BD BD-1272 User manual

BD-1272 Track Rail Saw
Owner’s & Parts Manual
Caution: Read all safety and
operating instructions before using
this equipment. This manual MUST
accompany the equipment at all times.
04.2013Revision 303
Manual Part No. 165267 Barranca Diamond Products, Inc.
1315 Storm Parkway
Torrance, CA 90501
Toll-Free: [phone]
Phone: [phone]
Fax: [phone]
www.barrancadiamond.com

22
BD-1272 RAIL SAW
We at Barranca Diamond Products want to thank you for selecting the Barranca Diamond BD-1272
Rail Saw. We are certain that you will be pleased with your purchase. Barranca Diamond takes pride
in producing top quality and dependable products for both hobbyists and commercial lapidary users
throughout the world.
Operated correctly, your BD-1272 Rail Saw should provide you with years of quality service. In order to
help you, we have included this owner’s manual. This owner’s manual contains information necessary
to operate and maintain your BD-1272 Rail Saw safely and correctly. Please take the time to familiarize
yourself with the BD-1272 Rail Saw by reading and understanding this manual.
If you should have questions concerning your BD-1272 Rail Saw, please feel free to call Barranca Dia-
mond at [phone] or toll free [phone].
TABLE OF CONTENTS
SAFETY
Safety Precautions 3-6
California Proposition 65 Warning 6
Electrical Requirements & Grounding Instructions 7-9
Warning Labels 10
Product Specications 11
ASSEMBLY
Rail Assembly 12
Rail Assembly Connector 13
Cutting Head Assembly 14
Material Clamps & Alignment 15
Hose Set-up 16
OPERATION, ADJUSTMENT & MAINTENANCE
Plunge Cutting for a 90° Cut 17
Plunge Cutting for a Miter Cut 18
MAINTENANCE
Blade Replacement 19
Filter replacement 20
Roller Wheel Replacement 20-21
EXPLODED VIEW AND PART LIST
Exploded View & Parts List 22-31
WARRANTY, RETURN, & CUSTOMER SERVICE
Warranty & Return & Customer Service 32-34

3
SAFETY PRECAUTIONS
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. In order to prevent injury, the
following safety precautions should be followed at all times!
READ OWNER'S MANUAL BEFORE USE
Before using this equipment, ensure that the person operating this machine has read and
understands all of the instructions in the manual. Precaution is the best insurance against accidents.
Read and understand all safety precautions, messages, warnings and hazard symbols. You are
responsible for your own safety.
ALWAYS USE SAFETY GLASSES
Safety glasses should always be worn when working around power tools. In addition, a face, dust
mask or respirator should be worn if a cutting operation is dusty. Everyday eyeglasses only have
impact resistant lenses and may not prevent eye injury - they are NOT safety glasses.
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.
Hand protection (plastic gloves) and a shop bib are recommended during sawing to prevent stains
to clothing. Avoid prolonged exposure of skin to the sawing lubricant and wash skin immediately
after contact. Do not touch the work material until the motor is off and the machine has come to a
complete stop.
ALWAYS USE HEARING PROTECTION
To reduce the possibility of hearing loss, always use hearing protection when operating power
equipment.
KEEP GUARDS IN PLACE
In order to prevent injury, never operate the saw without the 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.
ELECTRICAL SHOCK
Never touch electrical wires or motor components while the motor is running. Exposed, frayed or
worn electrical wiring and plugs can be sources of electrical shock that could cause severe injury or
burns.
DISCONNECT TOOLS
Power tools should always be disconnected before servicing or when changing accessories, such as
blades, bits, cutters and the like.
BD-1272 RAIL SAW SAFETY

4
BD-1272 RAIL SAW SAFETY
REDUCE THE RISK OF UNINTENTIONAL STARTS
Make sure the ON/OFF switch is in the OFF position before plugging in a power tool.
ROTATING OR MOVING 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.
MAINTAIN TOOLS WITH CARE
Keep tools clean for the best and safest performance. Always follow maintenance instructions for
lubricating and when changing accessories.
KEEP WORK AREA CLEAN
Cluttered work areas and benches invite accidents.
DO NOT USE IN DANGEROUS OR HAZARDOUS ENVIRONMENTS
Do not operate equipment in dangerous or hazardous environments. Do not use power tools in
damp or wet locations nor expose them to rain. Always keep the work area well lighted. Always work
in a well ventilated area.
KEEP CHILDREN AWAY
All visitors and children should be kept a safe distance from the work area. Keep power cords
disconnected when tool is not in use.
MAKE THE WORKSHOP KID-PROOF
Make the workshops kid-proof by using padlocks, master switches and by disconnecting all power
cords.
USE THE RIGHT TOOL
Do not force a tool or an attachment to do a job that it was not designed to do.
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 FORCE THE TOOL
A power tool will do a better job and operate more safely at the feed rate for which it was designed.
USE THE RIGHT TOOL TO SERVICE THE SAW
Do not force a tool or an attachment when servicing or operating this power tool. Use the correct
tools for service or adjustments.
DO NOT OVERREACH
Keep proper footing and balance at all times by not overreaching.
DO NOT OPERATE A TOOL WHEN TIRED
When tired, take a break and relax.

5
BD-1272 RAIL SAW SAFETY
DIRECTION OF FEED
All blades, grinding wheels or polishing belts should always be installed such that rotation is in the
direction of the arrow imprinted on the blade, wheel or belt.
ONLY OPERATE AT THE PROPER SPEED
Severe personal injury and damage to the motor or equipment can result if operated at speeds
above maximum.
NEVER LEAVE A TOOL RUNNING UNATTENDED – TURN POWER OFF
Do not leave a tool until it comes to a complete stop. Always turn the tool off, and disconnect
the power cord to its source, when leaving the work area or when work is finished. Do not leave
extension cords attached to the power cord or power receptacle (wall outlet) when leaving the work
area.
CHECK FOR DAMAGED OR WORN PARTS
Before using a power tool, check for damaged parts. A guard or any other part that is damaged
should be carefully checked to determine if it 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.
USE RECOMMENDED ACCESSORIES AND PARTS
Consult the owner’s manual for recommended accessories and parts. Using improper parts and
accessories may increase the risk of personal and/or bystander injury.
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. The table on
page 8, shows the correct AWG (American Wire Gauge) size to use depending on cord length and
nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number,
the heavier the cord.
USE THE PROPER POWER SOURCE
This tool is only to be used with a 120 volt 60 HZ power source. Ensure power source is at least 15
amps and 110 to 120 volts. Low voltage current can adversely effect electric motor performance and
overall life.
USE THE RECOMMENDED COOLING AND LUBRICATING FLUIDS
Never operate a tool dry that requires coolant or lubricant. This can lead to shortened tool life, tool
damage and personal injury.
MAINTAIN TOOLS
Keep the diamond blade sharp, the sawing lubricant clean and reservoir filled to the correct level
for the best and safest performance. Always follow the maintenance instructions for sharpening the
blade, lubricating and servicing the saw.

6
Sawing and drilling generate 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).
WARNING
CALIFORNIA PROPOSITION 65 MESSAGE
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities con-
tain 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, cement and other masonry products
•Arsenic and chromium, from chemically treated lumber
For further information, consult the following sources:
http://www.osha.gov/dsg/topics/silicacrystalline/index.html
http://www.cdc.gov/niosh/docs/96-112/
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 dust masks that are specially designed to lter out microscopic particles. Where
use of a dust extraction device is possible, it should be used. To achieve a high level of dust collec-
tion, use an industrial vacuum cleaner.
SILICA DUST WARNING
Grinding/cutting/drilling of masonry, concrete, metal and other materials with silica in their composition
may give off dust or mists containing crystalline silica. Silica is a basic component of sand, quartz,
brick clay, granite and numerous other minerals and rocks. Repeated and/or substantial inhalation of
airborne crystalline silica can cause serious or fatal respiratory diseases, including silicosis. In ad-
dition, California and some other authorities have listed respirable crystalline silica as a substance
known to cause cancer. When cutting such materials, always follow respiratory precautions.
Use appropriate NIOSH-approved respiratory protection where dust hazard may occur. Paper masks
or surgical masks without a NIOSH approval number are not recommended because they do little to
protect the worker. For more information about respirator programs, including what respirators have
received NIOSH approval as safe and effective, please visit the NIOSH website at:
http://www.cdc.gov/niosh/topics/respirators
Observe OSHA regulations for respirator use (29 C.F.R.§1910.134 and §1503.1).
Visit http://www.osha.gov for more information.
ON
(
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BD-1272 RAIL SAW SAFETY

7
BD-1272 RAIL SAW 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!
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 fit the outlet; have the proper outlet installed by a
qualified electrician.
• Improper connections of the equipment-grounding conductor can result in a risk of electric shock.
The equipment-grounding conductor is the wire that has a green outer surface, 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 qualified 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.
This tool is intended for use on a circuit that has an
outlet that looks like the one shown in Sketch A of
(Figure 1). The tool has a grounding plug that looks
like the plug illustrated in Figure 1. 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
qualified electrician. The green-colored rigid ear, plug,
and the like, extending from the adapter, must be
connected to a permanent ground such as a properly
grounded outlet box.
To reduce the risk of electrocution, keep all connections dry and off the ground.
A Ground Fault Circuit Interrupter (GFCI) should be provided on the circuit(s) or outlet(s) to be used
for this machine. Receptacles are available, having built-in GFCI protection, and may be used for this
measure of safety.
Figure 1
NOTE: Use of a temporary adapter is not permitted in Canada.
Grounding
Means
(A)
Metal Screw
Cover of
Grounded
Outlet Box
(D)
ADAPTER
(C) Grounding
Pin
Grounding
Pin (B)

8
BD-1272 RAIL SAW SAFETY
ELECTRICAL REQUIREMENTS AND GROUNDING INSTRUCTIONS (continued)
To avoid the possibility of the appliance plug or receptacle getting wet, position the saw to one side
of a wallmounted 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.
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.
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 form the extension cord.
To reduce the risk of electrocution, keep all connections dry and off the ground. Do not touch the plug
with wet hands.
Use of under-sized extension cords result in low voltage to the motor that can result in motor burnout
and premature failure. Barranca 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.
Supporting
Surface
Power
Tool
Drip Loop
Power
Cord
Figure 2: Drip Loop
EXTENSION CORD LENGTH
Nameplate
Amperes
115V 25' 50' 75' 100' 150' 200'
250V 50' 100' 150' 200' 300' 400'
0 - 5 16 16 16 14 12 12
5.1 - 8 16 16 14 12 10 •
8.1 - 12 14 14 12 10 • •
12.1 - 15 12 12 10 10 • •
15.1 - 20 10 10 10 • • •

9
BD-1272 RAIL SAW SAFETY
The BD-1272 Rail Saw is equipped with a number of safety decals. These decals are provided for
operator safety and maintenance information. The illustration below also shows the location of these
decals. Should any of these operation or safety decals become unreadable, replacements can be
obtained by calling [phone].
OPERATION & SAFETY DECALS
D & F
(behind)
A
Figure 1. Safety Decal Sheet, Part No. 166011
C
B
E
SERVICE OR
WARRANTY
FOR INFORMATION ON
PLEASE CALL
1-800-474-5594
Most motor problems are caused by improper
voltage and extension cords. Cord should be
one-piece and short as possible. Cord
selection should match the following table.
1-2 H.P.
25’
50’
75’
100’
150’
250’
Max. Cord Length
Max. Cord Length
Max. Cord Length
No. 12 Wire
No. 10 Wire
No. 8 Wire
115v 230v
NOTICE
!
WARNING
Grinding/cutting/drilling of masonry, concrete, metal and other materials with silica in
their composition may give off dust or mists containing crystalline silica. Silica is a basic
component of sand, quartz, brick clay, granite and numerous other minerals and rocks.
Repeated and/or substantial inhalation of airborne crystalline silica can cause serious
or fatal respiratory diseases, including silicosis. In addition, California and some other
authorities have listed respirable crystalline silica as a substance known to cause cancer.
!
CAUTION
DO NOT
operate without
guards in place.
!
DO NOT operate
this equipment
before reading
the owner’s
manual!
WARNING
!
This saw is to be used
with a Ground Fault
Circuit Interrupter.
!CAUTION
Decal A
Decal C
Decal D
Decal E
Decal F
Decal B

10
BD-1272 RAIL SAW PRODUCT SPECIFICATIONS
• Adjustable height plunge-cutting head
• Lightweight precision extruded aluminum rails provide accurate and even tracking during all
cutting operations
• Rails have replaceable slip-on pads to protect material surface from scratches
• Precision, maintenance-free bearings provide smooth and reliable tracking of the cutting head
• Replaceable dust lter
• Valve controlled water feed
• 72” 120V standard U-ground electrical cord
• Saw comes complete with two sets of 72” rail, rail connector plate, 12” blade capacity cutting
head, two hold-down clamps and standard garden hose water connector
• Additional rails for extending cutting capacity sold separately
BD-1272 Saw Specications
Model 164920
Motor 120V 50/60 Hz
Amps 15
Horsepower 1-3/4” HP
Blade RPM 3,500
Blade Capacity 12” (254 mm)
Arbor Size 1” (25.4 mm)
Standard Length of Cut 130” (3,202mm)
Maximum Depth of Cut 2-7/8” (73mm)
Depth of Cut at 45º 2-1/4 (57mm)
Weight 95 lbs. (43kgs.)
Dimensions (LxWxH) - inches 144” x 16” x 13”
Dimensions (LxWxH) - millimeters 3,658 x 406 x 330

11
BD-1272 RAIL SAW ASSEMBLY
1. Lay Rails (A & B) on a at and leveled surface.
2. Align ends of Rails.
3. Slide Parallel Rail Support Brackets (C) from both ends of rail.
4. Tighten screws until Brackets hold Rails rmly in place (D).
5. Repeat Step 1 through 4 if a length of more than 6 feet is needed.
A
B
C
D
C
D
Rail Assembly

12
BD-1272 RAIL SAW ASSEMBLY
Rail Assembly Connector
1. Slide the Rail Assembly (A) into the Connector Plate Assembly (B).
2. Tighten screws (C) lightly until connector plate is rmly seated.
3. Slide the other half of the Rail Assembly (D) into the Rail Connector Assembly (B).
4. Fully tighten screws.
A
B
A
D
D
C
The Rail Connector Assembly is required to hold two Rail Assemblies together.

13
BD-1272 RAIL SAW ASSEMBLY
Cutting Head Assembly
1. Place the Rail Assembly (B) on slab.
2. Slide the Cutting Head Assembly (A) until the Carrier Wheels (C) are over Rail Assembly (B).
3. Move the Cutting Head Assembly along the Rail Assembly with a sliding motion.
A
B
WARNING
C
Ensure that the power is disconnected before installing the Cutting Head Assembly to Rails.
The Cutting Head Assembly is pre-assembled and aligned at the factory.

14
BD-1272 RAIL SAW ASSEMBLY
Material Clamps & Alignment
1. Position Saw Assembly (A) on the slab. The inner side of the blade is approximately 6.25 inches
from the top edge of the aluminum rail.
2. Slide the Material Clamps from both ends of the Rail Assembly until the Clamp Foot (B) is
underneath the slab.
3. Tighten screws (C) until the Saw Assembly is secured to the slab without any side movement.
4. To realign the Rail Assembly, slightly loosen the Material Clamps. Realign the Rail Assembly by
tapping the ends of the Rail Assembly.
5. Repeat Steps 3 and 4 if realignment is necessary.
A
C
B
WARNING
Ensure that the electrical cord is not connected before assembling and aligning material clamps.

15
Hose Set-Up
1. Connect Plastic Fitting (A) to Nipple (B).
2. Connect Hose Fitting (C) to Water Hose.
B
AC
BD-1272 RAIL SAW SET-UP

16
A
B
CAUTION
Always use a Grounded Fault Circuit Interrupter (GFCI) with this saw.
Plunge Cutting for a 90˚ Cut
1. Loosen the Tri-Knob (A). Raise the blade to the highest position and move the Saw Assembly to
the beginning of the cut.
2. Adjust the Valve (B) for the desired amount of water ow.
3. Depress motor switch and lower the blade slowly into the material.
4. Tighten the Tri-Knob (A) once the blade cuts through the material. Follow the direction of the cut.
BD-1272 RAIL SAW OPERATION

17
Plunge Cutting for a Miter Cut
1. Loosen the Round Knob (A) and adjust the blade to the desired angle (0-45 degrees). Tighten
the Round Knob. Recheck the set angle along the entire rail system.
2. Loosen the Tri-Knob (B). Raise the blade to the highest position and move the Saw Assembly to
the beginning of the cut.
3. Adjust the Valve (C) for the desired amount of water ow.
4. Depress motor switch and lower the blade slowly into the material.
5. Tighten the Tri-Knob (B) once the blade cuts through the material. Follow the direction of the cut.
B
A
C
BD-1272 RAIL SAW OPERATION

18
T
U
R
N
WARNING
Always disconnect the unit from the power supply.
Blade Replacement
1. Remove knobs on outer blade guard.
2. Remove the Blade Guard.
3. Use the open wrenches provided with this unit. Place wrench (A) over the ats on blade shaft
(located on the inner side of the blade). Hold the wrench stationary. Place wrench (B) on the Hex
Screw at the end of the blade shaft. Turn wrench (B) counter-clockwise to remove the screw.
4. Replace the blade and ensure that the blade is oriented with the arrow in a counterclockwise
position. Tighten the screw clockwise to secure the new blade.
5. Rotate the blade by hand to check it for tightness.
AB
BLADE
INNER GUARD
BD-1272 RAIL SAW MAINTENANCE

19
Filter Replacement
1. Pull Filter Cap (A) off.
2. Replace Filter.
3. Snap Filter Cap back on.
A
Roller Wheel Replacement
1. Remove the Hex Screws (A) and Round Knob (B).
2. Remove Motor and Blade Guard Assembly from the Carrier Assembly.
3. Remove Carrier Assembly from the Rail Assembly. Place the Carrier Assembly on a at and
level surface.
A
A
B
WARNING
Disconnect the unit from the power supply.
BD-1272 RAIL SAW MAINTENANCE

20
Roller Wheel Replacement Continued
4. Unscrew the wheel(s) with a 3/16 hex key. Ensure that the eccentric bushings (A) and straight
bushings (C), located in the middle of each carrier casting, do not move.
5. Install new wheels by screwing into bushings.
6. Slide the Carrier Assembly back in the rail to check for wheel alignment.
7. If carrier assembly does not line up with rails, loosen set screw(s) (B) located on the bottom of
carrier legs.
8. Align straight bushing(s) (C) so groove on wheel is centered on rail rib. Hold bushing in place while
tightening set screw. DO NOT FULLY TIGHTEN AT THIS TIME.
A
C
CC
A
B
BD-1272 RAIL SAW MAINTENANCE