MK Diamond BX-3 User Manual

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Page 1

www.mkdiamond.com

BX-3 MASONRY SAW

OWNER'S MANUAL, PARTS LIST &

OPERATING INSTRUCTIONS

Revision 100

Manual Part No. 158168

Caution: Read all safety and operating instructions

before using this equipment. This owners manual MUST accompany the equipment at all times.

09.2011

Page 2

INTRODUCTION

Congratulations on your purchase of a Diamond Vantage Tile Saw. We are certain that you will be pleased with your purchase. We take pride in producing the finest construction power tools and diamond blades in the industry.

Operated correctly, your Saw should provide you with years of service. In order to help you, we have included this manual. This owners manual contains information necessary to operate and maintain your Saw safely and correctly. Please take a few minutes to familiarize yourself with the Saw by reading and reviewing this manual.

If you should have questions concerning your Saw, please feel free to call our friendly customer service department at: 866.322.4078

Regards,

Diamond Vantage

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 (including the Serial Number) and mail it in as soon as possible.

Page 3

TABLE OF CONTENTS

SAFETY

Safety Message/Alert Symbols Damage Prevention Message General Safety Precautions and Hazard Symbols California Proposition 65 Message Hazard Symbols Electrical Requirements and Grounding Instructions Safety Decal Locations

Product Specications

4 5 5 6 7

8-9

UNPACKING AND ASSEMBLY

Contents Transport Assembly

SETUP, ADJUSTMENT AND OPERATION

Setup Adjustment and Operation Cleanup

MAINTENANCE AND TROUBLESHOOTING

Maintenance Troubleshooting

EXPLODED VIEW AND PARTS LIST

Exploded View Parts List

THEORY OF DIAMOND BLADE

Theory

ACCESSORIES

Accessories and Replacement Parts

13 13 14

15-16 17-19

21-26 27-28

31-32

ORDERING AND RETURN INSTRUCTIONS

Ordering Information Return Materials Policy Contact Information and Limited Warranty

35 35 35

Page 4

BX-3 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

A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol ( ) and one of three words: DANGER, WARNING, or CAUTION.

DANGER

WARNING

CAUTION

You WILL be KILLED or SERIOUSLY INJURED if you do not follow directions.

You CAN be KILLED or SERIOUSLY INJURED if you do not follow directions.

You CAN be INJURED if you do not follow directions. It may also be used to alert against unsafe practices.

DAMAGE PREVENTION AND INFORMATION 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.

NOTE:

Equipment and/or property damage may result if these instructions are not followed.

GENERAL SAFETY PRECAUTIONS AND HAZARD SYMBOLS

In order to prevent injury, the following safety precautions and symbols should be followed at all times!

SAFETY PRECAUTIONS

ALWAYS read this Owner’s Manual before operating the machine.

ALWAYS keep the Blade Guards in place.

REMOVE ADJUSTING KEYS AND WRENCHES

Form a habit of checking to see that keys and adjusting wrenches are removed from the power tool before it is turned on.

KEEP WORK AREA CLEAN

Cluttered work areas and benches invite accidents.

DO NOT USE IN DANGEROUS PLACES

DO NOT use power tools in damp or wet locations nor expose them to rain. Always

keep the work area well lighted.

KEEP CHILDREN AWAY

All visitors and children should be kept a safe distance from work area.

Page 5

BX-3 SAFETY

MAKE THE WORKSHOP KID PROOF

Make the workshops kid proof by using padlocks, master switches or by removing starter keys.

DO NOT FORCE THE TOOL

A power tool will do a job better and safer operating at the rate for which it was designed.

USE THE RIGHT TOOL

DO NOT force a tool or an attachment, to do a job that it was not designed to do.

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 10 shows the correct AWG size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage. The smaller the gage number, the heavier the cord.

USE PROPER APPAREL

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 covering to contain long hair.

ALWAYS wear approved eye protection.

ALWAYS wear approved respiratory protection.

SECURE WORK

Clamps or a vise should be used to hold work whenever practical. Keeping your hands free to operate a power tool is safer.

DO NOT OVERREACH

Keep proper footing and balance at all times by not overreaching.

MAINTAIN TOOLS WITH CARE

Keep tools clean for the best and safest performance. Always follow maintenance instructions for lubricating, and when changing accessories.

ON / OFF

DISCONNECT TOOLS

Power tools should always be disconnected before servicing or when changing accessories, such as blades, bits, cutters, and the like.

ALWAYS place the power ON/OFF switch in the OFF position when the saw is not in use.

Page 6

BX-3 SAFETY

USE RECOMMENDED ACCESSORIES

Consult the owner’s manual for recommended accessories. Using improper accessories

may increase the risk of personal or by-stander injury.

NEVER STAND ON THE TOOL

Serious injury could occur if a power tool is tipped, or if a cutting tool is unintentionally contacted.

CHECK FOR DAMAGED PARTS

Before using a power tool, check for damaged part. A guard or any other part that is damaged should be carefully checked to determine if 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.

DIRECTION OF FEED

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.

NEVER LEAVE A TOOL UNATTENDED

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

WARNING

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. 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.

Page 7

(

)

BX-3 SAFETY

HAZARD SYMBOLS

ELECTRICAL SHOCK

NEVER touch electrical wires or components while the engine is running. They can be

sources of electrical shock which could cause severe injury or burns.

ROTATING PARTS

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the motor with covers, shrouds, or guards removed.

OVER SPEED

NEVER tamper with the governor components or settings to increase the maximum

speed. Severe personal injury and damage to the engine or equipment can result if operated at speeds above maximum.

DO NOT EXPOSE TO RAIN DO NOT expose to rain or use in damp locations.

WARNING

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 protection 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

Page 8

BX-3 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!

WARNING

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. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

• 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 like the one shown in Sketch A. The tool has a grounding plug that looks like the plug illustrated in Sketch A. A temporary adapter, which looks like the adapter illustrated in sketches B and C, may be used to connect this plug to a 2-pole receptacle as shown in Sketch B, if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualied electrician. The green-colored rigid ear, lug, and the like, extending from the adapter, must be connected to a permanent ground such as a properly grounded outlet box.

NOTE: Use of a temporary adapter is not permitted in Canada.

Metal Screw

Grounding

(A)

ADAPTER

Grounding

Means

(C)

Cover of

Grounded

Outlet Box

Grounding

(B)

(D)

Circuit and Adapter Information

Page 9

Surface

BX-3 SAFETY

WARNING

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 extension 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.

Power Cord

Drip Loop Information

Power Tool

Drip Loop

Supporting

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.

Page 10

BX-3 SAFETY

WARNING

To reduce the risk of electrocution, keep all connections dry and off the ground. Do not touch the plug with wet hands.

WARNING

Use of under sized extension cords result in low voltage to the motor that can result in motor burnout and premature failure. MK Diamond warns that equipment returned to us showing signs of being run in a low voltage condition, through the use of undersized extension cords will be repaired or replaced totally at the customer's expense. There will be no warranty claim.

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 of extension cord.

EXTENSION CORD MINIMUM GAGE FOR LENGTH

VOLTS TOTAL LENGTH OF CORD IN FEET

25 ft. AWG 50 ft. AWG 100 ft. AWG 150 ft. AWG

115v 14 12 Not Recommended Not Recommended

230v N/A 14 12 N/A

Page 11

BX-3 SAFETY

SAFETY LABEL LOCATIONS:

Safety labels are located according to Figures 1 to 4 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

.oN traP noitpircseD noitacoL metI

675551 lebaL ytefaS noituaC rebmeM ssorC reppU ,ediS tfeL .1

2. Right Side, Upper Cross Member 733451 lebaL gninraW noitalahnI tsuD 276551 lebaL gninraW droC noisnetxE rebmeM ssorC reppU ,kcaB .3

4. Blade Guard Serial Number

and Motor Specifications 158096

BRICK SAW SPECIFIC WARNINGS:

Read Owners Manual Wear Protective Gear for –

• Head

• Lungs

• Ear

• Eye

Page 12

BX-3 SAFETY

PRODUCT SPECIFICATIONS:

The BX-3 is a versatile lightweight, dry, masonry saw. Operated and used according to this manual, the BX-3 will provide years of dependable service.

General Description: The BX-3, Brick Xtreme, is engineered as a 14" dry saw, consisting of a powerful 115v motor in a hard plastic case. The saw is capable of cutting brick and masonry up to 8" x 8" x 16" in size; the blade has a five (5) inch cutting depth.

Motor and Weight Specifications: Motor and Weight specifications for the BX-3 are listed in Table 2 below.

v 511 egatloV

A 51 egarepmA

zH 06 ycneuqerF

mpr 005,3 MPR

*.sbl 54 thgieW

Table 2

Blade Capacity: The BX-3 uses a 14-inch diameter segmented dry MK Diamond blade with a .110-inch cutting width.

Masonry Types: The BX-3 can cut a variety of masonry types including, cinder block, slump stone block, wall brick, paver brick, concrete block and cylinders, roofing tile, marble, granite, decorative rock or almost any other nonferrous material.

NOTE: The BX-3 is not designed to cut plastic or ferrous (metals) material.

Spring Assisted Cutting Head: The BX-3 is designed with a spring assisted Cutting Head to allow for easier step cutting. The Cutting Head can be locked in the down position when cutting smaller pieces.

Lockable Trigger Switch: The BX-3 is designed with a lockable trigger-operating switch in the handle to allow for ease of operation.

Removable Motor Air Filter: The BX-3 is designed with an easy clean motor air filter to extend the life of the motor.

Replaceable Motor Brushes: The BX-3 is designed with replaceable motor brushes to extend operating life.

Page 13

BX-3 CONTENTS

UNPACKING:

Your BX-3 has been shipped from the factory thoroughly inspected. Only minimal assembly is required.

If not already done, remove the BX-3 from the carton and place it on a flat surface. Remove Strapping. Remove the Accessories box from the main carton and place along side the BX-3 (Owners Manual is in Accessories Box).

CONTENTS:

In the containers, you will find one (1) BX-3, one (1) 14 inch segmented dry diamond blade (or segmented block blade), one (1) movable cutting table, one (1) adjustable cutting guide, one replacement motor air filter, one (1) blade wrench, one (1) shaft wrench, one (1) owner's manual and one (1) warranty card.

BX-3 Segmented Dry

Diamond Blade

- OR -

Blade

Wrench

Shaft

Wrench

Adjustable

Cutting Guide

www.diamondvantage.com

BX-3 MASONRY SAW

OWNERS MANUAL, PARTS LIST &

OPERATING INSTRUCTIONS

09.2011

Revision 100

Manual Part No. 158168-DV

Caution: Read all safety and operating instructions

before using this equipment. This owners manual MUST accompany the equipment at all times.

Owner's

Manual

Movable Cutting

Table

Warranty

Card

Extra Motor

Air Filter

TRANSPORT:

The BX-3 weighs approximately forty (45) pounds (Without the Movable Cutting Table), making transport easy.

Always observe safe lifting practices when lifting the BX-3.

NOTE: Lock the Cutting Head in the DOWN position, and remove the Movable Cutting Table when

transporting the BX-3.

Due to its lightweight construction, the BX-3 is designed to be carried by the durable aluminum frame. Simply lock the spring assisted cutting head in the DOWN position, grasp the frame by the lower front and upper back cross members, lift and transport the BX-3 to the desired work location

Locking Pin

Inserted

Cutting Head Locked Down

Lift Point

Page 14

BX-3 ASSEMBLY

ASSEMBLY:

Follow the assembly instructions to prepare your BX-3 for operation.

1. Movable Cutting Table Installation:

Cutting Table

Front

Roller Wheels

Guide Rails

Ease of Movement

(See Maintenance Section

If Problems Arise)

Guide Rail

(A)

Position Movable Cutting Table

Roller Wheels

(B)

Seat Roller Wheels on

(C)

Verify Correct Seating

Guide Rails

2. Adjustable Cutting Guide Installation:

Turn to Loosen

Loosen Thumbscrew

(A)

Ruler/Sto

(B)

Position Adjustable Cutting Guide

Align

Parallel Slots

Turn to Tighten

(C)

Seat and Tighten

Adjustable Cutting Guide

3. Diamond Blade Installation:

NOTE: When installing the Retaining Screw, do not “cross-thread" and DO NOT over tighten the screw.

Motor Shaft

Retaining Screw

Rotate Blade

Wrench

Counte

-clockwise

Seat Blade on

Inner Flange

Seated

Hold Shaft

Wrench

Outer Flange

(A)

Identify Retaining Screw

and Outer Flange

Hold Shaft

Wrench

Stationary

Wrench Clockwise

Rotate Blade

Stationary

(B)

Remove Retaining Screw

and Outer Flange

Rotation Direction

(C)

Install and Seat Blade –

Verify Rotation

(D)

Install Retaining Screw and

Outer Flange - Tighten

Page 15

BX-3 SETUP

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 trigger switch, locking button is in the "RELEASE" position.

• Before connecting the BX-3 to a power supply, be sure the voltage, cycle and phase of the job site power

source meet the requirements of TABLE 3

VOLTAGE: 115v CYCLE: 60hz PHASE: single phase

TABLE 3

• If using an extension power cord, make sure the length and wire gauge corresponds to the requirements listed in TABLE 1 on page 7. 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.

• Use an approved Ground Fault Circuit Interrupter (GFCI)

• Do not cover the motor vents as this could lead to motor overheating.

Portable Generator: If using a portable generator to provide power, ensure the generator meets the following minimum requirements:

8 kW 120/240 volts 66.7/33.3 amps Single Phase

Pre-start Inspection:

The pre-start inspection should be performed before beginning any job.

NOTE: In order to avoid breaker tripping, a 20-amp circuit breaker should be used.

If the Diamond Blade shows signs of fatigue cracking, replace the blade before starting work.

Cracks

(A)

Inspect Blade for Damage – Verify

Blade Correct for Material Being Cut

Replace if Excessively Grooved

(See Maintenance Section

if Problems Arise)

(B)

Inspect Wooden Strip for

Excessive Grooves

Check for Cleanliness

(See Maintenance Section)

Ease of Movement

(See Maintenance Section

Trigger Lock

(Push to Lock)

if Problems Arise)

(C)

Movable Cutting Table

Moves Freely

Trigger Switch

(Push to Unlock)

Inspection

Points

Inspect for Damage

(D)

(E)

Inspect Motor Air Filter for

Cleanliness

Underside of Handle

(F)

Verify Trigger Switch Unlocked

Page 16

BX-3 SETUP

If an extension cord is used, first verify it meets the requirements of TABLE 1 (page 9). Plug the BX-3 into the extension cord; plug the extension cord into a GFCI. Finally, plug the GFCI into the power source in that order.

GFCI

Power Source

(G)

Plug GFCI into BX-3

(H)

Plug GFCI into Power Source

Page 17

BX-3 ADJUSTMENT

ADJUSTMENT AND OPERATION:

1. Cutting Setup:

Ruler/Stop

Set Edge of Cutting

Guide to Desired Cut

Length on Ruler/Stop

Set against Adjustable

Cutting Guide and

Ruler/Stop

Ruler Markings

(A)

Set Adjustable Cutting Guide

Adjustable

Cutting Guide

(B)

Position Masonry Piece

Ruler/Stop

DO NOT FORCE the blade to cut, it will do the job better and safer at rate for which it was designed.

2. 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.

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.

Depress Trigger to

Start (Lock if Desired)

(A)

Step Cut Setup

Hold Work in Position

Push Direction

(B)

Step Cut “Push” Stroke

Lower Cutting Head 1/4 -1/2

Inch During

Push Stroke

Step Cut “Pull” Stroke

Lower Cutting

Head Additional

1/4 -1/2 Inch During

Pull Stroke

Pull Direction

(C)

Repeat “Push”

and “Pull” Strokes

Until Cut Complete

(D)

Repeat Steps B and C

Until Cut Complete

Raise Cutting

Head

Cutting Complete

Release Trigger Switch

Allow Blade to

Stop Before

Removing Work

(E)

Page 18

BX-3 ADJUSTMENT

3. Chop Cutting:

A Chop Cut is performed by cutting completely through an object in one pass.

Depress Trigger to

Start (Lock if Desired)

Position

Work Below

Cutting Head

(A)

Chop Cut Setup

Hold Roller

Trolley Stationery

(B)

Lower Cutting Head

to Begin Cutting

Release Trigger Switch

Allow Blade to

Raise Cutting

Head

Stop Before

Removing Work

(D)

Cutting Complete

4. Cutting with the Cutting Head Locked Down:

This method is preferred when cutting small objects.

Lower Cutting

Head Smoothly

to Cut

Lock Trigger Switch

Continue to Lower Cutting Head until

Cut Complete

(C)

Continue Lowering Head

until Cut Complete

Push Slowly to Cut

Align Holes and

Lock Cutting

Head in Position

(A)

Lock Cutting Head in

the Down Position

Unlock Trigger Switch

When Cut Complete

Continue to Push until Cut Complete

Allow Blade to

Stop Before

Removing Work

(D)

Continue Pushing Piece into

Blade until Cut Complete

(B)

Locked Cutting Head Setup

Remove Locking

Pin to Release

Cutting Head

Hold in Position

(E)

Cutting Complete

Hold Work in Position

Push Slowly to Cut

(C)

Slowly Push Piece toward Blade

to Begin the Cut

Page 19

BX-3 ADJUSTMENT

5. 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.

Turn to Loosen

Align 45° Slots

to Ruler/Stop

Set against Adjustable

Cutting Guide and

Ruler/Stop

Remove Adjustable

Cuttin

Guide

Remove Adjustable

Cutting Guide

DO NOT FORCE TOOL, it will do the job better and safer at the rate for which it was designed.

Lock Cutting Head in

the Down Position

(A)

Align Holes and

Head in Position

(D)

Unlock Trigger Switch when Cut Complete

Lock Cutting

Ruler/Stop

(B)

Reposition Adjustable

Cutting Guide

Lock Trigger Switch

(E)

Locked Cutting Head Setup

Unlock Trigger Switch when Cut Complete

Hold Work in Position

Adjustable

Cutting Guide

Ruler/Stop

(C)

Position Adjustable

Cutting Guide

Push Slowly to Cut

(F)

Slowly Push Piece toward Blade

to Begin the Cut

Continue to Push until Cut Complete

(G)

Continue Pushing Piece into

Allow Blade to

Stop Before

Removing Work

(H)

Cutting Complete

Remove Locking

Pin to Release

Cutting Head

Release Cutting Head

Hold in Position

(I)

Blade until Cut Complete

Page 20

BX-3 ADJUSTMENT

6. Cleanup:

Power Source

GFCI

Pull Straight Back

To Remove Cap

(A)

Unplug GFCI from Power Source

Always wear eye protection when using compressed air.

Pull Foam Filter

Out of Filter Cap

(D)

Remove Filter from Filter Cap

Push Filter Cap

onto Spacer Pins to seat

(B)

Unplug GFCI from BX-3

Tap on Hard Surface to Dislodge Dirt

(E)

Clean Filter by Tapping on Hard

Surface or using Compressed Air

Clean Roller

Wheels

(C)

Remove Motor Filter Cap

Install Foam Filter

into Filter Cap

(F)

Reinstall Filter into Filter Cap

lign Filter Cap

Retaining Clips

to Spacer Pins

Install Motor Filter

Cap onto Motor

(G)

Clean Guide Rails

(H)

Clean the Movable Cutting Table

Roller Wheels and Guide Rails

Clean Remainder of BX-3

(I)

Clean BX-3

Usin

Clean Cloth

Page 21

BX-3 MAINTENANCE

MAINTENANCE:

1. General Maintenance:

The following maintenance should be performed following each use. Use Light oil, such as WD-40 or 3 in 1 when lubricating parts.

Lubricate

Torsion Spring

Lubricate Guide Rails

(A)

Lubricate Cutting Head

Torsion Spring

Lubricate Movable Cutting Table

Roller Wheels and Guide Rails

(B)

2. Monthly Maintenance:

The following should be performed monthly. Items should be lubricated as directed.

Lubricate

Roller Wheels

Clean and Lubricate

(A)

Clean and Lubricate Inner Flange

and Motor Shaft

(B)

Clean and Lubricate

Blade Retaining Screw

Inspect for

Wea

(C)

Check Roller Wheels and

Guide Rails for Wear

Page 22

BX-3 MAINTENANCE

3. 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 smooth 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.

Set up for Operation

(See Setup, Adjustment

and Operation)

(A)

Set BX-3 for Operation

Ruler/Stop Set Edge of Cutting

Set Adjustable Cutting Guide

Guide to Desired Cut

Length on Ruler/Stop

Ruler Markings

(B)

Adjustable

Cutting Guide

Position Dressing Stick

to Cut 1/16-inch Strips

DON'T FORCE TOOL, it will do the job better and safer at the rate for which it was designed.

Depress Trigger to

Start (Lock if Desired)

Lower Cutting

Head while

Pushing Dressing

Stick into Blade

Set against Adjustable

Cutting Guide and

Ruler/Stop

(C)

Repeat Cut

Stroke 8-times

Stick in Position

(D)

Set up for Blade Dressing

Release Trigger Switch

llow Blade to Stop

Raise Cutting

Head

Before Removing

Dressing Stick

(G)

Dressing Complete

Hold Dressing

Push Direction

Begin Blade Dressing

(E)

(F)

Repeat Cut Stroke

to Dress Blade

Page 23

BX-3 MAINTENANCE

4. Diamond Blade Change-out:

Disconnect the tool before servicing and when changing accessories, such as blades, bits, cutters, and the like.

Set up for Operation

(See Setup, Adjustment

and Operation)

(A)

Setup BX-3 for Operation

Hold Shaft

Wrench

Stationary

Retaining Screw

Counte

(B)

Remove Retaining Screw

and Outer Flange

Rotate Blade

Wrench

-clockwise

Remove Blade from

Motor Shaft

Remove Blade

(C)

NOTE: When installing the Retaining Screw, do not “cross-thread" and DO NOT over tighten the screw.

Seat Blade on

Inner Flange

Rotation Direction

(D)

Install Blade Under Blade Guard

and Onto Motor Shaft

Hold Shaft

Wrench

Stationary

Install Outer Flange and

Retaining Screw – Tighten

Rotate Blade

Wrench Clockwise

(E)

Page 24

BX-3 MAINTENANCE

5. 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

Counte

-clockwise

Roller Wheels

(A)

Place Movable Cutting

Table On Work Bench

1/2-Inch Wrench

(B)

Remove Roller Wheels

(C)

Prepare for Installation

Of New Roller Wheels

with Roller Wheels Up

NOTE: When installing the Retaining Bolt, do not “cross-thread" and DO NOT over tighten the Nut.

Washe

Roller Wheel

(D)

Install Wheel/Washer Assembly

Into Movable Cutting Table

Install Movable Cutting

Table (See Setup,

Adjustment and Operation

1/2-Inch Wrench

Install Roller Wheel

Retaining Nut – Tighten

Rotate Wrench

Counte

(E)

-clockwise

Lubricate with

Light Oil (WD-40,

(F)

Lubricate Roller Wheels

Clean Holes

3 in 1, etc)

(G)

Install Movable Cutting Table

Page 25

BX-3 MAINTENANCE

6. 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).

Phillips

Screwdrive

Protective

Wooden Strip

Roller Wheels

(A)

Place Movable Cutting Table on

Work Bench – Wheels Up

with Roller Wheels U

Worn Wooden

Strip

New Wooden

Strip

(D)

Replace Worn

Protective Wooden Strip

Retaining Screw

(B)

Remove the Two Protective

Wooden Strip Retaining Screws

Phillips

Screwdrive

Retaining Screw

(E)

Place Movable Cutting Table on

Work Bench – Wheels Up,

Reinstall Retaining Screws

(C)

Place Movable Cutting Table on

Work Bench – Wheels Down

Install Movable Cutting

Table (See Setup,

Adjustment and Operation

(F)

Install Movable Cutting Table

Page 26

BX-3 MAINTENANCE

7. Motor Brush Change-out:

Disconnect the tool before servicing and when changing accessories, such as blades, bits, cutters, and the like.

Disconnect BX-3

Disconnect the BX-3

One Cap on

Either Side of Moto

Phillips

Screwdrive

(A)

Locate and Remove One

Motor Brush Cap

Rotate Screw Driver

Counte

-clockwise

(B)

Clean Brush Housing of Carbon All Carbon

Dust and Fragments

Remove Motor Brush and

Clean Brush Housing

NOTE: When installing motor brushes, care must be taken to ensure the spring end is straight before

installing the Motor Brush Cap.

Remove Motor Brush

(C)

Align Motor Brush

with Brush Housing

and Install the Brush

(D)

Align and Install

New Motor Brush

Phillips

Screwdrive

(E)

Install Motor Brush Cap

Rotate Screw

Driver Clockwise

Replace Second

Motor Brush

(F)

Install the Second Motor Brush

(Repeat Steps B to E)

Page 27

BX-3 TROUBLESHOOTING

TROUBLESHOOTING:

Verify the Lockable Switch is unlocked and the saw is disconnected from the power source before performing any troubleshooting procedure.

1. Motor Stops Turning:

Verify Connected

If GFCI Tripped,

Reset and Restart

BX-3 once

(A)

Verify all Plugs Fully Connected

If Connected, go to Step B

If Breaker Tripped,

Reset once -

Attempt Restart

If not

Tripped,

go to Step E

(D)

Verify Circuit Breaker

Not Tripped

2. Blade Will Not Cut Properly:

If “Glazed,” Dress (See Blade Dressing)

If not “Glazed,

go to Step B

If GFCI not Tripped,

go to Step C

(B)

Check Ground Fault Circuit

Interrupter (GFCI) Tripped

If Circuit is 115

Volts, go to

Step F

not115 Volts,

Change Circuit

(E)

Verify Source Voltage

is 115 Volts

If Rotation

Not Correct,

Reposition Blade

If Circuit is

If Rotation

Correct, go

to Step C

If Less than

20 Amps,

Switch to 20

Amp Breaker

(C)

Verify Circuit Breaker is

20 Amp or Greater

If 20 Amp

Or Greater,

go to Step D

If Core Not Bent, go to

Step D

(A)

Check for Smoothness

or “Glazing”

Contact Place of Purchase or

MK Diamond (800 421-5830)

To Verify Blade

If Blade

Correct, go

to Step E

(B)

Check for Proper Rotation

If Core Bent, Chan

e Blade

(C)

Ensure Blade

Core Not Bent

(D)

Verify Blade Correct for

Material Being Used

Page 28

BX-3 MAINTENANCE

3. Movable Cutting Table Does Not Move Correctly:

If Dirty,

If Clean, go

to Step B

(A)

Check Guide Rails Clean

Clean

Rails

(B)

Check for Roller

Wheel Damage

If Damaged

Replace

If Not

Damaged,

go to

Step C

If Binding

Present, Return

to MK Diamond

If No Binding,

go to Step D

(C)

Verify Ease and Freedom

of Movement

Page 29

BX-3 EXPLODED VIEW

Page 30

BX-3 PARTS LIST

PARTS LIST:

n/p KM ytQ noitpircseD metI

a/n 1 thgiR ,emarF ,ylbmessA A

763751 1 thgiR ,emarF ,gnitsaC 1A 963751 1 tfeL ,emarF ,gnitsaC 2A 483751 3 emarF latnoziroH ,troppuS 3A 039751 6 02-¼ ,rotcennoC ebuT 4A 419151 6 paC daeH xeH ½ 1 x 02-¼ ,wercS 5A 519151 6 talF EAS ¼ ,rehsaW 6A 195251 6 kcoL tilpS ¼ ,rehsaW 7A 383751 2 liaR ediuG elbaT ,partS 8A 073251 01 paC daeH xeH ,¾ x 02-¼ ,wercS 9A 195251 01 kcoL tilpS ¼ ,rehsaW 01A 170851 2 ½ x )¼( 61# devoorG daeH dnuoR ,dutS evirD 11A 959751 1 ”3XB“ evisehdA ,lebaL 21A 675551 1 noituaC ytefaS ,lebaL 31A 433451 1 ASU KM ,lebaL 41A 690851 1 waS kcirB ,laireS ,gaT 51A 733451 1 56 porP ,lebaL 61A 276551 1 droC noisnetxE ,gninraW ,lebaL 71A

a/n 1 tnuoM rotoM ,mrA ,ylbmessA B

995751 1 tnuoM rotoM ,mrA ,gnitsaC 1B 239751 2 egnalF nolyN ,gnihsuB 2B 859751 1 ”emertX kcirB“ evisehdA ,lebaL 3B

a/n 1 pmalC toviP ,ylbmessA C

395751 1 pmalC toviP ,gnitsaC 1C 386451 2 paC .dH tekcoS ¼ 1 x 02-¼ ,wercS 2C 195251 2 kcoL tilpS ¼ ,rehsaW 3C

D7 Insert, Expansion, ¼-20 Standard 2 158147

Pin, Pivot  .625 x 5.6

1 157645

825751 1 tnioP puC ¼ x 02-¼ teS ,wercS 5C 207751 1 noisroT ,gnirpS 6C 622851 1 kcolB potS 7C 785251 1 paC dH tekcoS ,8/5 x 02-¼ ,wercS 8C 339751 1 gniR lluP /w tneteD ,niP 9C 270851 1 draynaL 01C

a/n 1 hctiwS & eldnaH ,ylbmessA D

478751 1 reppU ,eldnaH 1D 578751 1 rewoL ,eldnaH 2D 651851 8 mm21 x 5.3M ,wercS 3D 785251 2 paC .dH tekcoS ,¾ x 02-¼ ,wercS 4D 519151 2 talF ,EAS ¼ ,rehsaW 5D 195251 2 kcoL tilpS ¼ ,rehsaW 6D

439751 1 reggirT ,hctiwS 8D 678751 1 gnitnuoM hctiwS ,wercS ,etalP 9D 539751 1 V021 rewoP CA ,droC 01D 088751 1 eriW ,revoC 11D 061851 1 daeH talF tekcoS ,¼ 1 x 23-6 # ,wercS 21D 132851 5 EAS talF 6# ,rehsaW 31D

a/n 1 rotoM ,ylbmessA E

R-108751 1 MPR 0053 ,pmA 51 / tloV 511 CA ,rotoM 1E

501851 1 retuO ,egnalF 2E

Page 31

BX-3 PARTS LIST

n/p KM ytQ noitpircseD metI

601851 1 rennI ,egnalF 3E 701851 1 egnalF xeH mm02 x 5.1 – 01M ,wercS 4E 851851 4 paC daeH xeH mm02 x 1-6M ,wercS 6E 951851 4 kcoL tilpS 6M ,rehsaW 7E 778751 1 rotoM ,paC 8E 878751 1 retliF rotoM ,paC 9E 978751 2 wercS paC ,niP recapS 01E 927751 1 tnemelE retliF 11E 751851 2 gnippaT ,naP daeH obmoC ,½ 1 x 6# ,wercS 21E

1 elbaT ,ylbmessA F

H8-A Blade, MK-BX30, Dry Cutting 14”, Segmented Block 1 157944

133082

441851 1 elbaT ,gnitsaC 1F 783431 1 eluR ,potS 2F 073251 4 paC daeH xeH ¾ x 02-¼ ,wercS 3F 149351 4 rehsaW htooT lanretxE /w xeH ,02-¼ ,tuN 4F 090331 4 relloR ,leehW 5F 150151 4 rehsaW htooT lanretxE /w xeH ,81-61/5 ,tuN 6F 724651 1 tresnI elbaT ,pirtS dooW 7F 740151 2 .lihP daeH naP 1 x 8# ,wercS 8F 672132 1 mrA gnirauqS ,gnitsaC 01F 551151 1 bmuhT ,½ 1 x 81-61/5 ,wercS 11F 651151 1 erauqS 81-61/5 ,tuN 21F

a/n 1 kcaP yrosseccA ,ylbmessA H

901851 1 tuN edalB ,hcnerW 5H 011851 1 tfahS ,hcnerW 6H 927751 1 tnemelE retliF artxE 7H 759751 1 detnemgeS ,”41 gnittuC yrD ,01XB-KM ,edalB 8H

861851 1 launaM s'renwO

Page 32

BX-3 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. As a result, a diamond blade for cutting soft, abrasive material must have a hard metal matrix composition to resist this erosion long enough for the exposed diamonds to be properly utilized. Conversely, a blade for cutting a hard, nonabrasive material must have a soft bond to ensure that it will erode and expose the diamonds embedded in the matrix. These simple

principles are the foundation of “controlled bond erosion”.

Types of Cutting: There are two basic types of cutting-Dry or Wet. The choice of which type of blade to use depends on:

• The requirements of the job

• The machine/tool utilizing the diamond blade

• The preference of the operator

In the case of DRY cutting, the overwhelming popularity and quantity of hand-held saws and the flexible nature of MK Diamond blades to professionally handle most ceramic, masonry, stone and concrete materials,

make the DRY cutting blade a very attractive tool. When using a DRY blade, the user must be aware of distinct operating practices to ensure optimum performance. DRY cutting blades require sufficient airflow about the blade to prevent overheating of the steel core. This is best accomplished by shallow, intermittent cuts of the material with periods of “free-spinning” (for several seconds) between each

cooling process.

For WET cutting applications, MK has the exact blade to compliment both the material to be cut and the wet

cutting machine to be used. During cutting operations, liberal amounts of water act as a coolant to support

the cutting effectiveness and longevity of the WET blade. Additionally, using water adds to the overall safety

of cutting operations by keeping the dust signature down.

Know All You Can About the Material You Wish to Cut

cut, to maximize the

Page 33

BX-3 ACCESSORIES

ACCESSORIES AND REPLACEMENT PARTS:

NOITPIRCSED REBMUN METI

1. 157957 MK-BX10, Dry Cutting 14" Segmented Blade

2. 157944 MK-BX30, Dry Cutting 14" Segmented Block

Blade

231276 Adjustable Cutting Guide*

133090 Roller Wheel*

156427 Protective Wooden Strip*

157729 Motor Air Filter*

152610 Ground Fault Circuit Interrupter

157981 BX-3 Stand

(Stand contains Owners Manual)

*Included at time of shipping

Page 34

BX-3 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.

When ordering direct from MK Diamond, please have the following information ready before calling:

• The Model Number of the saw

• The Serial Number of the saw

• Where the saw was purchased and when

• The Part Number for the part(s) being ordered

• The Part Description for the part(s) being ordered

NOTE: There is a $25.00 minimum order when ordering direct from MK Diamond. A $5.00 charge will be added to orders having a net billing value under $50.00. All purchases must be made using VISA, MasterCard or American Express.

All parts may be ordered by calling toll free to – 800 421-5830 or 310 539-5221 and asking for Customer Service. For technical questions, call – 800 474-5594.

RETURN MATERIALS POLICY

To expedite the service relative to the return of a product purchased through MK Diamond, please observe the following:

NOTE: When returning all items, they must have been purchased within the previous twelve (12) months.

• Have the Model Number of the saw

• Have the Serial Number of the saw

• Have the location of where the saw was purchased

• Have the date when the saw was purchased

• Contact Customer Service for approval to return the item(s)

• Obtain a Returned Goods Number (RGA) authorizing the return

• Follow the packaging instructions in the following section

• Ensure your item(s) are prepaid to the destination

For returned items, call toll free to – 800 421-5830 or 310 539-5221 and ask for Customer Service. For technical questions, call – 800 474-5594 or 310 257-2845.

PACKAGING INSTRUCTIONS

• Remove the Cutting Head and Support Angle Assembly

• Dry the saw before shipping

• When packing, include the following: Saw, Diamond Blade, Blade Guard and Support Angle

Assembly and Adjustable Cutting Guide (Other Accessories are not required)

• Package the unit in its original container or one of comparable size (do not ship the unit partially

exposed)

• Ensure all parts are secured in the packaging to prevent moving

AUTHORIZED SERVICE CENTERS

For quicker repair time, you may contact MK Diamond Customer Service, toll free, at 800 421-5830 or 310 539-5221 for the Authorized Service Center closest too you or visit our web site at www.mkdiamond.com. For technical questions, call – 800 474-5594.

Page 35

BX-3 CONTACT AND LIMITED WARRANTY

CONTACT:

Please contact MK Diamond Products, Inc. Customer Service Department with any questions you might have regarding distributors, parts or service. Telephone: (800) 421-5830 Fax: (310) 539-5158 E-mail: Customer_Service@MKDiamond.com Customer Service Hours: Monday through Friday, 6AM-4PM PST

MK Diamond Products, Inc. 1315 Storm Parkway Torrance, CA 90501

MK DIAMOND PRODUCTS, INC. LIMITED WARRANTY

MK DIAMOND PRODUCTS, INC. will guarantee every machine they build, to be free from defects in material and workmanship for (1) one year from date of purchase. The obligation of MK DIAMOND PRODUCTS, INC. under this warranty is limited to the repair or replacement of any parts which, under normal use, prove to be defective in material or workmanship. The parts involved or the unit in question should be returned to MK DIAMOND PRODUCTS, INC. or to a point designated by us, transportation prepaid.

This warranty does not obligate us to bear the cost of labor or transportation charges in connection with replacement or repair of defective parts. Likewise, it shall NOT apply to any unit which has been subjected to misuse, neglect or accident. This warranty does NOT apply to any machine which has been repaired or altered outside our factory.

This warranty does NOT obligate MK DIAMOND PRODUCTS, INC., with respect to items not of our manufacture, such as engines, motors, hydraulics, etc., which are subject to their own guarantees and warranties.

We shall in no event be liable for consequential damages or contingent liabilities arising out of failure of any equipment or parts to operate properly.

The MK Diamond logo is a registered trademark of MK Diamond Products, Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

MK Diamond may have patents, patent applications, trade marks, copyrights of other intellectual property right covering this product in this document.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

The information and specications included in this publication were in effect at the time of approval for

printing.

Page 36

MK-101 Pro 24 Tile Saw

OWNERS MANUAL & OPERATING INSTRUCTION

DOCUMENT NO. 158808

MK Diamond Products, Inc.

1315 Storm Parkway

Torrance, CA 90501

Toll-Free: (800) 845-3729

Phone: (310) 539-2221

Fax: (310) 539-5158

www.mkdiamond.com