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Introduction

Follow this guide to remove and replace a faulty power cord in a Mk Diamond MK660 Wet Saw.

The replacement part is 153419.

Removing the motor before the power cord is not necessary, but makes the process easier.

  1. Before you begin, make sure to power off and unplug the device from the outlet. If the clear water pump hose is connected, remove it now. Loosen the plastic knob holding the saw's cutting head in place.
    • Before you begin, make sure to power off and unplug the device from the outlet.

    • If the clear water pump hose is connected, remove it now.

    • Loosen the plastic knob holding the saw's cutting head in place.

    • Lower the cutting head while keeping it steady.

  2. Unscrew the knob. Remove it from the cutting head.
    • Unscrew the knob.

    • Remove it from the cutting head.

  3. Loosen the plastic knob holding the blade cover in place. Loosen the plastic knob holding the blade cover in place.
    • Loosen the plastic knob holding the blade cover in place.

  4. Loosen the wing nut on the blade cover pivot shaft. Remove the wing nut and accompanying washer. Remove the wing nut and accompanying washer.
    • Loosen the wing nut on the blade cover pivot shaft.

    • Remove the wing nut and accompanying washer.

  5. Pivot the blade cover up and pull it off the shaft. Pivot the blade cover up and pull it off the shaft.
    • Pivot the blade cover up and pull it off the shaft.

  6. Insert the provided spanner wrench into one of the four tightening holes on the inner flange behind the blade. Use the the provided nut wrench to loosen the hex nut while providing counterforce with the spanner wrench. Use the the provided nut wrench to loosen the hex nut while providing counterforce with the spanner wrench.
    • Insert the provided spanner wrench into one of the four tightening holes on the inner flange behind the blade.

    • Use the the provided nut wrench to loosen the hex nut while providing counterforce with the spanner wrench.

  7. Remove the hex nut. Remove the outer flange.
    • Remove the hex nut.

    • Remove the outer flange.

  8. Remove the cutting blade. The blade can be sharp, so handle with care.
    • Remove the cutting blade.

    • The blade can be sharp, so handle with care.

  9. Pull the entire cutting head straight off the shaft holding it in place. Pull the entire cutting head straight off the shaft holding it in place. Pull the entire cutting head straight off the shaft holding it in place.
    • Pull the entire cutting head straight off the shaft holding it in place.

  10. Remove the eight Phillips #2 screws on the underside of the cutting head.
    • Remove the eight Phillips #2 screws on the underside of the cutting head.

  11. OPEN ALL THE TABS

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  12. Remove the bottom cover. Remove the bottom cover.
    • Remove the bottom cover.

  13. Remove the Phillips #2 screw holding the ground wires to the chassis. Loosen the wires from each other.
    • Remove the Phillips #2 screw holding the ground wires to the chassis.

    • Loosen the wires from each other.

    • The motor's ground wire is green with a yellow stripe.

    • Reassembly tip: there are three ground wires attached here that will need to be reinstalled upon reassembly.

  14. Remove the black wire's plug from the 4-pin rectifier. These plugs have two wires each, so removing one plug removes two wires.
    • Remove the black wire's plug from the 4-pin rectifier.

    • These plugs have two wires each, so removing one plug removes two wires.

  15. Remove the red/orange wire combo plug from the 4-pin rectifier. Use needle-nose pliers if you can't reach this plug with your fingers.
    • Remove the red/orange wire combo plug from the 4-pin rectifier.

    • Use needle-nose pliers if you can't reach this plug with your fingers.

  16. Be very careful with this connection, as even minimal bending can break the metal conductor in half. Use a pick to slightly pry up on the crimped metal arms holding the red and orange wires together. Repeat for both sides to loosen the connector.
    • Be very careful with this connection, as even minimal bending can break the metal conductor in half.

    • Use a pick to slightly pry up on the crimped metal arms holding the red and orange wires together.

    • Repeat for both sides to loosen the connector.

  17. Be very careful with this connection, as even minimal bending can break the metal conductor in half. Remove the red wire from the orange wire.
    • Be very careful with this connection, as even minimal bending can break the metal conductor in half.

    • Remove the red wire from the orange wire.

  18. Use two flathead screwdrivers to carefully pry the inner flange off the motor shaft. You may need to use the two screwdrivers to "walk" the flange off—it's press-fit onto the shaft. Try prying on various positions of the flange and rotating it as you work. Remove the inner flange.
    • Use two flathead screwdrivers to carefully pry the inner flange off the motor shaft.

    • You may need to use the two screwdrivers to "walk" the flange off—it's press-fit onto the shaft. Try prying on various positions of the flange and rotating it as you work.

    • Remove the inner flange.

  19. Remove the four Phillips #2 screws holding the motor in place.
    • Remove the four Phillips #2 screws holding the motor in place.

  20. Grab the motor with both hands and tilt it slightly upward. While keeping the motor tilted up, pull back and up to clear the electrical components behind the motor. Remove the motor.
    • Grab the motor with both hands and tilt it slightly upward.

    • While keeping the motor tilted up, pull back and up to clear the electrical components behind the motor.

    • Remove the motor.

    • You may need to bend the thermal overload switch slightly in order to lift the motor out.

  21. Remove the electrical tape from the twist-on wire connector connecting the three white wires. Remove the electrical tape from the twist-on wire connector connecting the three white wires.
    • Remove the electrical tape from the twist-on wire connector connecting the three white wires.

  22. Remove the twist-on wire connector. Remove the twist-on wire connector.
    • Remove the twist-on wire connector.

  23. Twist the three white wires apart from each other.
    • Twist the three white wires apart from each other.

  24. Remove the black wire from the switch assembly. Use needle-nose pliers if you can't reach this plug with your fingers.
    • Remove the black wire from the switch assembly.

    • Use needle-nose pliers if you can't reach this plug with your fingers.

  25. Use wire cutters to cut the angled plug off the end of the black wire so it can slide out of the power cord opening. Use wire cutters to cut the angled plug off the end of the black wire so it can slide out of the power cord opening. Use wire cutters to cut the angled plug off the end of the black wire so it can slide out of the power cord opening.
    • Use wire cutters to cut the angled plug off the end of the black wire so it can slide out of the power cord opening.

  26. Use an adjustable wrench to loosen the hex nut closest to the wall plug side of the power cord. Use an adjustable wrench to loosen the hex nut closest to the wall plug side of the power cord.
    • Use an adjustable wrench to loosen the hex nut closest to the wall plug side of the power cord.

  27. Pull back the flex guard from the cutting head chassis. Pull back the flex guard from the cutting head chassis.
    • Pull back the flex guard from the cutting head chassis.

  28. Make sure all power cord wires are disconnected before pulling the power cord out of the cutting head. Grab the outer sheath and slowly pull the power cord out of the cutting head. Remove the power cord.
    • Make sure all power cord wires are disconnected before pulling the power cord out of the cutting head.

    • Grab the outer sheath and slowly pull the power cord out of the cutting head.

    • Remove the power cord.

  29. If your replacement power cord does not have quick disconnect plugs on the end of its wires, strip about half an inch of insulation off of each wire to install new crimp connectors. Reassembly tip: This needs to be done after the cord is fed back into the cutting head, otherwise it won't fit. Reassembly tip: This needs to be done after the cord is fed back into the cutting head, otherwise it won't fit.
    • If your replacement power cord does not have quick disconnect plugs on the end of its wires, strip about half an inch of insulation off of each wire to install new crimp connectors.

    • Reassembly tip: This needs to be done after the cord is fed back into the cutting head, otherwise it won't fit.

Conclusion

To reassemble your device, follow these instructions in reverse order.

Carsten Frauenheim

Member since: 03/10/2020

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