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

11
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.
The MK-5005S can cut a variety of masonry types including, cinder block, slump stone block, wall
brick, paver brick, concrete block and cylinders, roong tile, marble, granite, decorative rock or almost
any other non-ferrous material.
The MK-5005S is a versatile masonry saw. Operated and used according to this manual, the MK-
5005S 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 Specications:
Motor and weight specications for the MK-5005S are listed in the table below.
Voltage 208 / 230v
Amperage 24
Frequency 50 Hz 60 Hz
RPM 2850 rpm 3,450
Weight 445 lbs.*
SPECIFICATION
BLADE CAPACITY
PEDDLE ASSISTED CUTTING HEAD
MASONRY TYPES
NOTE: The MK-5005S is not designed to cut plastic or ferrous (metals) material.
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.
MK-5005S PRODUCT SPECIFICATIONS
*Without Movable Cutting Table

12
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 Movable Cutting
Table Adjustable
Cutting Guide
Electric
Water Pump
Pump
Discharge Fitting
Blade
Wrench
Drain
Plug Owner’s
Manual
Pump
Manual
Warranty
Card
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.
The MK-5005S weighs approximately four hundred forty-ve (445) pounds (without the movable Cut-
ting Table).
Do not attempt to move the MK-5005S without a forklift.
Place the Cutting Head in the DOWN position, and remove the movable Cutting Table
when transporting the MK-5005S.
Due to its solid construction, the MK-5005S may only be transported with a forklift. Position the Cut-
ting 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.
WARNING
NOTE:
UNPACKING
CONTENTS
MK-5005S CONTENTS
TRANSPORT
Tie Down
Lift Points
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.

13
Follow the assembly instructions to prepare your MK-5005S for operation.
Adjustable Cutting Guide Installation
Diamond Blade Installation
MK-5005S ASSEMBLY
(A)
Position movable Cutting Table
(B)
Seat all four (4) Roller Wheels
on the Guide Rails
(C)
Verify correct seating of Roller
Wheels
(A)
Loosen the Thumbscrew. Align the
adjustable Cutting Guide above the
movable Cutting Table Ruler/Stop
(B)
Seat the adjustable Cutting
Guide and tighten the Thumb-
screw
(A)
Unlock Cutting Head
(B)
Raise the Cutting Head by
turning the Depth Control Wheel
clockwise
(C)
Remove the Retaining Screw
and Outer Flange with the blade
wrench. Turn counter-clockwise
to loosen
ASSEMBLY
Movable Cutting Table Installation

14
Water Pump Preparation
(B)
Press the end of the Cooling
Transfer Tube onto the Water
Pump Discharge Fitting
(A)
Install Water Pump
Discharge Fitting
MK-5005S ASSEMBLY
(D)
Install the Diamond Blade onto
the Blade Shaft
(E)
Verify the blade is seated on
the Blade Shaft and direction of
rotation is correct
(F)
Install Retaining Screw and
Outer Flange
(G)
Rotate Blade Wrench clockwise
to tighten

15
• Before powering or starting, check for damage that could prevent this equipment from proper oper-
ation 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.
• If using an extension power cord, make sure the length and wire gauge corresponds to the require-
ments. 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.
If the Diamond Blade shows signs of fatigue cracking, replace the blade before
starting work.
In order to avoid breaker tripping, a 30-amp circuit breaker should be used.
(F)
Inspect the MK-5005S for
general damage and/or loose
hardware
(D)
Inspect Wooden Strip for
excessive grooves
(E)
Verify movable Cutting Table
moves freely
(C)
Inspect the blade for damage
and verify it’s correct for the
material being cut
(A)
Ensure the ON/OFF Switch
is in the OFF position
(B)
Check all electrical connections
VOLTAGE: 230v
CYCLE: 50/60hz
PHASE: Single phase
SETUP
Pre-start Inspection
CAUTION
CAUTION
NOTE:
MK-5005S SETUP
The pre-start inspection should be performed before beginning any job.

16
Connecting the Water Pump
Water Pump Setup for Operation
1. To prevent the possibility of electrical shock, the MK-5005S MUST be de-ener-
gized when connecting the Water Pump.
2. To prevent the possibility of electrical shock, use only MK Diamond qualied
replacement parts.
To prevent pump damage, the Water Pump must be disconnected if cutting with a
Dry Blade.
(B)
Connect the Water Pump
power cord to the connection
found on the side of the motor
(A)
Ensure the ON/OFF Switch
is in the OFF position
(G)
Inspect the Pump Assembly for
damage – ensure the cord
is free of cracks or cuts
WARNING
NOTE:
NOTE:
The Water Pump can be setup for operation in two ways, External Water Source or Re-circulation.
If using a Dry Blade for operation, DO NOT connect the Water Pump.
MK-5005S SETUP

17
External Water Source
Re-circulation
(A)
Remove the Drain Plug
(B)
Place the Water Pump in an
external container
(C)
Fill the external container until
water completely covers the
Water Pump intake
(D)
Locate the Water Basin
Drain Connection (located in the
back of the Water Basin)
(A)
Ensure the Drain Plug is
installed in the Water Basin
(B)
Place the Water Pump in
the back of the Water Basin
(C)
Fill the Water Basin until water
completely covers the
Water Tank intake
(E)
Install an external drain line onto
the Drain Connection
NOTE:
NOTE:
NOTE:
This is the preferred method of cooling. This method may add as much as twenty (20)
percent to the life of the blade.
Follow all applicable Federal State and Local laws for the proper disposal of waste
water.
When using the re-circulation method, the water should be changed often for longer
pump life.
MK-5005S SETUP

18
1. While the MK-5005S can cut the materials listed earlier in this document, it is
specically designed to cut concrete masonry. Cutting another material with
the MK-5005S will reduce the life of the Diamond Blade.
2. Due to the material being cut, the Diamond Blade should not require dressing.
If dressing is required, use a soft stone such as sandstone.
DO NOT FORCE the blade to cut, it will do the job better and safer at the rate
for which it was designed.
(A)
Set edge of Cutting Guide to
desired cut length on Ruler/Stop
(A)
Ensure the ON/OFF Switch
is in the OFF position
(B)
Connect the MK-5005S to
the proper power source
Power Connection
Cutting Setup
NOTES:
CAUTION
MK-5005S OPERATION
(B)
Set material against adjustable
Cutting Guide and Ruler/Stop

19
MK-5005S OPERATION
Step Cutting
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.
NOTE:
A Step Cut is performed when a series of small cuts of increasing depth are used to complete a
single cut.
(A)
Adjust the height of the Cutting
Head as necessary, start motor
(B)
Open the Cooling Flow Control
Valve and adjust ow. Verify
proper cooling ow on both
sides of the blade
(C)
Step Cut "Push" Stroke. Lower
Cutting Head 1/4" -1/2"
during Push Stroke
(D)
Step Cut "Pull" Stroke. Lower
Cutting Head an additional 1/4”
to 1/2” and pull Cutting Table
forward
(E)
Repeat Steps C and D until cut
is complete. Turn the saw off
when work is complete

20
This method is preferred when cutting small objects.
(A)
Lower the Cutting Head until the
blade is just off the surface of
the movable Cutting Table
(B)
Set masonry piece
in position
(C)
Turn the motor ON
Cutting with the Cutting Head Positioned Down
MK-5005S OPERATION
Chop Cutting
A Chop Cut is performed by cutting completely through an object in one pass.
(A)
Adjust the height of the Cutting
Head as necessary, start motor
(C)
Hold the Cutting Table
stationary. Lower Cutting
Head smoothly to cut
(B)
Open the Cooling Flow Control
Valve and adjust ow. Verify
proper cooling ow on both
sides of the blade
(D)
Continue lowering Cutting Head
until cut is complete. Turn the
saw off when work is complete