BX-4 MK Diamond Products, Inc. BRICK SAW WITH OR WITHOUT MISTING DUST CONTROL OWNER’S MANUAL & OPERATING INSTRUCTIONS 14 5 4 3 2 1 1 2 3 4 5 6 U.S. Patent No. 7,284,547, 7,159,586 and 6,687,972 Revision 108 05.2013 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.
NOTES 2 BX-4
TABLE OF CONTENTS & INTRODUCTION TABLE OF CONTENTS PAGE NO.
SAFETY Read and follow all safety, operating and maintenance instructions. Failure to read and follow these instructions could result in injury or death to you or others. Failure to read and follow these instructions could also result in damage and/or reduced equipment life. SAFETY MESSAGES: Safety messages inform the user about potential hazards that could lead to injury, death and/or equipment damage.
SAFETY USE THE PROPER EXTENSION CORD. If using an extension cord make sure it is in good condition first. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage that will result in a loss of power and overheating. TABLE 1, Page 8 shows the correct AWG size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage.
SAFETY Hazard Symbols: ELECTRICAL SHOCK! Never touch electrical wires or components while the motor is running. Exposed, frayed or worn electrical motor wiring can be sources of electrical shock that could cause severe injury or burns. ACCIDENTAL STARTS! on Before plugging the equipment into an electrical outlet, be sure the trigger switch, locking button is in the “RELEASE” position to prevent accidental starting. Unplug the power tool before performing any service operation.
ELECTRICAL REQUIREMENTS & 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.
ELECTRICAL REQUIREMENTS & GROUNDING INSTRUCTIONS WARNING To avoid the possibly of the appliance plug or receptacle getting wet, position the Brick Saw to one side of a wall mounted receptacle. This will prevent water from dripping onto the receptacle or plug. A “drip loop,” shown in FIGURE 2, should be arranged by the user to properly position the power cord relative to the power source.
SAFETY LABEL LOCATIONS & SYMBOLS Safety labels are located according to figure 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.
PRODUCT SPECIFICATIONS PRODUCT SPECIFICATIONS: The BX-4 is a versatile lightweight, dry, masonry saw. Operated and used according to this manual, the BX-4 will provide years of dependable service. General Description: Part # Description 165486 With misting dust control 162761 Without misting dust control The BX-4, is engineered as a 14” dry saw with or without misting system. 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.
UNPACKING, TRANSPORT and ASSEMBLY UNPACKING • Your BX-4 has been shipped from the factory thoroughly inspected. Only minimal assembly is required. • If not already done, remove the BX-4 from the carton and place it on a flat surface. Check contents with list below. 14 9 5 4 3 2 8 7 6 5 4 3 2 1 1 2 3 4 5 1 1 2 6 2 1 4 5 6 4 3 6 5 3 7 8 MK Diamond Products, Inc.
UNPACKING, TRANSPORT & ASSEMBLY TRANSPORT The BX-4 weighs approximately seventy (70) pounds (With the Movable Cutting Table), making transport easy. 2 4 I CAUTION OFF PUMP SWITCH Always observe safe lifting practices when lifting the BX-4. 1 3 NOTE Lock the Cutting Head in the DOWN position, and remove the Movable Cutting Table when transporting the BX-4. Table Lock Due to its lightweight construction, the BX-4 is designed to be carried by the handles at the front & back of the saw.
UNPACKING, TRANSPORT & ASSEMBLY 2. DIAMOND BLADE INSTALLATION: Motor Shaft NOTE When installing the Retaining Screw, do not “cross-thread” and DO NOT over tighten the screw. • • Identify Motor Shaft, Retaining Screw (1) and Outer Flange (2). 2 Hold Shaft Wrench (3) stationary. Rotate Blade Wrench (4) counter-clockwise. Remove Retaining Screw and Outer Flange. 4 3 • 1 6 Seat Blade (5) on Inner Flange (6). Verify rotation direction of blade. 5 • Hold Shaft Wrench (3) stationary.
SETUP, ADJUSTMENT & OPERATION SETUP: CAUTION CAUTION • 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.
SETUP, ADJUSTMENT & OPERATION PRE-START INSPECTION: The pre-start inspection should be performed before beginning any job. 1 NOTE In order to avoid breaker tripping, a 20-amp circuit breaker should be used. CAUTION If the Diamond Blade shows signs of fatigue cracking, replace the blade before starting work. • • Inspect Blade for damage (1). Verify that the Blade is correct for the material being cut. Inspect Wooden Strip (2) for excessive grooves.
SETUP, ADJUSTMENT & OPERATION PRE-START INSPECTION: • Inspect Motor Air Filter (1) condition if required, shake or tap to remove excess debris. (See Cleanup Page 23) • Verify that the Trigger Switch (2) on the underside of the handle is unlocked. Depress release button (3) to unlock trigger. 1 2 CAUTION If an extension cord is used, first verify it meets the requirements of TABLE 1 (page 8). Plug the BX-4 into the extension cord; plug the extension cord into a Ground Fault Circuit Interrupter (GFCI).
SETUP, ADJUSTMENT & OPERATION ADJUSTMENT AND OPERATION: 1. ADJUSTABLE CUTTING GUIDE INSTALLATION: • Loosen knob (1) by turning counter-clockwise. • Seat the Adjustable Cutting Guide (2) along the Ruler/Stop (3). Turn knob (1) clockwise to tighten. 2 1 3 2. CUTTING SETUP: • Set the Adjustable Cutting Guide (1). Identify the Ruler/Stop (2). Set the edge of the Cutting Guide to the desired cut length on the Ruler/Stop.
SETUP, ADJUSTMENT & OPERATION 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.
SETUP, ADJUSTMENT & OPERATION 3. CHOP CUTTING: • • A Chop Cut is performed by cutting completely through an object in one pass. 1 Chop cut setup: Depress Trigger to start (lock if desired). Position work (1) below the Blade. 3 • Hold Cutting Table (2) stationary. Using the Handle (3), lower the Cutting Head to begin cutting. • Using the Handle (3), continue to lower the Cutting Head until the cut is complete. Cutting Head 2 • BX-4 When the cut is complete, release the Trigger Switch.
SETUP, ADJUSTMENT & OPERATION 4. CUTTING WITH THE CUTTING HEAD LOCKED DOWN: This method is preferred when cutting small objects. 3 • Set adjustable depth control by depressing button on 14 side of control (1) and moving Depth Control Screw (2) up or down to desired postion. Fine adjustments can be made by turning depth control screw. Tighten Tri-Knob (3) to hold Cutting Head in position. 1 2 5 4 3 2 1 1 • 2 3 4 5 6 Hold work in position, depress trigger to start motor.
SETUP, ADJUSTMENT & OPERATION 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. • Loosen the knob (1) and remove the Adjustable Cutting Guide (2). • Reposition the Adjustable Cutting Guide (2) by aligning it at 45 degrees to slots on the Ruler/Stop (3). 2 1 2 3 • 2 Position masonry work (4) against the Adjustable Cutting Guide (2) and Ruler/Stop (3).
SETUP, ADJUSTMENT & OPERATION 5. ANGLE CUTS CONTINUED: CAUTION DO NOT FORCE TOOL! It will do the job better and safer at the rate for which it was designed. • Slowly push the masonry work towards the Blade to begin the cut. • Continue to push the masonry work into the Blade until the cut is complete. • Unlock the Trigger Switch. Lock Button • 22 Allow the Blade to stop before removing the work.
SETUP, ADJUSTMENT & OPERATION 6. CLEANUP: WARNING • Always wear eye protection when using compressed air. • Disconnect unit from power supply & unplug GFCI from BX-4. • Pull straight back to remove the Motor Filter Cap (1). • Pull Foam Filter (2) out of the Filter Cap, 1 (Clean Foam Filter by tapping it on a hard surface or by using compressed air to dislodge dirt). • Reinstall the Foam Filter into the Filter Cap. 2 • Align the Filter Cap Retaining Hole with the Spacer Pins (3).
MAINTENANCE & TROUBLESHOOTING MAINTENANCE: 1. GENERAL MAINTENANCE: • The following maintenance should be performed following each use. Use light oil, such as WD-40 or 3-in1 when lubricating parts. • Lubricate the Cutting Head Torsion Spring. Spring Guide Rail • Lubricate the Movable Cutting Table Roller Wheels & Guide Rails. Wheel (4) 2. MONTHLY MAINTENANCE: The following should be performed monthly. Items should be lubricated as directed. • Clean and lubricate Inner Flange (1) and Motor Shaft.
MAINTENANCE & TROUBLESHOOTING 3. BLADE DRESSING: Diamond Blades perform best when dressed. Over time and use, diamonds on the outer edge of the blade 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# 152792) and by following the steps below.
MAINTENANCE & TROUBLESHOOTING 4. DIAMOND BLADE CHANGE-OUT: WARNING Disconnect the tool before servicing and when changing accessories, such as blades, bits, cutters, and the like. 2 • • Remove Retaining Screw (1) and Outer Flange (2): Hold Shaft Wrench (3) stationary. Rotate Retaining Screw counter-clockwise to loosen screw. 3 1 Remove Blade from Motor Shaft. 4 • Seat Blade on the Inner Flange (4) under Blade Guard and onto Motor Shaft. Note the indicated rotation direction.
MAINTENANCE & TROUBLESHOOTING 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 # 133090). • Place Movable Cutting Table on work bench with Roller Wheels up. • Using a 1/2-inch wrench to hold hex nut, hold Roller Wheel rotating nut stationary, rotate the Roller Wheel counter-clockwise with 3/16” hex key wrench to remove.
MAINTENANCE & TROUBLESHOOTING 6. PROTECTIVE WOODEN STRIP REPLACEMENT: The protective wooden strip is provided 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 # 156427). Place Movable Cutting Table on work bench with Roller Wheels facing upwards.
MAINTENANCE & TROUBLESHOOTING 4. Motor-Brush REPLACEMENT: WARNING Disconnect the tool before servicing and when changing accessories, such as blades, bits, cutters, and the like. • Insert a screwdriver into the Motor Brush Cap. Rotate counter-clockwise and remove the Cap. Repeat on the other side of the Motor. • Remove the Motor Brush. Clean the Brush Housing of all carbon dust and fragments. • Align a new Motor Brush with the Brush Housing. Insert the new Motor Brush.
MAINTENANCE & TROUBLESHOOTING TROUBLESHOOTING: WARNING Verify the Lockable Switch is unlocked and the saw is disconnected from the power source before performing any troubleshooting procedure. 1. MOTOR STOPS TURNING: Step A: Verify all plugs are fully connected. If connected, proceed to Step B. Step B: Check that the Ground Fault Circuit Interrupter (GFCI) is tripped. If GFCI is tripped, reset and restart the BX-4 once. If GFCI is not tripped, proceed to Step C.
MAINTENANCE & TROUBLESHOOTING 2. BLADE WILL NOT CUT PROPERLY: Step A: Check for smoothness or “glazing”. If “glazed,” dress Blade. See Blade Dressing section. If not “glazed,” proceed to Step B. Step B: Check for proper rotation. If rotation is not correct, reposition the Blade. If rotation is correct, proceed to Step C. Step C: Ensure the Blade core is not bent. If core is bent, change Blade. If core is not bent, proceed to Step D.
MAINTENANCE & TROUBLESHOOTING 3. MOVABLE CUTTING TABLE DOES NOT MOVE CORRECTLY: 1 Step A: Check that the Guide Rails (1) are clean. If dirty, clean the rails. If clean, proceed to Step B. 2 Step B: Check for Roller Wheel (2) damage. If damaged, replace the Roller Wheels. If not damaged, proceed to Step C. Step C: Verify the correct Blade is being used of the material. Contact the place of purchase or MK Diamond (800) 421-5830 for additional assistance.
MISTING SYSTEM OPERATION, MAINTENANCE & TROUBLESHOOTING CAUTION Do Not Run Pump Dry. Pump damage may result if adequate water flow is not present. 4 OPERATION: Pump, tubes, fittings & nozzles are pre-installed & inspected at factory. Set-up cutting with dust suppression system is accomplished by filling up Water Tank, Closing Cap, & pushing Tube into Push-to-Connect Coupling (6). 3 1 2 5 Step A: Fill up water tank with fresh clean water.
MISTING SYSTEM OPERATION, MAINTENANCE & TROUBLESHOOTING CAUTION Disconnect unit from power supply. Replacement of Nozzles: Step A: Remove tube cover (1) by loosening 2 screws on both side of blade guard with a phillips screw driver. 1 Step B: Remove blade. Blade Guard Step C: Remove 2 retaining rings which hold nozzles in place from the inner side of blade guard. Step D: Loosen nozzles by rotating counter-clockwise. Step E: Install new nozzles.
MISTING SYSTEM OPERATION, MAINTENANCE & TROUBLESHOOTING CAUTION Disconnect unit from power supply. Replacement of Pump: Step A: Using 4 mm hex key, remove 4 Pump cover Retaining Screws. Step B: Remove pump cover (1). 1 Cutting Head Step C: Disconnect electric terminals from pump. Remove tubes from both ends of pump. (Visually inspect tube condition. Replace tubes, if necessary). Step D: Re-connect electric terminals & tubes to pump. Step E: Secure tubes with tube clamps.
MISTING SYSTEM TROUBLESHOOTING No Mist: Step A: Check Pump Switch & Saw are on. Step B: Remove Nozzle & inspect. Nozzle should be open & free of all debris Step C: Inspect water intake filter. Ensure filter is free of excess debris & water in container is clean. Step D: Ensure tubing is undamaged & free of kinks or sharp bends. Step E: Check tubing connectors to ensure tubing is fully inserted in connector. Step F: Check Pump to ensure it is operating properly. If not, contact MK Diamond.
S Tsung Digitally signed by S Tsung DN: CN = S Tsung, C = US, O = MK Diamond Products, OU = Engineering Date: 2008.02.
6 22 21 24 3 1 23 2 31 30 28 29 32 18 17 4 19 14 15 20 10 16 13 11 8 5 7 9 25 26 27 12 ASSEMBLY FINAL (WITHOUT MISTING COMPONENTS) BX-4
PART LIST, ASSEMBLY, FINAL ASSY,FINAL (WITHOUT MISTING KIT #165013-MK) 007 BX-4 ITEM NO. PART NUMBER DESCRIPTION QTY.
22 21 16 20 18 19 17 14 2 15 14 9 8 7 7 1 23 6 12 10 28 11 25 27 6 5 4 26 24 3 13 ASSEMBLY, CUTTING HEAD BX-4
PART LIST, ASSEMBLY, CUTTING HEAD (P# 166238) ASSY, CUTTING HEAD I TEM N O. PART NUMBER DES CRIPT ION Q TY.
PARTS & LIST 8 7 6 1 7 6 2 5 4 3 3 4 1 2 ASSY, HANDLE (P#166237) 5 MOTOR & ACCESSORIES (P#166232) ITEM NO. PART NUMBER DES CRIPT ION Q T Y. 1 16 4 6 6 7 HANDLE, LOWER 1 IT E M N O . PA R T N U M BER D E S C R IP T IO N Q TY.
ASSEMBLY THE WHOLE FRAME & PART LIST 9 6 2 4 6 8 7 5 7 8 4 5 3 1 3 1 ASSY, LEFT FRAME 2 (P#166235) IT E M N O . PA R T N U M BER D E S C R IP T I O N Q T Y. 1 164649 FRA M E, LEFT 1 2 164722 PLA TE, RA IL SUPPO RT 1 3 164651 STA N D O FF, RA IL 7 4 164650 RA IL, STEEL 5 164774 6 164655 ASSY, RIGHT FRAME (P#166234) ITEM NO. PART NUMBER DESCRIPTION Q TY.
ASSEMBLY TABLE, TABLE LOCK & PART LIST 9 8 5 (P#166233) ASSY, TABLE 1 I TEM NO. PART NUMBER DES CRIP TION Q T Y. 1 164636 TABLE 1 2 164637 FENCE, TABE 1 3 164772 SCREW, PAN HD PHIL, M6x16mm 4 4 133090 WHEEL, ROLLER 4 5 164641 STRIP, WOOD 1 6 164797 W ASHER, TOOTH LOCK EXT, M4 2 7 164796 SCREW, WOOD, M4x20mm 2 8 164760 PIN, GUIDE 1 9 166239 KIT, TABLE LOCK 1 4 2 3 6 7 2 1 ASSY, RIP GUIDE (P#166230) ITEM NO . PART NUMBER D ESC RIP TION Q TY .
ZONE REV. DESCRIPTION DATE - INITAIL RELEASE 11/18/07 APPROVED ST A ITEM 7, NOZZLE P#164699-100 WAS 164699 3/3/08 ST ASSEMBLY MISTING SYSTEM & PART LIST 11 10 4 6 8 9 7 5 9 3 5 3 2 1 MODULE, MISTING ITEM NOPART . PA RT NU MBER ITEM NO. NUMBER QTY. QTY. VENDOR PART NUMBER 1 260515000 1 1 164703 164703 OVERTUBE , PLASTIC TUBE COVER, C PLASTIC 1 2 2 3 3 164704 164704 TUBING, TPVC, UBIN1/4x3/16x3.55" G, PVC, 1/4x3/16x3.
ASSEMBLY MISTING SYSTEM WATER TANK & PART LIST 4 6 5 3 2 9 1 7 8 10 (P#165013-MK) KIT, MISTING 46 ITEM NO. PART NUMBER DESCRIPTION Q TY. 1 16 6 2 4 0 MODULE, MISTING 1 2 16 5 0 0 8 TUBING, POLYURETHANE, 3/8x.245x19 1 3 164693 PUMP 1 4 16 5 0 0 5 TUBING, POLYURETHANE, 3/8x.
THEORY THEORY OF DIAMOND BLADES Diamond blades do not really cut; they grind the material through friction. Diamond crystals, often visible at the leading edge and sides of the rim/segment, remove material by scratching out particles of hard, dense materials, or by knocking out larger particles of loosely bonded abrasive material. This process eventually cracks or fractures the diamond particle, breaking it down into smaller pieces.
ACCESSORIES, ORDERING & RETURN INFORMATION ACCESSORIES: ITEM 48 NUMBER DESCRIPTION 1. 157957 MK-BX10, Dry Cutting 14” Segmented Blade 2. 157944 MK-BX30, Dry Cutting 14” Segmented Block Blade 3. 231276 Adjustable Cutting Guide 4. 133090 Roller Wheel 5. 156427 Protective Wooden Strip 6. 157729 Motor Air Filter 7. 152610 Ground Fault Circuit Interrupter 8.
ACCESSORIES, ORDERING & RETURN INFORMATION ORDERING INFORMATION: 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.
BX-4 MK Diamond Products, Inc. BRICK SAW WITH MISTING DUST CONTROL OWNER’S MANUAL & OPERATING INSTRUCTIONS 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.
