Baileigh Industrial BR-16E-36LT User manual

OPERATOR’S MANUAL
LOWER THROAT METAL BEAD ROLLER
MODEL: BR-16E-36LT (B8680)
© 2016 Baileigh Industrial, Inc.
Rev. 12/2016

Table of Contents
INTRODUCTION............................................................................................................. 1
GENERAL NOTES.......................................................................................................... 1
SAFETY INSTRUCTIONS .............................................................................................. 2
SAFETY PRECAUTIONS ............................................................................................... 4
Dear Valued Customer:................................................................................................... 4
TECHNICAL SPECIFICATIONS..................................................................................... 6
UNPACKING AND CHECKING CONTENTS.................................................................. 7
Cleaning ...................................................................................................................... 7
TRANSPORTING AND LIFTING .................................................................................... 8
INSTALLATION............................................................................................................... 9
ELECTRICAL................................................................................................................ 10
GENERAL BEAD ROLLING ......................................................................................... 12
ROLLER INSTALLATION AND REMOVAL .................................................................. 12
OPERATION................................................................................................................. 13
Controls ..................................................................................................................... 13
Rolling ....................................................................................................................... 13
Offsetting the Rolls .................................................................................................... 15
Support Tray.............................................................................................................. 16
MATERIAL SELECTION............................................................................................... 17
UNDERSTANDING SPRINGBACK .............................................................................. 17
LUBRICATION AND MAINTENANCE .......................................................................... 18
OPTIONAL TOOLING AVAILABLE............................................................................... 19
FRAME ASSEMBLY ..................................................................................................... 21
SHAFT HOUSING ASSEMBLY .................................................................................... 22
LOWER SHAFT ASSEMBLY........................................................................................ 23
CAM HOUSING ASSEMBLY ........................................................................................ 24
INTERMEDIATE SHAFT ASSEMBLY .......................................................................... 25
TOP SHAFT ASSEMBLY.............................................................................................. 26
BEARING BLOCK ASSEMBLY..................................................................................... 27
FENCE ASSEMBLY...................................................................................................... 28
Parts List ................................................................................................................... 29

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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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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 rolls when the machine is in
operation.
Keep hands and fingers clear of any gears or mechanisms. Make
sure guard is in place before operating machine.
BEWARE OF PINCH POINTS AND CRUSH HAZARD
Keep hands and fingers from between the roller and die when
bending materials to avoid possible injury.
NEVER place your hands, fingers, or any part of your body in the
die area of this machine.

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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.
Dear Valued Customer:
•All Baileigh machines should be used only for their intended use.
•Baileigh does not recommend or endorse making any modifications or alterations to a
Baileigh machine. Modifications or alterations to a machine may pose a substantial risk of
injury to the operator or others and may do substantial damage to the machine.
•Any modifications or alterations to a Baileigh machine will invalidate the machine's warranty.
PLEASE ENJOY YOUR BAILEIGH MACHINE!....PLEASE ENJOY IT SAFELY!
1. FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE OPERATING THE
MACHINE. Learn the machine’s application and limitations as well as the specific hazards.
2. Only trained and qualified personnel can operate this machine.
3. Make sure guards are in place and in proper working order before operating
machinery.
4. Remove any adjusting tools. Before operating the machine, make sure any adjusting tools
have been removed.
5. Keep work area clean. Cluttered areas invite injuries.
6. Overloading machine. By overloading the machine you may cause injury from flying parts.
DO NOT exceed the specified machine capacities.
WARNING:FAILURE TO FOLLOW THESE RULES MAY RESULT IN
SERIOUS PERSONAL INJURY

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7. Dressing material edges. Always chamfer and deburr all sharp edges.
8. 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.
9. 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.
10.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.
11.Use eye and ear protection. Always wear ISO approved impact safety goggles. Wear a full-
face shield if you are producing metal filings.
12.Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or
across a running machine.
13.Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool or
machine when you are tired.
14.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.
15.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.
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.Turn off power before checking, cleaning, or replacing any parts.
20.Be sure all equipment is properly installed and grounded according to national, state, and
local codes.
21.Inspect power and control cables periodically. Replace if damaged or bare wires are
exposed. Bare wiring can kill! DO NOT touch live electrical components or parts.
22.DO NOT bypass or defeat any safety interlock systems.
23.Keep visitors a safe distance from the work area.

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TECHNICAL SPECIFICATIONS
This bead roller is power driven and will form sheet metal up to 16 Gauge thickness mild steel
(or equivalent). Available die sets allow for the following operations to be performed: wiring,
edging, ogee bead, single bead, and elbow edging.
Capacity, Mild Steel
16ga. (.0598”) (1.52mm)
Capacity, Aluminum
14ga. (.0641”) (1.63mm)
Throat Depth
36” (914mm)
Arbor Diameter
.875” (22mm)
Standard Roll Diameter
2.5” (63.5mm)
Power
240VAC, 50hz
Motor HP
1/2hp (.37kw) 240V, 3ph
Shipping Dimensions (L x W x H)
60” x 44” x 68” (1524 x 1118 x 1727mm)
Weight
300lbs. (137kg)
•Inverter driven variable speed foot pedal control
•Forward and reverse rotation
•Left or right hand operator controls
•Quick release top roll
•Adjustable depth on bottom roll
•Depth stop included
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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UNPACKING AND CHECKING CONTENTS
Your Baileigh machine is shipped complete. 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 coating and/or grease on the exposed
unpainted metal surfaces. Fully and completely remove this protective coating using a
degreaser or solvent cleaner. Moving items will need to be moved along their travel path to
allow for cleaning the entire surface. 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.
Important: This waxy coating is NOT a lubricant and will cause the machine to
stick and lose performance as the coating continues to dry.
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 place the machine into service 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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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.
Follow these guidelines when lifting crane or hoist:
•Always lift and carry the machine with the lifting holes provided at the top of the machine.
•Use lift equipment such as straps, chains, capable of lifting 1.5 to 2 times the weight of the
machine.
•Take proper precautions for handling and lifting.
•Check if the load is properly balanced by lifting it an inch or two.
•Lift the machine, avoiding sudden accelerations or quick changes of direction.
•Locate the machine where it is to be installed, and lower slowly until it touches the floor.

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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.
•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.

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ELECTRICAL
Power Specifications
Your tool iswired for 240 volts, 50Hz alternating current. Before connecting the tool tothe
power source, make sure the machine is cut off from power source. Before switching on the
power, you must check the voltage and frequency ofthe power to see ifthey meet with the
requirement, the allowed change range for the voltage is ±5%, and for the frequency is±1%.
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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•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.
Power cord connection:
1. Turn the main disconnect switch on the control panel to the OFF position.
2. Unwrap the power cord and route the cord away from the machine toward the power supply.
a. Route the power cord so that it will NOT become entangled in the machine in any
way.
b. Route the cord to the power supply in a way that does NOT create a trip hazard.
3. Connect the power cord to the power supply and check that the power cord has not been
damaged during installation.
4. When the machine is clear of any obstruction. The main power switch may be turn ON to test
the operation. Turn the switch OFF when the machine is not in operation.

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GENERAL BEAD ROLLING
The primary purpose is to “roll form” into sheet metal, primarily “Beads”. A multitude of tools are
available for just about any profile you can think of. Bead rolling is both functional and artistic.
The functional portion of this operation will add strength and rigidity to sheet material. The
artistic portion will add aesthetic appeal to the design. Both operations require practice and
experience to perfect. When safety and machine capacity are taken into account, the remaining
is open to the imagination and creativity of the metal worker.
•Never exceed the machines capacity. Keeping in mind items like seams and hems increase
the material thickness which may exceed the machines capacity.
•Never handle material larger than you are able to comfortably control. Keep in mind that
when the material is being rolled, the forces of the rolls will cause the material to move and
twist. Use additional equipment such as back gauges, tables, and additional persons to
support and secure materials as needed.
•Take several passes. Most beads will require several passes to obtain the desired depth.
Planning and practice will assist with this. Practice on similar material to become familiar with
how the material will react and to predict the number of passes and the depth of each pass.
ROLLER INSTALLATION AND REMOVAL
1. Use the quick release lever (A) to open the roll gap
enough for the rolls to clear each other.
2. Loosen the retaining bolt (B) enough to remove the
slotted washer.
3. Remove the rolls.
4. Select and install the die set required for the
desired bead type. Either roller can be top or
bottom depending on your application.
5. Install the slotted washer and secure with the
retaining bolts.
6. The adjustable upper shaft makes it very easy to
align tools perfectly, as well as setting tool gaps
between step dies.
A
B

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OPERATION
Controls
•The main electrical box houses the majority of the
electronics which controls the machine.
•To power machine, plug into a standard 220V wall
outlet.
•Activate the power toggle switch to the “ON”
position. It takes approx. 20-30 seconds before the
motor drive is ready to run.
•The control panel has a speed pot control and a
selector for FWD/STOP/REV direction. Forward will
feed material from right to left. Reverse will feed
material from left to right.
•Select a direction of rotation.
•The bottom roll will begin to rotate as the foot pedal
is depressed and will gradually increase rotational
speed until it reaches the maximum speed set on
the potentiometer.
Rolling
1. Unplug the power cord whenever changing dies.
2. To operate the machine, a set of tooling needs to be selected and installed. Either roller can
be on top or bottom depending on your application.
3. With a set of tooling installed, the tool gap can be set with the top hand wheel (A). Clockwise
(cw) is down, counterclockwise (ccw) is up.
CAUTION: Always wear proper eye protection with side shields, safety
footwear, and leather gloves to protect from burrs and sharp edges.
CAUTION: Keep hands and fingers clear of the rolling dies. Be aware of
how the material moves as it is being formed. Normally the operator should stand in
front of the bead roller to avoid getting hit with the material as it is being formed. When
handling large heavy materials make sure they are properly supported.

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4. Set the back gauge as desired to
assist in positioning the material
between the dies. This also assists
in repeatability.
5. The quick release (B) is very
handy because it will always return
to the same depth setting.
6. When the material is positioned as
desired, closed the quick release
handle to close the gap between
the rolls to start to impress the rolls
into the material. This step may
require some experimentation to
get the proper depth so it is
recommended that you use a
scrap piece of the same material
you want to bead roll.
Note: Most beading
operations will need to be done in
several steps, increasing the depth on
each pass. Trying to bead too deep
will flex the machine, so take your
time with multiple passes.
•Do not start with the rolls completely closed as you may find that the rolls are too close
together and find it difficult to feed the material.
7. Place the Forward/Reverse switch in the desired position based upon direction of feed.
Forward will feed material from right to left. Reverse will feed material from left to right.
8. Step down on the foot pedal while feeding the work-piece through the die set. Check the
work-piece. It may be necessary to fine tune the adjustment to the depth of the bead to
reach the desired bead depth.
9. When doing beads, you can feed the panel from one end to the other, increase pressure,
and switch the machine to reverse, to back it up.
10.When the material has been fed through the rolls for one pass, release the foot pedal and
then, either remove the material if the bead is complete, or toggle the switch to the opposite
directions and feed the material back in the opposite direction increasing the pressure on the
rolls.
11.This may be repeated until the desired bead is achieved.
A
B

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Offsetting the Rolls
The top shaft and roll assembly has the ability to be
offset from the bottom roll from -.375” (9.5mm) to
+2.125” (54mm). This will allow the rolls to offset to
allow for material thickness is rolls like step rolls, or
offset to allow for experimentation with various end
results based upon the rolls being in different
positions relative to the lower roll.
1. Loosen the lock lever (A) to allow the top shaft to
be slide inward (top picture) or outward (lower
picture) until the desired alignment is achieved.
2. Hold the shaft in position and tighten the lock lever
(A).
Note: Test. Test the rolls on a scrap
piece of the same material as the project will be
completed on to become familiar with the finished
result. Bead rolling is an artistic process which can be
repeated, but not easily calculated without practice.
A
A

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Support Tray
1. When not in use, the support tray may be stored
in the slot (A) located in the upper back corner of
the frame.
It may be installed into the storage slot from
either side.
2. Loosen the lock lever and insert the mounting bar
into the lower bearing block while guiding the
support plate over and around rolls.
3. Align the opening in the support plate over the
rolls. This is typically to be centered. Do not allow
the rolls to rub on the support plate.
4. Tighten the lock lever to hold the support tray in
position.
A
C
B
D

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MATERIAL SELECTION
When selecting materials keep these instructions in mind:
•Material must be clean and dry. (without oil)
•Material should have a smooth surface so it processes easily.
•Dimensional properties of material must be consistent and not exceed the machine capacity
values.
•Chemical structure of material must be consistent.
•Buy certificated steel from the same vendor when possible.
UNDERSTANDING SPRINGBACK
Springback, also known as elastic recovery, is the result of the metal wanting to return to its
original shape after undergoing compression and stretch. After the bending leaf is removed from
the metal and the load is released, the piece part relaxes, forcing the bent portion of the metal to
return slightly to its original shape. The key to obtaining the correct bend angle is to over bend
the metal a little and allow it to spring back to the desired angle. All metals exhibit a certain
amount of spring back.
CAUTION: It must be determined by the customer that materials being
processed through the machine are NOT
potentially hazardous to operator or
personnel working nearby.

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LUBRICATION AND MAINTENANCE
Note: Proper maintenance can increase the life expectancy of your machine.
•Check daily for any unsafe conditions and fix immediately.
•Check that all nuts and bolts are properly tightened.
•On a weekly basis clean the machine and the area around it.
•Lubricate threaded components and sliding devices.
•Apply rust inhibitive lubricant to all non-painted surfaces.
•The adjusting block should be greased.
•Oil the shaft around the bronze bushing monthly with a drop or two of a 30 to 40 weight oil.
•The gearbox is oiled for life and does not require service.
WARNING:Make sure the electrical disconnect is OFF before working on
the machine.
Maintenance should be performed on a regular basis by qualified personnel.
Always follow proper safety precautions when working on or around any machinery.