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MK Diamond Products MK- 2005G Owner's Manual & Operating Instructions

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MK- 2005G
GAS POWERED BRICK 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.

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  • Page 1 MK- 2005G GAS POWERED BRICK 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.
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Page SAFETY: Safety Messages Damage Prevention Message General Safety Precautions and Hazard Symbols California Proposition 65 Message Safety Label Locations Brick Saw Specific Warnings Product Specifications UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY Unpacking Contents Transport Universal Stand Assembly SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Setup...

  • Page 4: Safety

    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.
  • Page 5 SAFETY 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 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.

  • Page 6: California Proposition 65 Message

    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.

  • Page 7: Safety Label Locations

    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 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.

  • Page 8: Product Specifications

    SAFETY PRODUCT SPECIFICATIONS: The MK-2005G is a versatile gas powered brick saw. Operated and used according to this manual, the MK- 2005G 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.

  • Page 9: Unpacking, Transport, Universal Stand And Assembly Unpacking

    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...

  • Page 10: Universal Stand

    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 Slide Water Basin Pivot Up...

  • Page 11: Assembly

    UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY ASSEMBLY: Follow the assembly instructions in this section to prepare your MK-2005G for operation. 1. Movable Cutting Table Installation: Cutting Table Front Move back and forth to verify ease of movement Roller Wheels Guide Rail Roller Wheels Guide Rails Position Movable Cutting...

  • Page 12: Diamond Blade Installation

    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. Cutting Head Blade Wrench Retaining Screw Install...
  • Page 13 UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY 7/16-inch Install Water Tighten Wing Nut Wrench Pump into Clamp Tighten Wing Nut Install Water Pump Install Water Pump retaining Install Water Pump adjustment clamp, wing nut and bolt clamp. wing nut and bolt 6.
  • Page 14 UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY 7. Filling Fuel Tank: 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.

  • Page 15: Setup, Startup, Adjustment, Operation And Shutdown Setup

    SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN SETUP: 1. Pre-start Inspection: The pre-start inspection should be performed before beginning any job. If the Diamond Blade shows signs of fatigue cracking, replace the blade before starting work. Cracks Verify Ease of Movement (See Maintenance Section) Replace if Excessively Grooved (See Maintenance Section)

  • Page 16: Water Pump Setup

    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.
  • Page 17 SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Clean Water Fill the Water Basin with clean water III. Dry Blade Operation: NOTE: Failure to perform the following steps will lead to premature pump failure. Pivot Plate 9/16-inch Wrench 9/16-inch Pivot Up Retaining Bolts Wrench Identify Water Pump Drive Loosen Water Pump Drive End...

  • Page 18: Startup

    SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN STARTUP: 1. Engine Start: 1. Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and/or death. 2. Avoid any areas or actions that expose you to carbon monoxide. NOTE: If restarting a warm engine leave the Choke Lever in the OPEN position. Direction of Fuel Valve Direction of...

  • Page 19: Adjustment And Operation

    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.

  • Page 20: Chop Cutting

    SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Direction of Movement Raise Cutting Throttle Lever Head Move the Throttle Lever to lower Raise Cutting Head once blade speed cut is complete 2. Chop Cutting: A Chop Cut is performed by cutting completely through an object in one pass. DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed.
  • Page 21 SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Hold Cutting Lower Cutting Continue to Lower Direction of Table Stationery Head Smoothly Cutting Head until Movement to Cut Cut Complete Throttle Lever Lower Cutting Head Continue lowering the Move the Throttle Lever to lower to begin the cut Cutting Head until the blade speed...
  • Page 22 SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Direction of Direction of Movement Movement Cooling Flow Control Valve Points Throttle Lever Open the Cooling Flow Control Verify cooling flow exists on Move the Throttle Lever to Valve and adjust flow both sides of the blade adjust blade speed (faster blade speed for smoother cuts) Direction of...

  • Page 23: Angle Cuts

    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. DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed. NOTE: Care must be used when cutting angles so as not to damage the Adjustable Cutting Guide.
  • Page 24 SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Loosen Locking Direction of Movement Handle to adjust Cutting Head Unlock Cutting Throttle Lever Push Slowly to Cut Head Slowly push piece toward the Move the Throttle Lever to Unlock Cutting Head blade – continue until the lower blade speed cut Is complete Raise Cutting...

  • Page 25: Shutdown

    SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN SHUTDOWN: 1. Normal Engine Shutdown: Engine Switch Direction of Direction of Fuel Valve Direction of Movement Movement Movement Throttle Lever Move the Throttle Lever to lower Place Engine Switch Place Fuel Valve in the blade speed in the OFF position OFF position...
  • Page 26 SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Engine Switch Direction of Drain Plug Clean Water Basin Movement Place Engine Switch Remove Drain Plug and dispose Clean Water Basin with soap in the OFF position of water (conform to Federal, and clean water State and local laws for disposal) NOTE: 1.

  • Page 27: Maintenance And Troubleshooting Maintenance

    MAINTENANCE AND TROUBLESHOOTING MAINTENANCE: 1. Initial Maintenance: Perform the following after initial purchase and operation of the MK-2005G. Inspect V-Belts Change Oil Change engine oil after 1 Check and adjust V-belt tension month or 1 20 operating hours Following 1 48 hours of operation (See Engine Oil Change) See V-belt Inspection...

  • Page 28: Monthly Maintenance

    MAINTENANCE AND TROUBLESHOOTING 3. Monthly Maintenance: The following should be performed monthly. Items should be lubricated as directed. Outer Flange 1/2-inch 1/2-inch Wrench Wrench Retaining 9/16-inch Bolt Wrench Remove and clean Diamond Verify all engine mounting Verify engine Adjustment Blade Outer Flange and bolts are tight Straps are tight Retaining Bolt...
  • Page 29 MAINTENANCE AND TROUBLESHOOTING 5. Yearly Maintenance: Perform the following maintenance every year. Air Filter Spark Plug Replace engine Air Filter Replace Spark Plug Check/Adjust Idle Speed (See Engine Air Filter Inspection (See Spark Plug Check/Adjust Valve Clearance Cleaning and Replacement) Adjustment and Replacement) (Shop Maintenance Required) Inspect V-Belts...

  • Page 30: Blade Dressing

    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”...
  • Page 31 MAINTENANCE AND TROUBLESHOOTING 8. Diamond Blade Change-out: Engine Switch Direction of Cutting Head Blade Wrench Retaining Screw and Outer Flange Movement Loosen Locking Turn counter- Handle to adjust clockwise to Cutting Head loosen Place Engine Switch Raise Cutting Head Identify and remove Retaining in the OFF position Screw and Outer Flange Install...
  • Page 32 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) Rotate Wrench Counter-clockwise Movable Cutting Table 1/2-Inch Wrench Roller Wheels Remove the Movable Place Movable Cutting...
  • Page 33 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"...
  • Page 34 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.
  • Page 35 MAINTENANCE AND TROUBLESHOOTING 12. Checking Oil Level: 1. Engine Oil Capacity is 0.63 US qt (0.6 l). NOTES: 2. When installing the Oil Dipstick, ensure the threads are aligned with the threads of the Oil Reservoir so as not to “cross-thread." Cutting Head Turn counter- 1/2-way up Dipstick...
  • Page 36 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. 10W-30 5W-30 -20ºF...
  • Page 37 MAINTENANCE AND TROUBLESHOOTING 14. Engine Air Filter Inspection Cleaning and Replacement: Turn counter- Paper Filter Turn counter- clockwise to clockwise to loosen loosen Dual Air Filter Air Filter Cover Foam Filter Remove Air Filter Cover Remove Dual Air Filter Separate outer Foam Filter from inner Paper Filter Paper Filter Clean Foam Filter...
  • Page 38 MAINTENANCE AND TROUBLESHOOTING Air Guide Turn clockwise to tighten Cyclone Filter Cyclone Filter Retaining Screw Assembly Cyclone Housing Assembly Install the Air Guide into Install the Cyclone Filter Install the 3 Cyclone the Cyclone Housing Assembly into the Air Filter Assembly Filter Cover retaining screws Turn clockwise...
  • Page 39 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.
  • Page 40 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 – W20EPR-U 2. When installing the Spark Plug, ensure the threads of the are aligned with the threads in the engine so as not to “cross-thread"...
  • Page 41 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.
  • Page 42 MAINTENANCE AND TROUBLESHOOTING Turn counter- 1/2-inch clockwise to Wrench loosen Turn counter- Adjustment clockwise to 1/2-inch Retaining Bolts Strap Bolt loosen Direction of Push Wrench Loosen engine mounting plate Loosen Engine Adjustment Push the Engine Mounting Plate If re-tensioning, go to step S Strap Lock-nut then loosen toward the front of the unit to the Engine Adjustment Strap...
  • Page 43 MAINTENANCE AND TROUBLESHOOTING 9/16-inch 9/16-inch 9/16–inch Wrench Wrench Wrench Turn counter- clockwise to Retaining Bolts Retaining Bolts loosen Locate Water Pump Pivot Plate Relocate Water Pump Pivot Install the Blade Guard Loosen retaining bolts Plate and retighten Adjustment Bar retaining bolts Install Blade Install the Diamond Blade II.

  • Page 44: Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING NOTE: DO NOT use a screwdriver when installing new belts. Pulley V-belt V-belt Remove the V-belt Install the new V-belt Verify the V-belt is seated in (MK Diamond Part No. 156294) The grooves of both pulleys Turn clockwise Check Tension Turn clockwise to tighten...

  • Page 45: Troubleshooting

    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 If not “Glazed, If Rotation (See Blade Dressing) go to Step B Correct, go to Step C...

  • Page 46: Cooling Flow

    MAINTENANCE AND TROUBLESHOOTING 3. Cooling Flow: Direction of Water Pump Movement Transfer Tube Control Valve Water Container Check Cooling Flow Remove Transfer Tube from Place Water Pump in clean Control Valve is open Blade Guard water source and check for flow (if no flow go to step G) NOTE: “Rodding”...

  • Page 47: Blade Stops Turning

    MAINTENANCE AND TROUBLESHOOTING 4. Blade Stops Turning: Verify Operation V-belt Return to MK Diamond for Repair Check engine operating if not restart Check V-belts Return to MK Diamond (See Setup, Startup, Adjustment, (See V-belt Inspection, Operation and Shutdown Adjustment and Replacement) 5.

  • Page 48: Exploded View And Parts List

    EXPLODED VIEW AND PARTS LIST EXPLODED VIEW: MK-2005G Revision 12/00, Effective Date December 26, 2000 Page 48...

  • Page 49: Parts List

    ENGINE GUARD INSTALLATION INSTRUCTION PARTS LIST: Item Description MK p/n Assembly, Frame, MK2000 Brick saw Frame, MK-2000 150595 Crossbar, Support 150594 Screw, 5/16-18 x 1 Hex Head Cap 151743 Washer, 5/16 Split Lock 151747 Washer, 5/16 SAE Flat 151754 Label, MK Brick saw 12 – 1/2 x 1-3/4 155230 Assembly, Upright Left Casting, Upright Left...
  • Page 50 EXPLODED VIEW AND PARTS LIST Item Description MK p/n Assembly, Blade Shaft 154636 Casting, Blade Shaft-Arbor 153791 Bearing, Blade Shaft 154594 Shaft, Blade 154639 Flange, Inner 154640 Pin, Arbor Alignment 153946 Flange, Outer 14 Inch M-Saw 132290 Screw, 1/2-20 x 1 1/4, Hex Head (Blade Bolt) 152122 Screw, 5/16-18 x 2 –1/4 153951...
  • Page 51 EXPLODED VIEW AND PARTS LIST Item Description MK p/n Key, 1-1/8 x 3/16 150344 Belt, Micro-V (Gates 220J-10) 156294 Casting, Belt Guard Outer 156672 Screw, 5/16-18 x 2 1/2 Hex Head 101675 Assembly, Table 133082 Casting, Table 153790 Stop-Rule, Table 134387 Screw, 1/4-20 x 3/4 Hex Head 152370...
  • Page 52 EXPLODED VIEW AND PARTS LIST Item Description MK p/n Washer, 5/16 Split Lock 151747 Washer, 5/16 SAE Flat 151754 Washer, 7/16 Flat Cut 101352 Assembly, Plates, Engine Mounting (Top & Bottom) Plate, Lower Engine Mounting 156296 Screw, 5/16-18 x 1, Socket Head Cap 151743 Washer, 5/16 Split Lock 151747...
  • Page 53 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.

  • Page 54: Theory Of Diamond Blades

    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.

  • Page 55: Accessories

    EXPLODED VIEW AND PARTS LIST ACCESSORIES: ITEM NUMBER DESCRIPTION 132332 Adjustable Cutting Guide 133090 Roller Wheel 156427 Protective Wooden Strip 156294 Micro-V Belt 152792 Dressing Stick 153439 Rubber Drain Plug MK-2005G Revision 12/00, Effective Date December 26, 2000 Page 55...

  • Page 56: Return Material Policy

    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.

  • Page 57: Operating Instructions

    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. MK DIAMOND PRODUCTS, INC 1315 STORM PARKWAY, TORRANCE, CA 90509-2803 310 539 5158...

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