MK Diamond MK-5005S User Manual
www.mkdiamond.com
MK-5005S BLOCK SAW
OWNER’S MANUAL
PARTS LIST &
OPERATING INSTRUCTIONS
Revision 104
Manual Part# 158769
Caution: Read all safety and operating instructions
before using this equipment. This parts list MUST
accompany the equipment at all times.
04.2014
INTRODUCTION
Congratulations on your purchase of a MK-5000S Block Saw. We are certain that you will be pleased
with your purchase. MK Diamond takes pride in producing the nest construction power tools and
diamond blades in the industry.
Operated correctly, your MK-5000S Block Saw should provide you with years of service. In order
to help you, we have included this manual. This Owner’s Manual contains information necessary to
operate and maintain your MK-5000S Block Saw safely and correctly. Please take the time to
familiarize yourself with the MK-5000S Block Saw by reading and reviewing this manual.
Read and follow all safety, operating and maintenance instructions.
If you should have questions concerning your MK-5000S Block Saw, please feel free to call our
friendly customer service department at: 800 421-5830
Regards,
MK Diamond
NOTE THIS INFORMATION FOR FUTURE USE:
MODEL NUMBER:
SERIAL NUMBER:
PURCHASE PLACE:
PURCHASE DATE:
NOTE: For your (1) one year warranty to be effective, complete the warranty card (in-
cluding the serial number) and mail it in as soon as possible.
2
TABLE OF CONTENTS
SAFETY Pages
Safety Messages 4
Damage Prevention Message 4
General Safety Precautions and Hazard Symbols 4-6
California Proposition 65 Message 6
Electrical Requirements and Grounding Instructions 8-9
Safety Label Locations 10
Product Specications 11
UNPACKING AND ASSEMBLY
Unpacking 12
Contents 12
Transport 12
Assembly 13-14
SETUP, ADJUSTMENT AND OPERATION
Setup 15-17
Adjustment and Operation 18-24
Cleanup 25
MAINTENANCE AND TROUBLESHOOTING
Maintenance 26-27
Troubleshooting 28-36
EXPLODED VIEW AND PARTS LIST
Exploded View 38-47
Parts List 48-52
THEORY
Theory of Diamond Blades 53
ACCESSORIES, ORDERING and RETURN INSTRUCTIONS
Accessories 54
Ordering Information 55
Return Material Policy 55
Packaging Instructions 55
Authorized Service Centers 55
3
MK-5005S 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
A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol ( ) and one of three words: DANGER, WARNING, or CAUTION.
DANGER
WARNING
CAUTION
You WILL be KILLED or SERIOUSLY INJURED if you do not follow directions.
You CAN be KILLED or SERIOUSLY INJURED if you do not follow directions.
You CAN be INJURED if you do not follow directions. It may also be used to alert
against unsafe practices.
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
ALWAYS read this Owner’s Manual before operating the machine.
ALWAYS keep the Blade Guards in place.
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 PLACES
DO NOT use power tools in damp or wet locations nor expose them to rain. Always
keep the work area well lit.
KEEP CHILDREN AWAY
All visitors and children should be kept a safe distance from work area.
4
MK-5005S SAFETY
MAKE THE WORKSHOP KID PROOF
Make the workshop 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.
USE THE PROPER EXTENSION CORD
If using an extension cord make sure it is in good condition first. When using an extension
cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage that will result in a loss of power and overheating.
TABLE, Page 9 shows the correct AWG size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage. The smaller the gage number,
the heavier the cord.
USE PROPER APPAREL
DO NOT wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry that may
be caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair.
ALWAYS wear approved eye protection.
ALWAYS wear approved respiratory protection.
SECURE WORK
Clamps or a vise should be used to hold work whenever practical. Keeping your
hands free to operate a power tool is safer.
DO NOT OVERREACH
Keep proper footing and balance at all times by not overreaching.
MAINTAIN TOOLS WITH CARE
Keep tools clean for the best and safest performance. Always follow maintenance instructions for lubricating and when changing accessories.
ON / OFF
DISCONNECT TOOLS
Power tools should always be disconnected before servicing or when changing accessories, such as blades, bits, cutters, and the like.
ALWAYS place the power ON/OFF switch in the OFF position when the saw is not in use.
5
MK-5005S 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.
NEVER STAND ON THE TOOL
Serious injury could occur if a power tool is tipped, or if a cutting tool is unintentionally
contacted.
CHECK FOR DAMAGED PARTS
Before using a power tool, check for damaged parts. A guard or any other part that is damaged should be carefully checked to determine if it would operate properly and perform its
intended function. Always check moving parts for proper alignment or binding. Check for
broken parts and mountings and all other conditions that may affect the operation of the
power tool. A guard, or any damaged part, should be properly repaired or replaced.
DIRECTION OF FEED
ALWAYS feed work into a blade or cutter against the direction of rotation. A blade or cutter
should always be installed such that rotation is in the direction of the arrow imprinted on
the side of the blade or cutter.
NEVER LEAVE A TOOL 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.
CALIFORNIA PROPOSITION 65 MESSAGE
WARNING
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
For further information, consult the following sources:
http://www.osha.gov/dsg/topics/silicacrystalline/index.html
http://www.cdc.gov/niosh/consilic.html
http://oehha.ca.gov/prop65/law/P65law72003.html
http://www.dir.ca.gov/Title8/sub4.html
Your risk from these exposures varies depending on how often you do this type of work. To reduce
your exposure to these chemicals, work in a well-ventilated area, and work with approved safety
equipment, such as those dust masks that are specially designed to lter out microscopic particles.
6
MK-5005S SAFETY
(
(
)
)
on
HAZARD SYMBOLS
ELECTRICAL SHOCK
NEVER touch electrical wires or components while the engine is running. Exposed,
frayed or worn electrical wires can be sources of electrical shock which could cause
severe injury or burns.
ACCIDENTAL STARTS
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 PARTS
Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never
operate the motor with covers, shrouds, or guards removed.
OVER SPEED
NEVER tamper with the governor components or settings to increase the maximum
speed. Severe personal injury and damage to the motor or equipment can result if operated at speeds above maximum.
DO NOT EXPOSE TO RAIN
DO NOT expose to rain or use in damp locations.
WARNING
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.
7
MK-5005S 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 current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet
that is properly installed and grounded in accordance with all local codes and ordinances.
• Do not modify the plug provided – if it will not t the outlet; have the proper outlet installed by a
qualied electrician
• Improper connections of the equipment-grounding conductor can result in a risk of electric
shock. The equipment-grounding conductor is the insulated conductor that has an outer
surface that is green, with or without yellow stripes. If repair or replacement of the electric cord
or plug is necessary, do not connect the equipment-grounding conductor to a live terminal
• Check with a qualied electrician or service personnel if the grounding instructions are not
completely understood, or if in doubt as to whether the tool is properly grounded
• Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that
accept the tool’s plug
• Repair or replace a damaged or worn cord immediately
WARNING
This tool is intended for use on a circuit that has an outlet that looks similar to the one shown in
Sketch B of Figure below. The tool has a grounding plug that looks similar to the plug illustrated in
Sketch A of Figure below. Make sure the tool is connected to an outlet having the same conguration
as the plug. No adapter is available or should be used with this tool. If the tool must be reconnected
for use on a different type of electric circuit, the reconnection should be made by qualied service
personnel; and after reconnection, the tool should comply with all local codes and ordinances.
If permanently connected, this tool should be connected to a grounded metal permanent wiring system; or to a system having an equipment-grounding conductor.
(A) (B)
NOTE: Use of a temporary adapter is not permitted in Canada.
8
MK-5005S SAFETY
WARNING
To avoid the possibility of the appliance plug or receptacle getting wet, position the machine to one
side of a wall mounted receptacle. This will prevent water from dripping onto the receptacle or plug. A
“drip loop,” shown in the picture below, should be arranged by the user to properly position the power cord
relative to the power source.
The “drip loop” is that part of the cord below the level of the receptacle, or the connector, if an extension cord is used. This method of positioning the cord prevents the travel of water along the power
cord and coming in contact with the receptacle.
If the plug or receptacle gets wet, DO NOT unplug the cord. Disconnect the fuse or circuit breaker
that supplies power to the tool. Then unplug and examine for presence of water in the receptacle.
Motor
Power
Cord
Drip
Loop
Saw
Floor
Drip Loop Information
WARNING
Use only extension cords that are intended for outdoor use. These extension cords are
identified by a marking “Acceptable for use with outdoor appliances; store indoors while
not in use." Use only extension cords having an electrical rating not less than the rating
of the product. Do not use damaged extension cords. Examine extension cords before
using and replace if damaged. Do not abuse extension cords and do not yank on any
cord to disconnect. Keep cords away from heat and sharp edges. Always disconnect the
extension cord from the receptacle before disconnecting the product from the extension
cord.
To reduce the risk of electrocution, keep all connections dry and off the ground. Do not
touch the plug with wet hands. Use of undersized extension cords result in low voltage to
the motor that can result in motor burnout.
To choose the proper extension cord:
• Locate the length of extension cord needed in the table below.
• Once the proper length is found, move down the column to obtain the correct AWG size required
for that length extension cord.
Extension Cord Minimum Gage for Length
Volts
240V 25 ft. (7.5 m) 50 ft. (15 m) 75 ft (23 m)
Total Length of Cord in Feet
AWG AWG AWG
10 10 8
9
MK-5005S SAFETY DECALS
OPERATION & SAFETY DECALS
The MK-5005S Block Saw is equipped with a number of safety decals. These decals are provided for
operator safety and maintenance information. Should any of these operation or safety decals become
unreadable, replacements can be obtained by calling (800) 262-1575.
CAUTION
!
DO NOT
operate without
guards in place.
CAUTION
!
FOR INFORMATION ON
SERVICE OR
WARRANTY
PLEASE CALL
1-800-474-5594
(E)
(F)
(G)
!
NOTICE
Most Motor Problems are caused by improper
voltage and extension cords. Cord should be
one-piece and short as possible. Cord
selection should match the following table.
1-2 H.P.
115v 230v
25’
100’
50’
150’
75’
250’
Max. Cord Length
Max. Cord Length
Max. Cord Length
!
Receptacle is for
water pump only.
125V .6 amps max.
CAUTION
No. 12 Wire
No. 10 Wire
No. 8 Wire
(H)
(I)
(A)
(B)
(C)
(D)
WARNING
!
DO NOT operate
this equipment
before reading
the owners’
manual!
!
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. In addition, California and some other
authorities have listed respirable crystalline silica as a substance known to cause cancer.
CAUTION
!
DO NOT
operate without
guards in place.
WARNING
!
In the event of
blade failure,
replace blade
guard
immediately.
Accidental start hazard.
Disconnect spark plug
prior to servicing.
Masonry Saw Warning Label Sheet Part# 166011
B
E
D
I
G
H
C
A
Location Description
A Arbor Housing/Front Read Manual
B
Blade Guard/Back
Proposition 65, Dust Warning
C Belt Guard/Front Guards in Place
D Blade Guard/Front Replace Blade Guard
E Blade Guard/Front Guards in Place
F
F
G
H
I
J
Motor/Side
Accidental Start
Motor Service or Warranty
Motor Accidental Start
Motor Notice extension cord
Motor Receptacle water pump
10
MK-5005S PRODUCT SPECIFICATIONS
SPECIFICATION
The MK-5005S is a versatile masonry saw. Operated and used according to this manual, the MK5005S will provide years of dependable service.
General Description:
The MK-5005S, is engineered as a 14” or 20” saw, consisting of a powerful 230v single phase motor.
The saw is capable of cutting brick and masonry up to 8” x 8” x 16” in size in a single pass.
Motor and Weight Specications:
Motor and weight specications for the MK-5005S are listed in the table below.
Voltage
Amperage
208 / 230v
24
Frequency 50 Hz 60 Hz
RPM 2850 rpm 3,450
Weight 445 lbs.*
*Without Movable Cutting Table
BLADE CAPACITY
The MK-5005S uses a 14-inch or 20-inch diameter segmented MK Diamond blade with a .125-inch
cutting width and a 1” arbor.
MASONRY TYPES
The MK-5005S can cut a variety of masonry types including, cinder block, slump stone block, wall
brick, paver brick, concrete block and cylinders, roong tile, marble, granite, decorative rock or almost
any other non-ferrous material.
NOTE:
The MK-5005S is not designed to cut plastic or ferrous (metals) material.
PEDDLE ASSISTED CUTTING HEAD
The MK-5005S is designed with a peddle assisted Cutting Head to allow the operator to use both
hands when cutting. The Cutting Head can be raised or lowered by the use of an adjusting wheel to
set the start of the cut.
11
11.2010
MK-5005S BLOCK SAW
OWNERS MANUAL
PARTS LIST &
OPERATING INSTRUCTIONS
www.mkdiamond.com
Caution: Read all safety and operating instructions
before using this equipment. This parts list MUST
accompany the equipment at all times.
Revision 101
Manual Part# 158769
MK-5005S CONTENTS
UNPACKING
Your MK-5005S has been shipped from the factory thoroughly inspected. Only minimal assembly is
required. If not already done, remove the MK-5005S from the pallet and place it on a at surface
using a forklift.
Remove the accessories from the Water Basin and place along side the MK-5005S.
CONTENTS
In the containers, you will nd one (1) MK-5005S, one (1) movable cutting table, one (1) adjustable
cutting guide, one (1) electric water pump, one (1) pump discharge tting, one (1) blade wrench, one
(1) drain plug, one (1) owner’s manual, one (1) pump manual and one (1) warranty card.
MK-5005S
Blade
Wrench
TRANSPORT
Movable Cutting
Table
Drain
Plug
Adjustable
Cutting Guide
Owner’s
Manual
Electric
Water Pump
Pump
Manual
Pump
Discharge Fitting
Warranty
Card
The MK-5005S weighs approximately four hundred forty-ve (445) pounds (without the movable Cutting Table).
NOTE:
WARNING
Place the Cutting Head in the DOWN position, and remove the movable Cutting Table
Do not attempt to move the MK-5005S without a forklift.
when transporting the MK-5005S.
Due to its solid construction, the MK-5005S may only be transported with a forklift. Position the Cutting Head in the DOWN position, remove the movable Cutting Table, and transport the saw using the
eight (8) lift points positioned strategically around the base. Use tie downs when transporting the saw.
Tie Down
Lift Points
12
MK-5005S ASSEMBLY
ASSEMBLY
Follow the assembly instructions to prepare your MK-5005S for operation.
Movable Cutting Table Installation
(A)
Position movable Cutting Table
Adjustable Cutting Guide Installation
(A)
Loosen the Thumbscrew. Align the
adjustable Cutting Guide above the
movable Cutting Table Ruler/Stop
Diamond Blade Installation
(B)
Seat all four (4) Roller Wheels
on the Guide Rails
(B)
Seat the adjustable Cutting
Guide and tighten the Thumb-
screw
(C)
Verify correct seating of Roller
Wheels
(A)
Remove the Retaining Screw
and Outer Flange with the blade
wrench. Turn counter-clockwise
to loosen
13
MK-5005S ASSEMBLY
(D)
Install the Diamond Blade onto
the Blade Shaft
(G)
Rotate Blade Wrench clockwise
to tighten
Verify the blade is seated on
the Blade Shaft and direction of
rotation is correct
(E)
(F)
Install Retaining Screw and
Outer Flange
Water Pump Preparation
(A)
Install Water Pump
Discharge Fitting
(B)
Press the end of the Cooling
Transfer Tube onto the Water
Pump Discharge Fitting
14
MK-5005S SETUP
SETUP
CAUTION
• Before powering or starting, check for damage that could prevent this equipment from proper operation or performing its intended function. Check for binding and alignment of moving parts. Check
for damaged, broken, or missing parts.
• Verify the ON/OFF switch is in the OFF position.
• Before connecting the MK-5005S to a power supply, be sure the voltage, cycle and phase of the
job site power source meet the requirements of the table below.
VOLTAGE: 230v
CYCLE: 50/60hz
PHASE: Single phase
• If using an extension power cord, make sure the length and wire gauge corresponds to the requirements. 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.
• Do not cover the motor vents as this could lead to motor overheating.
Pre-start Inspection
The pre-start inspection should be performed before beginning any job.
CAUTION
If the Diamond Blade shows signs of fatigue cracking, replace the blade before
starting work.
NOTE:
Ensure the ON/OFF Switch
is in the OFF position
In order to avoid breaker tripping, a 30-amp circuit breaker should be used.
(A)
Check all electrical connections
(B)
Inspect the blade for damage
(C)
and verify it’s correct for the
material being cut
Inspect Wooden Strip for
(D)
excessive grooves
Verify movable Cutting Table
(E)
moves freely
15
(F)
Inspect the MK-5005S for
general damage and/or loose
hardware
MK-5005S SETUP
(G)
Inspect the Pump Assembly for
damage – ensure the cord
is free of cracks or cuts
Connecting the Water Pump
WARNING
1. To prevent the possibility of electrical shock, the MK-5005S MUST be de-energized when connecting the Water Pump.
2. To prevent the possibility of electrical shock, use only MK Diamond qualied
replacement parts.
NOTE:
To prevent pump damage, the Water Pump must be disconnected if cutting with a
Dry Blade.
(A)
Ensure the ON/OFF Switch
is in the OFF position
Water Pump Setup for Operation
(B)
Connect the Water Pump
power cord to the connection
found on the side of the motor
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.
16
MK-5005S SETUP
External Water Source
NOTE:
This is the preferred method of cooling. This method may add as much as twenty (20)
percent to the life of the blade.
(A)
Remove the Drain Plug
NOTE:
Follow all applicable Federal State and Local laws for the proper disposal of waste
water.
(B)
Place the Water Pump in an
external container
(C)
Fill the external container until
water completely covers the
Water Pump intake
(D)
Locate the Water Basin
Drain Connection (located in the
back of the Water Basin)
Re-circulation
NOTE:
When using the re-circulation method, the water should be changed often for longer
pump life.
(A)
Ensure the Drain Plug is
installed in the Water Basin
(E)
Install an external drain line onto
the Drain Connection
(B)
Place the Water Pump in
the back of the Water Basin
17
(C)
Fill the Water Basin until water
completely covers the
Water Tank intake