MK Diamond Products MK-5005S User manual

12.2010
MK-5005S BLOCK SAW
OWNER’S 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

2
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 or-
der to help you, we have included this manual. This Owner’s Manual contains information nec-
essary 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.
INTRODUCTION

3
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 Specications 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
TABLE OF CONTENTS

4
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 instruc-
tions could also result in damage and/or reduced equipment life.
SAFETY 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.
DAMAGE PREVENTION AND INFORMATION MESSAGES
NOTE: Equipment and/or property damage may result if these instructions are not followed.
In order to prevent injury, the following safety precautions and symbols should be followed at all times!
GENERAL SAFETY PRECAUTIONS AND HAZARD SYMBOLS
SAFETY PRECAUTIONS
Form a habit of checking to see that keys and adjusting wrenches are removed from
the power tool before it is turned on.
Cluttered work areas and benches invite accidents.
DO NOT use power tools in damp or wet locations nor expose them to rain. Always
keep the work area well lit.
All visitors and children should be kept a safe distance from work area.
A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preced-
ed by a safety alert symbol ( ) and one of three words: DANGER, WARNING, or CAUTION.
DANGER You WILL be KILLED or SERIOUSLY INJURED if you do not follow directions.
WARNING You CAN be KILLED or SERIOUSLY INJURED if you do not follow directions.
CAUTION You CAN be INJURED if you do not follow directions. It may also be used to alert
against unsafe practices.
ALWAYS read this Owner’s Manual before operating the machine.
ALWAYS keep the Blade Guards in place.
REMOVE ADJUSTING KEYS AND WRENCHES
KEEP WORK AREA CLEAN
KEEP CHILDREN AWAY
DO NOT USE IN DANGEROUS PLACES
MK-5005S SAFETY

5
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 under-
sized 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 name-
plate ampere rating. If in doubt, use the next heavier gage. The smaller the gage number,
the heavier the cord.
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 cov-
ering to contain long hair.
Keep proper footing and balance at all times by not overreaching.
Clamps or a vise should be used to hold work whenever practical. Keeping your
hands free to operate a power tool is safer.
Keep tools clean for the best and safest performance. Always follow maintenance in-
structions for lubricating and when changing accessories.
Power tools should always be disconnected before servicing or when changing acces-
sories, such as blades, bits, cutters, and the like.
Make the workshop kid proof by using padlocks, master switches or by removing starter
keys.
A power tool will do a job better and safer operating at the rate for which it was designed.
DO NOT force a tool or an attachment to do a job that it was not designed to do.
MAKE THE WORKSHOP KID PROOF
DO NOT FORCE THE TOOL
USE THE RIGHT TOOL
USE THE PROPER EXTENSION CORD
USE PROPER APPAREL
ALWAYS wear approved eye protection.
ALWAYS wear approved respiratory protection.
ALWAYS place the power ON/OFF switch in the OFF position when the saw is not in use.
ON / OFF
SECURE WORK
DO NOT OVERREACH
MAINTAIN TOOLS WITH CARE
DISCONNECT TOOLS
MK-5005S SAFETY

6
Consult the Owner’s Manual for recommended accessories. Using improper accessories
may increase the risk of personal or by-stander injury.
Serious injury could occur if a power tool is tipped, or if a cutting tool is unintentionally
contacted.
Before using a power tool, check for damaged parts. A guard or any other part that is dam-
aged 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.
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.
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
USE RECOMMENDED ACCESSORIES
NEVER LEAVE A TOOL UNATTENDED
NEVER STAND ON THE TOOL
CHECK FOR DAMAGED PARTS
DIRECTION OF FEED
WARNING
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities con-
tain 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/SLTC/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.
MK-5005S SAFETY

7
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 protec-
tion 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.
HAZARD SYMBOLS
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.
Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never
operate the motor with covers, shrouds, or guards removed.
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 oper-
ated at speeds above maximum.
DO NOT expose to rain or use in damp locations.
WARNING
ROTATING PARTS
ELECTRICAL SHOCK
OVER SPEED
DO NOT EXPOSE TO RAIN
MK-5005S SAFETY
((
)
)
on
on
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.

8
(A) (B)
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!
In case of a malfunction or breakdown, grounding provides a path of least resistance for electric cur-
rent to reduce the risk of electric shock. This tool is equipped with an electric cord having an equip-
ment-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.
WARNING
• Do not modify the plug provided – if it will not t the outlet; have the proper outlet installed by a
qualied 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 qualied 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 conguration
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 qualied 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 sys-
tem; or to a system having an equipment-grounding conductor.
NOTE: Use of a temporary adapter is not permitted in Canada.
MK-5005S SAFETY

9
Drip Loop Information
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 exten-
sion 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.
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.
WARNING
MK-5005S SAFETY
Motor
Saw
Floor
Power
Cord
Drip
Loop
Extension Cord Minimum Gage for Length
Volts Total Length of Cord in Feet
240V 25 ft. (7.5 m) 50 ft. (15 m) 75 ft (23 m)
AWG AWG AWG
10 10 8

10
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 [phone].
OPERATION & SAFETY DECALS
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.
!
DO NOT operate
this equipment
before reading
the owners’
manual!
WARNING
!
WARNING
In the event of
blade failure,
replace blade
guard
immediately.
!
CAUTION
DO NOT
operate without
guards in place.
!
CAUTION
DO NOT
operate without
guards in place.
!
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
CAUTION
Accidental start hazard.
Disconnect spark plug
prior to servicing.
!
(I)
Receptacle is for
water pump only.
125V .6 amps max.
!CAUTION
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.
25’
50’
75’
100’
150’
250’
Max. Cord Length
Max. Cord Length
Max. Cord Length
No. 12 Wire
No. 10 Wire
No. 8 Wire
115v 230v
NOTICE
!
SERVICE OR
WARRANTY
FOR INFORMATION ON
PLEASE CALL
1-800-474-5594
Masonry Saw Warning Label Sheet Part# 166011
A
C
B
DEIH
G
Location Description
A Arbor Housing/Front Read Manual
BBlade Guard/Back Proposition 65, Dust Warning
C Belt Guard/Front Guards in Place
D Blade Guard/Front Replace Blade Guard
EBlade Guard/Front Guards in Place
F Motor/Side Accidental Start
GMotor Service or Warranty
HMotor Accidental Start
IMotor Notice extension cord
JMotor Receptacle water pump
F
MK-5005S SAFETY DECALS