upper shock mount), and
#151053(fender washer) at location A.
2. Attach support arm(itme3) to engine guard(item 1) with items 9, 10, 11, and 12. Fasten
the screw and nut loosely.
3. Fit engine guard onto the engine upper mounting plate.
Meanwhile, Screw item 8 through items 5 and 6 into the threaded hole on the side of the
engine. Do not tighten the screw.
4. Install item 4, 5 and 6 through engine guard and engine upper mounting plate. Fasten
the screw and nut loosely.
5. Reinstall items removed listed in step 1.
6. Secure all fasteners after placing engine guard in correct position.
**Note: Drilling two 11/32 dia. holes in engine upper mount (item2) are required on all old
style upper mounts.
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 53
ACCESSORIES, ORDERING and RETURN INSTRUCTIONS
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 t he
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-2005G Revision 12/00, Effective Date December 26, 2000
Page 54
EXPLODED VIEW AND PARTS LIST
ACCESSORIES:
ITEM NUMBER DESCRIPTION
1.
2.
3.
4.
5.
6.
132332
133090
156427
156294
152792
153439
Adjustable Cutting Guide
Roller Wheel
Protective Wooden Strip
Micro-V Belt
Dressing Stick
Rubber Drain Plug
MK-2005G Revision 12/00, Effective Date December 26, 2000
Page 55
EXPLODED VIEW AND PARTS LIST
ORDERING INSTRUCTIONS:
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: All when returning 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 Materials Authorization (RMA) 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-2005G, 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-2005G Revision 12/00, Effective Date December 26, 2000
Page 56
p
MK- 2005G
GAS POWERED BRICK 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
ecially designed to filter out microscopic particles.
s
MK DIAMOND PRODUCTS, INC
1315 STORM PARKWAY, TORRANCE, CA 90509-2803
310 539 5158
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