Baileigh Industrial TN-800 User manual

OPERATOR’S MANUAL
TUBE AND PIPE NOTCHER
MODEL: TN-800 (B8550)
© 2015 Baileigh Industrial, Inc.

Table of Contents
INTRODUCTION............................................................................................................. 1
GENERAL NOTES.......................................................................................................... 1
SAFETY INSTRUCTIONS .............................................................................................. 2
SAFETY PRECAUTIONS ............................................................................................... 5
TECHNICAL SPECIFICATIONS..................................................................................... 7
UNPACKING AND CHECKING CONTENTS.................................................................. 8
Cleaning ...................................................................................................................... 8
TRANSPORTING AND LIFTING .................................................................................... 9
INSTALLATION............................................................................................................... 9
ASSEMBLY AND SET UP ............................................................................................ 10
GETTING TO KNOW YOUR MACHINE ....................................................................... 11
ELECTRICAL................................................................................................................ 13
Plug Connection ........................................................................................................ 14
OPERATION................................................................................................................. 15
Cutter Selection......................................................................................................... 15
Material Insertion ....................................................................................................... 16
Setting Offset............................................................................................................. 17
Notching .................................................................................................................... 18
Angle Notching .......................................................................................................... 18
Repeat Notching........................................................................................................ 19
Material Removal....................................................................................................... 19
Off-Center Notching................................................................................................... 19
MATERIAL SELECTION............................................................................................... 20
STANDARD PIPE SIZES AND SCHEDULES TABLE .................................................. 20
TROUBLESHOOTING .................................................................................................. 21
ELECTRICAL SCHEMATIC.......................................................................................... 22
LUBRICATION AND MAINTENANCE .......................................................................... 23
Oil Disposal ............................................................................................................... 23
Storing Machine for Extended Period of Time ........................................................... 23
PARTS DIAGRAM ........................................................................................................ 24
Base Assembly.......................................................................................................... 24
Spindle Assembly...................................................................................................... 25
Forward Riser Assembly ........................................................................................... 26
Motor and Gearbox Assembly ................................................................................... 27
Rear Riser Assembly................................................................................................. 28
Crank Shaft Assembly ............................................................................................... 29
Vise Assembly........................................................................................................... 30
Slide Base Assembly................................................................................................. 31
Parts List ................................................................................................................... 31

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1
INTRODUCTION
The quality and reliability of the components assembled on a Baileigh Industrial machine
guarantee near perfect functioning, free from problems, even under the most demanding working
conditions. However if a situation arises, refer to the manual first. If a solution cannot be found,
contact the distributor where you purchased our product. Make sure you have the serial number
and production year of the machine (stamped on the nameplate). For replacement parts refer to
the assembly numbers on the parts list drawings.
Our technical staff will do their best to help you get your machine back in working order.
In this manual you will find: (when applicable)
•Safety procedures
•Correct installation guidelines
•Description of the functional parts of the machine
•Capacity charts
•Set-up and start-up instructions
•Machine operation
•Scheduled maintenance
•Parts lists
GENERAL NOTES
After receiving your equipment remove the protective container. Do a complete visual
inspection, and if damage is noted, photograph it for insurance claims and contact your
carrier at once, requesting inspection. Also contact your distributor and inform them of the
unexpected occurrence. Temporarily suspend installation.
Take necessary precautions while loading / unloading or moving the machine to avoid any
injuries.
Your machine is designed and manufactured to work smoothly and efficiently. Following proper
maintenance instructions will help ensure this. Try and use original spare parts, whenever
possible, and most importantly; DO NOT overload the machine or make any unauthorized
modifications.

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2
Note: This symbol refers to useful information throughout the manual.
LEARN TO RECOGNIZE SAFETY INFORMATION
This is the safety alert symbol. When you see this symbol on
your machine or in this manual, BE ALERT TO THE
POTENTIAL FOR PERSONAL INJURY!
Follow recommended precautions and safe operating
practices.
UNDERSTAND SIGNAL WORDS
A signal word – DANGER, WARNING, or CAUTION
is used with the safety alert symbol. DANGER
identifies a hazard or unsafe practice that will result in
severe Injury or Death.
Safety signs with signal word DANGER or WARNING are
typically near specific hazards.
General precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety messages in this
manual.
IMPORTANT
PLEASE READ THIS OPERATORS MANUAL CAREFULLY
It contains important safety information, instructions, and necessary operating
procedures. The continual observance of these procedures will help increase your
production and extend the life of the equipment.
SAFETY INSTRUCTIONS

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3
SAVE THESE INSTRUCTIONS.
Refer to them often and use them to instruct others.
PROTECT EYES
Wear safety glasses or suitable eye protection
when working on or around machinery.
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment or loss of
hearing. Wear suitable hearing protective devices such as ear muffs or
earplugs to protect against objectionable or uncomfortable loud noises.
BEWARE OF PINCH POINTS
Keep hands and fingers away from the slide plate and pivot points
when operating on and around this machine. Keep chuck guard in
place at all times while the machine is running.
ROTATING TOOL HAZARD
Keep hands and body clear while operating. Rotating
chuck can cut, dismember, snag, and entrap. Flying
chips, splinters, and other particles can cause serious
injury or death.

4
4
BEWARE OF PIERCING POINTS
NEVER place Keep hands, fingers, or any part of your body away
from rotating tooling bit.
CUTTING HAZARD
Keep hands and fingers away from the rotating cutters. These rotating
cutters can be extremely dangerous if you do not follow proper safety
procedures. NEVER place hands directly over or in front of the
cutter. Keep the tooling guard in place and closed at all times
while operating this machine.
ENTANGLEMENT HAZARD – ROTATING SPINDLE
Contain long hair, DO NOT wear jewelry or loose fitting clothing.

5
5
SAFETY PRECAUTIONS
Metal working can be dangerous if safe and proper operating procedures are not followed. As
with all machinery, there are certain hazards involved with the operation of the product. Using
the machine with respect and caution will considerably lessen the possibility of personal injury.
However, if normal safety precautions are overlooked or ignored, personal injury to the operator
may result.
Safety equipment such as guards, hold-downs, safety glasses, dust masks and hearing
protection can reduce your potential for injury. But even the best guard won’t make up for poor
judgment, carelessness or inattention. Always use common sense and exercise caution in
the workshop. If a procedure feels dangerous, don’t try it.
REMEMBER: Your personal safety is your responsibility.
1. Only trained and qualified personnel can operate this machine.
2. Make sure guards are in place and in proper working order before operating
machinery.
3. Remove any adjusting tools. Before operating the machine, make sure any adjusting tools
have been removed.
4. Keep work area clean. Cluttered areas invite injuries.
5. Overloading machine. By overloading the machine you may cause injury from flying parts.
DO NOT exceed the specified machine capacities.
6. Dressing material edges. Always chamfer and deburr all sharp edges.
7. Do not force tool. Your machine will do a better and safer job if used as intended. DO NOT
use inappropriate attachments in an attempt to exceed the machines rated capacity.
8. Use the right tool for the job. DO NOT attempt to force a small tool or attachment to do the
work of a large industrial tool. DO NOT use a tool for a purpose for which it was not
intended.
9. Dress appropriate. DO NOT wear loose fitting clothing or jewelry as they can be caught in
moving machine parts. Protective clothing and steel toe shoes are recommended when
using machinery. Wear a restrictive hair covering to contain long hair.
WARNING: FAILURE TO FOLLOW THESE RULES MAY RESULT IN
SERIOUS PERSONAL INJURY

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6
10.Use eye and ear protection. Always wear ISO approved impact safety goggles. Wear a full-
face shield if you are producing metal filings.
11.Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or
across a running machine.
12.Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool or
machine when you are tired.
13.Check for damaged parts. Before using any tool or machine, carefully check any part that
appears damaged. Check for alignment and binding of moving parts that may affect proper
machine operation.
14.Observe work area conditions. DO NOT use machines or power tools in damp or wet
locations. Do not expose to rain. Keep work area well lighted. DO NOT use electrically
powered tools in the presence of flammable gases or liquids.
15.Blade adjustments and maintenance. Always keep blades sharp and properly adjusted for
optimum performance.
16.Keep children away. Children must never be allowed in the work area. DO NOT let them
handle machines, tools, or extension cords.
17.Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust.
Always lock up tools and keep them out of reach of children.
18.DO NOT operate machine if under the influence of alcohol or drugs. Read warning
labels on prescriptions. If there is any doubt, DO NOT operate the machine.
19.DO NOT touch live electrical components or parts.
20.Turn off power before checking, cleaning, or replacing any parts.
21.Be sure all equipment is properly installed and grounded according to national, state, and
local codes.
22.Inspect power and control cables periodically. Replace if damaged or bare wires are
exposed. Bare wiring can kill!
23.DO NOT bypass or defeat any safety interlock systems.
24.Keep visitors a safe distance from the work area.

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7
TECHNICAL SPECIFICATIONS
Mill Speed
177rpm
Maximum Notching Capacity
3" Diameter using a 1" end mill (76mm / 25mm)
Minimum Notching Capacity
.5" Diameter using a .5" end mill and .5" reducer bushing
(12mm / 12mm / 12mm)
Angle Adjustment
0 – 60°
End Mill Size
1" Standard / 1/2" Optional (25mm / 12mm optional)
Power
240V, 50hz
Motor
1hp (.75kw)
Shipping Weight
540lbs. (245kg)
Shipping Dimensions
66" x 44" x 60" (1676 x 1118 x 1524mm)
Note: The photos and illustrations used in this manual are representative only and
may not depict the actual color, labeling or accessories and may be intended to illustrate
technique only.
Note: The specifications and dimensions presented here are subject to change
without prior notice due to improvements of our products.

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8
UNPACKING AND CHECKING CONTENTS
Your Baileigh machine is shipped complete in one crate. Separate all parts from the packing
material and check each item carefully. Make certain all items are accounted for before
discarding any packing material.
Cleaning
Your machine may be shipped with a rustproof waxy oil coating and grease on the exposed
unpainted metal surfaces. To remove this protective coating, use a degreaser or solvent
cleaner. For a more thorough cleaning, some parts will occasionally have to be removed. DO
NOT USE acetone or brake cleaner as they may damage painted surfaces.
Follow manufacturer’s label instructions when using any type of cleaning product. After cleaning,
wipe unpainted metal surfaces with a light coating of quality oil or grease for protection.
WARNING:
SUFFOCATION HAZARD! Immediately discard any plastic
bags and packing materials to eliminate choking and suffocation hazards to children
and animals.
If any parts are missing, do not plug in the power cable, or turn the power switch on
until the missing parts are obtained and installed correctly.
WARNING: DO NOT USE gasoline or other petroleum products to clean
the machine. They have low flash points and can explode or cause fire.
CAUTION: When using cleaning solvents work in a well-ventilated area.
Many cleaning solvents are toxic if inhaled.
GAS

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9
TRANSPORTING AND LIFTING
IMPORTANT: Lifting and carrying operations should be carried out by skilled workers,
such as a truck operator, crane operator, etc. If a crane is used to lift the machine, attach the
lifting chain carefully, making sure the machine is well balanced.
Follow these guidelines when lifting with truck or trolley:
•The lift truck must be able to lift at least 1.5 – 2 times
the machines gross weight.
•Make sure the machine is balanced. While
transporting, avoid rough or jerky motion, and maintain
a safe clearance zone around the transport area.
•Use a fork lift with sufficient lifting capacity and forks
that are long enough to reach the complete width of
the machine.
•Remove the securing bolts that attach the machine to
the pallet.
•Approaching the machine from the side, lift the machine on the frame taking care that there
are no cables or pipes in the area of the forks.
•Move the machine to the required position and lower gently to the floor.
•Level the machine so that all the supporting feet are taking the weight of the machine and no
rocking is taking place.
INSTALLATION
IMPORTANT:
Consider the following when looking for a suitable location to place the machine:
•Overall weight of the machine.
•Weight of material being processed.
•Sizes of material to be processed through the machine.
•Space needed for auxiliary stands, work tables, or other machinery.
•Clearance from walls and other obstacles.
•Maintain an adequate working area around the machine for safety.
•Have the work area well illuminated with proper lighting.
•Keep the floor free of oil and make sure it is not slippery.

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10
•Remove scrap and waste materials regularly, and make sure the work area is free from
obstructing objects.
•If long lengths of material are to be fed into the machine, make sure that they will not extend
into any aisles.
•LEVELING: The machine should be sited on a level, concrete floor. Provisions for securing it
should be in position prior to placing the machine. The accuracy of any machine depends on
the precise placement of it to the mounting surface.
•FLOOR: This tool distributes a large amount of weight over a small area. Make certain that
the floor is capable of supporting the weight of the machine, work stock, and the operator.
The floor should also be a level surface. If the unit wobbles or rocks once in place, be sure to
eliminate by using shims.
•WORKING CLEARANCES: Take into consideration the size of the material to be
processed. Make sure that you allow enough space for you to operate the machine freely.
•POWER SUPPLY PLACEMENT: The power supply should be located close enough to the
machine so that the power cord is not in an area where it would cause a tripping hazard. Be
sure to observe all electrical codes if installing new circuits and/or outlets.
ASSEMBLY AND SET UP
1. Remove the machine from the skid it was shipped on and install the casters.
2. Check the oil level and top off if necessary.
3. Read through the remainder of the manual and become familiar with the tool installation and
settings as well as normal operation.
4. Position the machine as desired following the installation guidelines.
5. Follow the electrical guidelines to connect the machine to a power supply.
WARNING: For your own safety, DO NOT connect the machine to the
power source until the machine is completely assembled and you read and
understand the entire instruction manual.

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GETTING TO KNOW YOUR MACHINE
•You have made a practical choice in purchasing a Model TN-800 Eccentric Cut Notching
Machine. It has been carefully built of high quality materials and designed to give many
years of efficient service. The simplicity of design and minimum effort required to operate
the machine contributes towards meeting schedules and producing greater profits.
•The TN-800 is an electric powered end-mill notching machine specially designed to notch a
variety of materials using only one end mill. The Patented Eccentric Cut feature, allows the
user to feed an end mill cutter through an adjustable eccentric path. Creating a perfect weld
joint when mating two or more pieces of tubing together.
•The TN-800 Notching Machine you have purchased is built of solid steel and high quality
components, ensuring maximum rigidity and long life.
A
B
C
D
E
F
G
H
I
J
K
L
M
N

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12
Item
Description
Function
A
Swivel Casters
Steer and control the machine when moving.
B Large Feed Wheel
Rotates the spindle head on the oscillation plate to
create the eccentric pattern used for milling.
C Y Feed Hand Wheel
Used to move the vise bed along the length of the end
mill.
D Vise Pivot Clamp Handle
Release the handle to rotate the vise to the desired
angel. Lock the handle to lock the vise at the desired
angle.
E
X Feed Hand Wheel (far
side not shown)
Used to move the vise bed into and away from the end
mill.
F Vise
Used to hold and secure the material to be notched.
May be rotated to feed the material into the end mill at
an angle from 0° - 45°
G Lexan Guard
Safety cover to covers the mill and milling area during
machining to prevent inadvertent contact.
H
End Mill
Machining tool to create the cut.
I
Spindle
Turns the end mill.
J On/Off Switch
Starts and stops the notcher motor and herby the
notcher.
K
Gear Box
Transfers power from the motor to the spindle.
L
Motor
Powers the notcher for milling.
M
Chip Box
Collets the chips from the cutting process.
N
Wheels
Used to roll the machine to various locations.

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13
ELECTRICAL
Motor Specifications
Your tool is wired for 240 volt, 50Hz alternating current. Before connecting the tool to the power
source, make sure the machine is cut off from power source.
Considerations
•Observe local electrical codes when connecting the machine.
•The circuit should be protected with a time delay fuse or circuit breaker with a amperage
rating slightly higher than the full load current of machine.
•A separate electrical circuit should be used for your tools. Before connecting the motor to the
power line, make sure the switch is in the “OFF” position and be sure that the electric current
is of the same characteristics as indicated on the tool.
•All line connections should make good contact. Running on low voltage will damage the
motor.
•In the event 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.
CAUTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE BY
A CERTIFIED ELECTRICIAN!
Check if the available power supply is the same as listed on the machine nameplate.
WARNING: Make sure the grounding wire (green) is properly connected
to avoid electric shock. DO NOT switch the position of the green grounding wire if any
electrical plug wires are switched during hookup.
WARNING: In all cases, make certain the receptacle in question is
properly grounded. If you are not sure, have a qualified electrician check the
receptacle.

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14
•Improper connection of the equipment-grounding conductor can result in risk of electric
shock. The conductor with insulation having an outer surface that is green with or without
yellow stripes is the equipment-grounding conductor. 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.
•Repair or replace damaged or worn cord immediately.
Extension Cord Safety
Extension cord should be in good condition and meet the minimum wire gauge requirements listed
below:
LENGTH
AMP RATING
25ft
50ft
100ft
1-12
16
16
14
13-16
14
12
12
17-20
12
12
10
21-30
10
10
No
WIRE GAUGE
An undersized cord decreases line voltage, causing loss of power and overheating. All cords
should use a ground wire and plug pin. Replace any damaged cords immediately.
Plug Connection
•Have an electrician install the correct power supply for the application.
•Once hooked up, turn on the power supply and start the machine.

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OPERATION
Cutter Selection
1. Before any notching can take place, the
proper cutter must be chosen. If the material
to be notched is 1" (25.4mm) diameter up to
3" (76.2mm) diameter, the supplied 1"
(25.4mm) cutter will work properly.
2. If the material is smaller than 1" (25.4mm),
then an optional reducer bushing and 1/2"
(12.7mm) diameter cutter must be installed.
(This will notch from 1/2" (12.7mm) up to 1"
(25.4mm) diameter material.
3. To install the cutter, first unplug the power
cord and open the Lexan guard.
4. Loosen the set screws (A) located on the
spindle and insert the desired cutter, align
the flats on the cutter with the holes on the
spindle.
5. Tighten the set screws (A).
CAUTION: Always wear proper eye protection with side shields, safety
footwear, and leather gloves to protect from burrs and sharp edges.
WARNING: BEFORE THE MAIN LEXAN GUARD IS OPENED, THE
POWER CORD MUST BE UNPLUGGED FROM ITS SOURCE.
A

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Material Insertion
1. Once the proper cutter is installed, the
material to be notched can be inserted into
the vise.
2. Open the vise and insert the material so that
the end toward the cutter extends past the
vise jaw approximately 2" (50.8mm).
Material should be kept as close as possible
to the vise jaws to get accurate notches.
3. Tighten the vise.
4. If an angle notch is required, loosen the
cam handle (A) and rotate vise to the
desired angle, not to exceed 45 deg. DO
NOT rotate the vise so that the lead screw
(B) in in front of the end mill.
5. Using the "X" and "Y" hand wheels, position
the material up to the cutter leaving about
1/2" (12.7mm) of clearance between the
cutter and material.
6. The "X" and "Y" Table gibs are set tight from the factory. This is because they are only used
in positioning. The gibs may be loosened; however, this may induce chatter or vibration
when notching material.
7. Position the material as far back (toward the chuck) on the cutter as possible. Visually check
for possible interferences and correct by extending out more material and/or repositioning.
B
A
X
Y

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17
Setting Offset
1. Once the cutter and material are installed,
the cutter offset can be set.
2. If using the 1’ (25.4mm) cutter on 1”
(25.4mm) material or the 1/2" (12.7mm)
cutter on 1/2” (12.7mm) material, set the
machine to the “12 o’clock” position (fine
tune as needed) and move on to setting any
desired angle and notching the material.
Important: Machine must be in
the home or "12 o'clock" position.
3. Do this by rotating the large feed hand
wheel (A) in the counter clockwise direction
until the red pointer lines (B) up with the red
indicator at the 12 o'clock position.
4. At this point all offset adjustments and table
positioning will be made, this is also the start and end point of every notch.
5. On the face of the "V" groove guide plate, there will be (3) 3/4" main bolts (C) which need to
be loosened before the offset screw can be activated.
6. Once the (3) bolts are loose, use the 5/8”
wrench included to adjust the offset screw
(D) until the desired notch diameter is
displayed on the scale (E).
Note: The scale readings are
based on using 1" diameter cutter.
7. After the offset is reached, tighten the (3)
main bolts. VERY IMPORTANT!
8. Be sure nothing is in contact with the cutter
and reconnect the power cord.
C
B
A
D
E

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18
Notching
1. Activate the start switch making sure the cutter is rotating the correct way. With the cutter
rotating, the notch can be created.
2. Using the large feed hand wheel, slowly rotate in the counter clockwise direction. As the
cutter makes contact with the material, continue to rotate feeding slow enough not to
damage the cutter. The cutter control shaft is equipped with a 1-way clutch which prevents
the cutter from being turned in the counterclockwise direction.
3. Once the cutter passes completely through the material, continue to rotate the hand wheel
until the red pointer lines up with the red indicator pin at the 12 o’clock position.
4. If the material needs to be notched deeper, advance the "X" hand wheel, moving the
material closer toward the cutter, repeat these steps until the desired notch depth is
achieved.
5. Alternate depth notch, if you know how deep you need to notch, mark that depth on the
material. Rotate the red indicator to the 6' o'clock position, then feed with the "X" handwheel
until the cutter reaches the mark, Then make one complete revolution to complete the notch.
Angle Notching
To notch at an angle, the vise needs to be
rotated left or right. For small angles, rotating to
the right is ok, but for large angle, rotating the
vise to the left is preferred.
IMPORTANT: Never rotate the vise to
the right so that the lead screw is in front of the
end mill. The vise could be inadvertently moved
into the end mill damaging the vise, end mill
and possibly the spindle.
1. Precut the material to the desired angle
prior to notching. This will create an edge
that is parallel to the end mill.
2. Loosen the vise pivot lock handle and rotate
the vise to the desired angle and lock the
pivot handle.
3. Load the material into the vise similar to a square end cut and proceed with the milling.
A