MK-5005S BLOCK SAW OWNER’S MANUAL & OPERATING INSTRUCTIONS CAUTION: Read all safety and operating instructions before using this equipment 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-5005S Block 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-5005S 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-5005S safely and correctly.
TABLE OF CONTENTS Page SAFETY: Safety Messages Damage Prevention Message General Safety Precautions and Hazard Symbols California Proposition 65 Message Electrical Requirements and Grounding Instructions Safety Label Locations Brick Saw Specific Warnings Product Specifications 4 4 4 6 7 9 9 10 UNPACKING AND ASSEMBLY Unpacking Contents Transport Assembly 11 11 11 12 SETUP, ADJUSTMENT AND OPERATION Setup Adjustment and Operation Cleanup 14 17 24 MAINTENANCE AND TROUBLESHOOTING Maintenance Troubleshootin
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.
SAFETY 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 1, Page 7 shows the correct AWG size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage.
SAFETY Hazard Symbols: 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. ACCIDENTAL STARTS! on Before plugging the equipment into an electrical outlet, be sure the On/Off Switch is in the OFF position to prevent accidental starting. Unplug the power tool before performing any service operation.
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! 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.
SAFETY To avoid the possibility of the appliance plug or receptacle getting wet, position the Block Saw to one side of a wall mounted receptacle. This will prevent water from dripping onto the receptacle or plug. A "drip loop," shown in FIGURE 2, 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 Motor the connector, if an extension cord is used.
SAFETY SAFETY LABEL LOCATIONS: Safety labels are located according to Figures 1 to 7 below. The labels contain important safety information. Please read the information contained on each safety label. These labels are considered 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 1A. 1B. 1C. 2. 3. 4A. 4B. 4C. 5A. 5B. 6. 7.
SAFETY PRODUCT SPECIFICATIONS: 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 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 Specifications: Motor and Weight specifications for the MK-5005S are listed in Table 2 below.
UNPACKING, TRANSPORT and ASSEMBLY 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 flat surface using a forklift. Remove the Accessories from the water basin and place along side the MK-5005S (Owners Manual is in Accessories Packet).
UNPACKING, TRANSPORT and ASSEMBLY ASSEMBLY: Follow the assembly instructions to prepare your MK-5005S for operation. 1. Movable Cutting Table Installation: Guide Rails Roller Wheels Cutting Table Front Guide Rail (A) Position Movable Cutting Table Verify ease of movement (See Maintenance Section If Problems Arise) Roller Wheels (B) Seat all four Roller Wheels on the Guide Rails (C) Verify Correct Seating 2.
UNPACKING, TRANSPORT and ASSEMBLY Rotate Blade Wrench clockwise to tighten Rotation Arrow Facing out Retaining Screw and Outer Flange Rotation Direction (D) Verify the Blade is seated on the Blade Shaft and direction of rotation is correct (E) Install Retaining Screw and Outer Flange, then tighten 4.
SETUP, ADJUSTMENT and OPERATION SETUP: • • • 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.
SETUP, ADJUSTMENT and OPERATION Inspect for cracks or cuts Inspect for damage (D) Inspect the Pump Assembly for damage – ensure the cord is free of cracks or cuts 2. Connecting the Water Pump: 1. 2. To prevent the possibility electrical shock, the MK-5005S MUST be de-energized when connecting the Water Pump. To prevent the possibility of electrical shock, use only MK Diamond qualified replacement parts NOTE: To prevent pump damage, the Water Pump must be disconnected if cutting with a Dry Blade.
SETUP, ADJUSTMENT and OPERATION 3. Water Pump Setup for Operation: 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. I. External Water Source: This is the preferred method of cooling. This method may add as much as 20 percent to the life of the blade.
SETUP, ADJUSTMENT and OPERATION ADJUSTMENT AND OPERATION: 1. Power Connection: ON/OFF Switch Off Position (A) Ensure the ON/OFF Switch is in the OFF position (B) Connect the MK-5005S to the proper power source 2. Cutting Setup: NOTES 1. While the MK-5005S can cut the materials listed earlier in this document, it is specifically designed to cut concrete masonry. Cutting another material with the MK-5005S will reduce the life of the diamond blade. 2.
SETUP, ADJUSTMENT and OPERATION 3. Step Cuts: A Step Cut is performed when a series of small cuts of increasing depth are used to complete a single cut. 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.
SETUP, ADJUSTMENT and OPERATION 4. Chop Cutting: A Chop Cut is performed by cutting completely through an object in one pass. Position work below Cutting Head ON/OFF Switch On Position Direction of movement Control Valve (A) Chop Cut Setup (Adjust the height of the Cutting Head as necessary) (B) Turn the motor ON (C) Open the Cooling Flow Control Valve and adjust flow DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed.
SETUP, ADJUSTMENT and OPERATION 5. Cutting with the Cutting Head Positioned Down: This method is preferred when cutting small objects. ON/OFF Switch Lower Cutting Head until just above table Hold Work in Position Turn counterclockwise to lower (A) Lower the Cutting Head until the blade is just off the surface of the Movable Cutting Table On Position (B) Set masonry piece in position (C) Turn the motor ON DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed.
SETUP, ADJUSTMENT and OPERATION 6. Cutting with the Piece Position Vertically: This method may be used when "notching” the masonry piece. Set against Adjustable Cutting Guide and Ruler/Stop ON/OFF Switch Direction of Movement On Position Control Valve (A) Position Masonry Piece (Adjust the height of the Cutting Head as necessary) (B) Turn the motor ON (C) Open the Cooling Flow Control Valve and adjust flow DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed.
SETUP, ADJUSTMENT and OPERATION 7. Angle Cuts: Angle Cuts may be performed using the Step Cut, Chop Cut, Cutting Head Positioned Down methods or with the masonry piece positioned vertically. The following example utilizes the Step Cut method.
SETUP, ADJUSTMENT and OPERATION 8. Cutting using the Foot Pedal: The Foot Peddle may be used to Step Cut, Chop Cut, cut with the Cutting Head Positioned Down, or with the masonry piece positioned vertically. Using the Foot Peddle frees both of the operator's hands for holding the masonry piece. The following example utilizes the Step Cut method.
SETUP, ADJUSTMENT and OPERATION 9. Cleanup: Pump Suction Water Pump In container External Container (A) Clean the Water Pump suction of all debris ON/OFF Switch (B) Place the Water Pump in an external container Cooling Flow Points (C) Run the saw until clear water is seen at the blade cooling ports (Approx.
MAINTENANCE AND TROUBLESHOOTING MAINTENANCE: 1. New Maintenance: Perform the following after initial purchase and operation of the MK-5005S. Inspect V-belt (A) Check and adjust V-belt tension Following 1st 48 hours of operation (See V-belt Inspection) 2. Maintenance Following Use: The following maintenance should be performed following each use. Use Light oil, such as WD-40 or 3 in 1 when lubricating parts.
MAINTENANCE AND TROUBLESHOOTING 3. Monthly Maintenance: The following should be performed monthly. Items should be lubricated as directed.
MAINTENANCE AND TROUBLESHOOTING 4. Diamond Blade Change-out: Disconnect the tool before servicing and when changing accessories, such as blades, bits, cutters, and the like.
MAINTENANCE AND TROUBLESHOOTING 5. MK-5005S Lubrication Points: Use standard grease when lubricating the MK-5005S. Clean the Zerk fitting when finished lubricating. Apply grease slowly; stop when grease is seen between joints.
MAINTENANCE AND TROUBLESHOOTING 6. 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. – 152493).
MAINTENANCE AND TROUBLESHOOTING 7. 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. – 157748).
MAINTENANCE AND TROUBLESHOOTING 8. V-Belt Inspection, Adjustment and Replacement: The MK-5005S is designed with a power transmission V-belt. In order to ensure the MK-5005S operates a peak efficiency, the V-belt should be inspected monthly, and changed if the v-belt shows damage and/or excessive wear. NOTE: When a new belt is installed, it should be inspected and re-tensioned after the first forty-eight (48) hours of operation.
MAINTENANCE AND TROUBLESHOOTING Outer V-belt (J) Remove the outer V-belt Inner V-belt (K) Remove the inner V-belt Belt Seated (L) Install 2 new V-belts (MK Diamond Part No.
MAINTENANCE AND TROUBLESHOOTING TROUBLESHOOTING: 1.
MAINTENANCE AND TROUBLESHOOTING 2.
MAINTENANCE AND TROUBLESHOOTING 3.
MAINTENANCE AND TROUBLESHOOTING NOTE: “Rodding” cooling channels is performed by inserting a small wire rod through the cooling inlet on top of the Blade Guard and directing the rod out through each of the cooling flow tubes located on the underside of the Blade Guard. The cooling channels should be “rodded” until all ports are free of foreign debris.
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 37
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 38
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 39
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 40
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 41
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 42
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 43
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 44
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 45
EXPLODED VIEW AND PARTS LIST EXPLODED VIEWS: MK-5005S Revision 07/04, Effective Date August 1, 2004 Page 46
EXPLODED VIEW AND PARTS LIST PARTS LIST: Item Description A Frames A1 Frame, MK-5000 Main Qty 1 Part # 155541 B B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 Pivot Bracket Bracket, Elevation Pivot Washer, 3/8 ID x 1-1/2 OD, Fender Washer Screw, 1/4-20 x 1/2 Hex Head Screw, 3/8-16 x 3/4 Hex Head Bumper, 1/4 ID x 1-1/2 OD x 3/4 Washer, 1/4 SAE Flat Nut, 1/4-20 Hex Fitting, Grease (zerk) Bushing, 1 x 1-1/4 x 2 MIS Shaft, Pivot Arm MK-5000 Screw, 1/4-20 x 1/4 Socket Head Set, Cone point 1 2 2 2 2 2 2 1 2 1 2 156285
EXPLODED VIEW AND PARTS LIST Item C28 C29 C30 Description Shaft, Cutting Head Pivot Collar, 3/4 Set Washer, 3/8 Split Lock D D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D15 D16 D17 D18 E E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15 F F1 F2 F3 MK-5005S Qty 1 1 1 Part # 154828 153814 150925 Depth Control Housing, Adjustment Shaft Screw, 3/4- 6 x 10-7/8, Depth Control Spacer, 3/4 ID x 1 OD x 3/4 Locknut, Feed Screw Nut, 3/8- 16 Hex Hd.
EXPLODED VIEW AND PARTS LIST Item F4 F5 F6 F7 F8 F9 F10 F11 Description Bolt, 1/2 x 1/2 Socket Head Shoulder Screw, Adjustment Nut, 1/2- 20 Jam Bolt 5/16- 18 x 1 Hex HD Washer, 5 /16 SAE Flat Washer, 5/16 Split Lock Nut, 5/16- 18, Hex HD Nut, 1/2- 20 Jam (LH) Qty 4 4 4 4 4 4 4 4 Part # 151753 154433 154460 151743 151754 151747 101196 154461 G G1 G2 G3 G4 G5 G6 G7 G8 G9 G10 G11 G12 Blade Shaft MK-5000 Casting, Blade Shaft MK-5000 (comp) Pin, Arbor Alignment Screw, 1/2- 20 x 1-1/4 Hex HD Cap Flange, Blad
EXPLODED VIEW AND PARTS LIST Item KA KA1 KA2 KA3 KA4 KA5 KA6 KA7 KA8 KA9 KA10 KA11 KA12 KA13 Description Belt Guards, Gas Casting, Belt Guard, Motor, Outer (comp) Casting, Belt Guard, Motor, Inner (comp) Casting, Belt Guard, Arbor, Outer (comp) Casting, Belt Guard, Arbor, Inner (comp) Screw, Hex Head 3/8-16 x 1-1/4 Washer, Lock, Split 3/8 Washer, Flat Cut 5/16 Screw, Hex Head 5/16-18 x 2-1/2 Washer, Lock, Split 5/16 Washer, Flat, SAE 5/16 Screw, Hex Head 5/16 x 1-1/4 Belt, Micro-V 16J270 Belt, Micro-V 16J4
EXPLODED VIEW AND PARTS LIST Item Description Qty Part # S S1 S2 S3 S4 S5 S6 Accessory Pack Carton, Accessory Pack MK-5000 Insert, Accessory Pack MK-5000 Plug, Rubber Drain Wrench, Masonry Saw MK-5005S Owners Manual Blade, MK-799DE 1 1 1 1 1 1 152432 152433 153439 134056 158769 158237 T T1 T2 Carton Carton, 5000 Pallet, 5000 1 1 152994 152072 V V1A V2B V3 V4 V5 V6 V7 V8 V9 Motors Motor, 5Hp, 208-230V, 60Hz, 1ph Pulley, 16J31 X 1.
THEORY 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.
ACCESSORIES, ORDERING and RETURN INFORMATION ACCESSORIES: ITEM 1.
ACCESSORIES, ORDERING and RETURN INFORMATION ORDERING INFORMATION: You may order MK Diamond products through your local MK Diamond distributor or, you may order direct from MK Diamond. NOTES: 1. There is a minimum order requirement when ordering direct from MK Diamond. All purchases must be made using VISA or MasterCard. 2. The MK-5005S may come equipped with either a Baldor or Leeson motor. If ordering electrical parts, contact MK Diamond with the motor type to ensure the correct parts are ordered.
MK-5005S MASONRY 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.
