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.
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. This owners manual contains information necessary to operate and maintain your MK-2005G safely and correctly.
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 4 4 4 6 7 7 8 UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY Unpacking Contents Transport Universal Stand Assembly 9 9 9 10 11 SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Setup Startup Adjustment and Operation Shutdown Cleanup 15 18 19 25 25 MAINTENANCE AND TROUBLESHO
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 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. HOT PARTS! Engine components can become extremely hot from operation.
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. The saw should always be shutdown before servicing or when changing accessories such as blades, bits, cutters, and the like. USE RECOMMENDED ACCESSORIES. Consult the owner's manual for recommended accessories.
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.
SAFETY PRODUCT SPECIFICATIONS: The MK-2005G is a versatile gas powered brick saw. Operated and used according to this manual, the MK2005G 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. The saw is capable of cutting masonry up to five (5) inches (127 mm) in height in a single pass. Motor Specifications: Honda motor specifications for the MK-2005G are listed in Table 1 below.
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.
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 out back of Saw Pivot Up (A) Open the Universal Stand and place on flat surface (B) Position Water Pump clear of Water Basin (C) Remove Water Basin 2.
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 Roller Wheels Guide Rail (A) Position Movable Cutting Table Roller Wheels above Saw Guide Rails Roller Wheels Guide Rails (B) Seat Movable Cutting Table Roller Wheels on Saw Guide Rails Move back and forth to verify ease of movement (C) Verify Movable Cutting Table is seated correctly 2.
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.
UNPACKING, TRANSPORT, UNIVERSAL STAND and ASSEMBLY 7/16-inch Wrench Install Water Pump into Clamp Tighten Wing Nut Install Water Pump Tighten Wing Nut (D) Install Water Pump retaining clamp, wing nut and bolt (E) Install Water Pump adjustment clamp. wing nut and bolt 6. Filling Oil Reservoir: NOTE: SAE 10W-30 is recommended for general use in temperatures of – 4ºF (20ºC) and above. If you are operating outside of this range, consult the chart in this manual. Engine Oil Capacity is 0.63 US qt (0.6l).
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. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc. 5. Wipe up spills immediately. NOTES: 1. Fuel can damage paint and plastic. Be careful not to spill fuel when filling the fuel tank.
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.
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. I. External Water Source: This is the preferred method of cooling when using a "wet" diamond blade.
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Clean Water (D) Fill the Water Basin with clean water III. Dry Blade Operation: NOTE: Failure to perform the following steps will lead to premature pump failure.
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.
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN ADJUSTMENT AND OPERATION: NOTE: 1. 2. 3. Step Cutting is the preferred cutting method for all cuts. When cutting hard material Step Cutting should always be used. Step Cutting will extend the life of the Diamond Blade. 1. Step Cuts: A Step Cut is performed when a series of small cuts of increasing depth are used to complete a single cut. Step Cuts are used for large objects or for hard objects such as Firebrick and Pavers.
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Direction of Movement Raise Cutting Head Throttle Lever (K) Move the Throttle Lever to lower blade speed (J) Raise Cutting Head once 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. Note: Skip steps C and D, if cutting dry.
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Hold Cutting Table Stationery Lower Cutting Head Smoothly to Cut Continue to Lower Cutting Head until Cut Complete Direction of Movement Throttle Lever (G) Lower Cutting Head to begin the cut (H) Continue lowering the Cutting Head until the cut is complete (J) Move the Throttle Lever to lower blade speed Raise Cutting Head (J) Raise Cutting Head once cut is complete 3.
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Direction of Movement Direction of Movement Control Valve (D) Open the Cooling Flow Control Valve and adjust flow Cooling Flow Points Throttle Lever (E) Verify cooling flow exists on both sides of the blade (F) Move the Throttle Lever to adjust blade speed (faster blade speed for smoother cuts) Direction of Movement Hold Work in Position (G) Setup to Cut Throttle Lever Push Slowly to Cut (H) Slowly push piece toward the blade – continue until th
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. Skip steps F and G, if cutting dry.
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Loosen Locking Handle to adjust Cutting Head Direction of Movement Push Slowly to Cut Throttle Lever (J) Slowly push piece toward the blade – continue until the cut Is complete (K) Move the Throttle Lever to lower blade speed Unlock Cutting Head (L) Unlock Cutting Head Raise Cutting Head (M) Raise Cutting Head once cut is complete MK-2005G Revision 1, Effective Date December 26, 2000 Table of Contents Page 24
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN SHUTDOWN: 1. Normal Engine Shutdown: Direction of Movement Engine Switch Direction of Movement Direction of Movement Fuel Valve Throttle Lever (A) Move the Throttle Lever to lower blade speed (B) Place Engine Switch in the OFF position (C) Place Fuel Valve in the OFF position 2.
SETUP, STARTUP, ADJUSTMENT, OPERATION and SHUTDOWN Engine Switch Direction of Movement (D) Place Engine Switch in the OFF position NOTE: Drain Plug Clean Water Basin (E) Remove Drain Plug and dispose of water (conform to Federal, State and local laws for disposal) (F) Clean Water Basin with soap and clean water 1. To extend operating life, the MK-2005G should be cleaned following every use. 2. Using a garden hose or pressure washer can force water into the air cleaner or muffler opening. 3.
MAINTENANCE AND TROUBLESHOOTING MAINTENANCE: 1. New Maintenance: Perform the following after initial purchase and operation of the MK-2005G. Inspect V-Belts Change Oil (A) st Change engine oil after 1 st month or 1 20 operating hours (See Engine Oil Change) (B) Check and adjust V-belt tension st Following 1 48 hours of operation See V-belt Inspection 2. Maintenance Following Use: To extend the life of the MK-2005G, the following procedure should be performed after each use.
MAINTENANCE AND TROUBLESHOOTING 3. Monthly Maintenance: The following should be performed monthly. Items should be lubricated as directed.
MAINTENANCE AND TROUBLESHOOTING 5. Yearly Maintenance: Perform the following maintenance every year. Air Filter (A) Replace engine Air Filter (See Engine Air Filter Inspection Cleaning and Replacement) Spark Plug (B) Replace Spark Plug (See Spark Plug Adjustment and Replacement) (C) Check/Adjust Idle Speed Check/Adjust Valve Clearance (Shop Maintenance Required) Inspect V-Belts (D) Inspect V-belts (See V-Belt Inspection, Adjustment and Replacement) 6.
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” or bend giving the illusion of an alignment problem. When this occurs, the blade will need to be dressed. The diamond blade can be dressed using the MK Dressing Stick (part number 152792) and by following the steps below.
MAINTENANCE AND TROUBLESHOOTING 8.
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.
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" the piece instead of performing a smooth cut (MK Diamond Part No. – 156427).
MAINTENANCE AND TROUBLESHOOTING 11. Check Fuel Level: 1. 2. 3. 4. 5. NOTES: Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. To fuel, stop engine if running and allow it to cool. Refuel in a well-ventilated area. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc. Wipe up spills immediately. 1. Fuel can damage paint and plastic. Be careful not to spill fuel when filling the fuel tank.
MAINTENANCE AND TROUBLESHOOTING 12. Checking Oil Level: NOTES: 1. 2. Engine Oil Capacity is 0.63 US qt (0.6 l). When installing the Oil Dipstick, ensure the threads are aligned with the threads of the Oil Reservoir so as not to “cross-thread.
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. 30 10W-30 5W-30 -20ºF 0ºF 20ºF -30ºC -20ºC -10ºC NOTES: 1. 2. 40ºF 0ºC 60ºF 10ºC 80ºF 100ºF 20ºC 30ºC 40ºC Drain used oil while the engine is warm.
MAINTENANCE AND TROUBLESHOOTING 14.
MAINTENANCE AND TROUBLESHOOTING Air Guide Cyclone Housing (M) Install the Air Guide into the Cyclone Housing Turn clockwise to tighten Cyclone Filter Assembly (N) Install the Cyclone Filter Assembly into the Air Filter Cover Retaining Screw Cyclone Filter Assembly (O) Install the 3 Cyclone Filter Assembly retaining screws Turn clockwise to tighten Air Filter Cover (P) Install Air Filter Cover MK-2005G Revision 1, Effective Date December 26, 2000 Table of Contents Page 38
MAINTENANCE AND TROUBLESHOOTING 15. Fuel Sediment Cup Cleaning: 1. 2. 3. 4. 5. NOTES: Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. To fuel, stop engine if running and allow it to cool. Refuel in a well-ventilated area Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc. Wipe up spills immediately. 1. Conform to Federal, State and Local laws for the proper disposal of fuel 2.
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" the plug.
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. 2. When new belts are installed, they should be inspected and re-tensioned after the first fortyeight (48) hours of operation. When performing any maintenance on the power transmission V-belts, always start with the belt on the Blade Guard side. I.
MAINTENANCE AND TROUBLESHOOTING Turn counterclockwise to loosen 1/2-inch Wrench 1/2-inch Wrench Retaining Bolts (J) Loosen engine mounting plate If re-tensioning, go to step S NOTE: Turn counterclockwise to loosen Adjustment Strap Bolt (K) Loosen Engine Adjustment Strap Lock-nut then loosen the Engine Adjustment Strap Direction of Push (L) Push the Engine Mounting Plate toward the front of the unit to loosen the V-belt DO NOT use a screwdriver when installing new belts.
MAINTENANCE AND TROUBLESHOOTING 9/16-inch Wrench 9/16-inch Wrench Retaining Bolts Retaining Bolts (V) Locate Water Pump Pivot Plate Loosen retaining bolts (W) Relocate Water Pump Pivot Plate and retighten retaining bolts 9/16–inch Wrench Turn counterclockwise to loosen (X) Install the Blade Guard Adjustment Bar Install Blade (Y) Install the Diamond Blade II.
MAINTENANCE AND TROUBLESHOOTING NOTE: DO NOT use a screwdriver when installing new belts. Pulley V-belt V-belt (G) Remove the V-belt (H) Install the new V-belt (MK Diamond Part No.
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.
MAINTENANCE AND TROUBLESHOOTING 3.
MAINTENANCE AND TROUBLESHOOTING 4. Blade Stops Turning: V-belt Verify Operation Return to MK Diamond for Repair (A) Check engine operating if not restart (See Setup, Startup, Adjustment, Operation and Shutdown (B) Check V-belts (See V-belt Inspection, Adjustment and Replacement) (C) Return to MK Diamond 5.
EXPLODED VIEW AND PARTS LIST EXPLODED VIEW: MK-2005G Revision 1, Effective Date December 26, 2000 Table of Contents Page 48
EXPLODED VIEW AND PARTS LIST PARTS LIST: Item A A1 A2 A3 A4 A5 A6 Description Assembly, Frame, MK2000 Brick saw Frame, MK-2000 Crossbar, Support Screw, 5/16-18 x 1 Hex Head Cap Washer, 5/16 Split Lock Washer, 5/16 SAE Flat Label, MK Brick saw 12 – 1/2 x 1-3/4 Qty 1 1 1 1 4 4 1 MK p/n 150595 150594 151743 151747 151754 155230 B B1 B2 B3 B4 Assembly, Upright Left Casting, Upright Left Screw, 5/16-18 x 3/4, Hex Head Washer, 5/16 Split Lock Washer, 5/16 SAE Flat 1 1 6 6 6 150592 151369 151747 151754 C C
EXPLODED VIEW AND PARTS LIST Item F F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Description Assembly, Blade Shaft Casting, Blade Shaft-Arbor Bearing, Blade Shaft Shaft, Blade Flange, Inner Pin, Arbor Alignment Flange, Outer 14 Inch M-Saw Screw, 1/2-20 x 1 1/4, Hex Head (Blade Bolt) Screw, 5/16-18 x 2 –1/4 Washer, 5/16 Split Lock Washer, 5/16 SAE Flat Qty 1 1 2 1 1 2 1 1 4 4 4 MK p/n 154636 153791 154594 154639 154640 153946 132290 152122 153951 151747 150923 G G1 G2 G3 G4 G5 G6 G7 G8 Assembly, Blade Guard Casting,
EXPLODED VIEW AND PARTS LIST Item L8 L9 L10 L11 Description Key, 1-1/8 x 3/16 Belt, Micro-V (Gates 220J-10) Casting, Belt Guard Outer Screw, 5/16-18 x 2 1/2 Hex Head Qty 2 1 1 2 MK p/n 150344 156294 156672 101675 M M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 Assembly, Table Casting, Table Stop-Rule, Table Screw, 1/4-20 x 3/4 Hex Head Nut, 1/4-20, Keps Wheel, Roller Nut, 5/16-18 Keps Wood Strip, Table Insert Screw, Pan HD Phil.
EXPLODED VIEW AND PARTS LIST Item U U1 U2 U3 U4 U5 U6 U7 U8 U9 U10 U11 U12 Description Assembly, Plates, Engine Mounting (Top & Bottom) Plate, Lower Engine Mounting Screw, 5/16-18 x 1, Socket Head Cap Washer, 5/16 Split Lock Washer, 5/16 SAE Flat Washer, 5/16 Flat Cut Plate, Engine Mounting, Upper Screw, 5/16-18 x 2, Socket Head Cap Washer, Fender, 5/16 ID x 1.
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. This process eventually cracks or fractures the diamond particle, breaking it down into smaller pieces.
EXPLODED VIEW AND PARTS LIST ACCESSORIES: ITEM NUMBER DESCRIPTION 1. 132332 Adjustable Cutting Guide 2. 133090 Roller Wheel 3. 156427 Protective Wooden Strip 4. 156294 Micro-V Belt 5. 152792 Dressing Stick 6.
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.
MK- 2005G GAS POWERED BRICK 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.
