Baileigh Industrial PH-28HD-VS User manual

OPERATOR’S MANUAL
POWER HAMMER
MODEL: PH-28HD-VS (B9045)
© 2018 Baileigh Industrial, Inc.
Rev. 02/2018

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
Levelling Feet .............................................................................................................. 9
ELECTRICAL................................................................................................................ 10
OPERATION................................................................................................................. 12
Setup and Adjustments ............................................................................................. 12
Operation................................................................................................................... 14
MATERIAL SELECTION............................................................................................... 15
LUBRICATION AND MAINTENANCE .......................................................................... 15
PLATE ASSEMBLY ...................................................................................................... 16
UPPER / LOWER RAM ASSEMBLY ............................................................................ 17
SPROCKET ASSEMBLY .............................................................................................. 18
SPRING ASSEMBLY .................................................................................................... 19
LEVER ASSEMBLY ...................................................................................................... 20
SLIDE STROKE ASSEMBLY........................................................................................ 21
QUICK RELEASE ASSEMBLY..................................................................................... 22
V-BELT ASSEMBLY POST .......................................................................................... 23
GUARD AND CONTROL BOX ASSEMBLY ................................................................. 24
Parts List ................................................................................................................... 25

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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 modifications.

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Note: This symbol refers to useful information throughout the manual.
SAFETY INSTRUCTIONS
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.
NOTICE, which is not related to personal injury, is used without a symbol.
DANGER: Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING: Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION: Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTICE: Indicates a situation which, if not avoided, could
result in property damage.
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.
DANGER
WARNING
CAUTION
NOTICE

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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 servo motors drive belt and
pulleys when performing maintenance. Keep motor guards in place
at all times while the machine is running.
BEWARE OF CRUSH HAZARD
NEVER place your hands, fingers, or any part of your body in the die
area of this machine.

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HIGH VOLTAGE
USE CAUTION IN HIGH VOLTAGE AREAS. DO NOT assume the
power to be off.
FOLLOW PROPER LOCKOUT PROCEDURES.
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 will not 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.
WARNING: FAILURE TO FOLLOW THESE RULES MAY RESULT IN
SERIOUS PERSONAL INJURY

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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.
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 machine’s 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 appropriately.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.

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21.Keep all cords dry, free from grease and oil, and protected from sparks and hot metal.
22.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.
23.Keep visitors a safe distance from the work area.
TECHNICAL SPECIFICATIONS
Mild Steel Capacity
16ga. (1.519mm)
Aluminum Capacity
12ga. (2mm)
Speed
0 - 1000 beats / min (Variable)
Throat Depth
28" (711mm)
Working Height
52" (1321mm)
Length of Stroke Adjustment
Variable from 1/4" – 3/4" (6.35 – 19mm)
Power
240V, 1 Phase, 50Hz
Motor
3hp, (2.25kw)
Shipping Dimensions
48" x 48" x 96" (1220 x 1220 x 2439mm)
Shipping Weight
2,000lbs. (907kgs)
Based on a material tensile strength of *60000 PSI – mild steel
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: S
UFFOCATION 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
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, then lower slowly until it touches the floor.
NOTICE: 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.

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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 machine 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.
Levelling Feet
1. Remove the machine from the pallet and install the leveling feet.
2. Once the machine is moved to its location, level the machine keeping firm even contact on
all four feet.

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ELECTRICAL
Power Specifications
Your tool is wired for 240 volts, 50Hz alternating current. Before connecting the tool to the power
source, make sure the machine is cut off from power source. Before switching on the power, you
must check the voltage and frequency of the power to see if they meet with the requirement, the
allowed 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.
ATTENTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE BY A
CERTIFIED ELECTRICIAN!
Your Baileigh Machine is
Check if the available power supply is the same as required by the machine (consult
nameplate on machine)
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
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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:
3. Turn the main disconnect switch on the control panel to the OFF position.
4. 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 is a way that does NOT create a trip hazard.
5. Connect the power cord to the power supply and check that the power cord has not been
damaged during installation.
6. When the hammer and dies area is clear of any obstruction. The main disconnect may be
turn ON to test the operation. Turn the main disconnect to OFF when the machine is not in
operation.

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OPERATION
The PH-28HD Power Hammer is a multi-stroke reciprocating machine.
The upper slide ram (hammer) is connected to the crank toggle mechanism via a multi stack leaf
spring. As the crank turns, speed and momentum load the spring which in turn “throws” the
upper slide ram down with spring force and gravity. The amount of throw and force are
controlled by speed and/or stroke.
The speed is controlled through a variable foot control and a limiting potentiometer on the upper
control box.
The foot control fully depressed will max out at whatever the limiting potentiometer is set to.
Using a power hammer is a highly artistic operation. It requires time and experience to become
proficient at creating the desired results. The best recommendation is to practice, take notes,
experiment, and seek out advice through technical colleges, individual mentoring with an
experienced operator, and through online forums and trade magazines. Practice!
Setup and Adjustments
1. Turn the main disconnect “off”.
2. Rotate the stroke handwheel to raise the upper
slide ram (hammer) to the high point of the stroke.
CAUTION: Always wear proper hearing and
eye protection with side
shields, safety footwear, and leather gloves to protect from burrs and sharp edges.
Keep hands and fingers clear of the hammer dies.
When handling large heavy sheets make sure they are properly supported.
WARNING: HEARING PROTECTION MUST BE WORN ALWAYS WHEN
OPERATING THIS MACHINE.

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3. Pull outward and down on the release lever to raise
the hammer to allow additional clearance for tool
changes. Verify that the lever is locked into the
lower position (Up position shown).
4. Install the desired tooling (sold separately) into the
lower and upper rams and lock in position using the
retaining pins.
5. Pull outward and up on the release lever to lower
the hammer to the operating position. Verify that
the lever is locked into the upper position (Shown).
IMPORTANT: The tool change release lever
MUST be locked in the UP position before and during
operation. Operating the power hammer with the
release lever in the lower position will damage the
machines operating linkage.
6. Adjust the anvil height by loosening the two guide
screws just enough to allow the anvil to move up or
down.
7. Turn the handwheel on the right side of the frame
so that the hammer tool is at the lowest (closest)
point of its travel.
8. Turn the adjustment collar to raise or lower the
anvil post. The initial setting for the gap between
the lower and upper tool should be the same as the
material thickness.
Note: Shown with no tool installed.
Normal adjustment would have a tool set installed.

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9. Next, adjust the stroke as needed to provide the amount of force desired to produce the
results desired. The longer the stroke, the greater the force generated. When starting for the
first time, use the factory setting (typically the mid-point) until some practice has occurred to
become familiar with the machines operation.
Operation
1. Set the control switch to the “ON Foot Control”
position.
2. Set the limiting potentiometer to 100%, about 1000
BPM (Beats Per Minute), slowly press the foot
control, the machine should begin to “hammer”,
hitting harder the faster you go.
3. Turn the main disconnect to ON.
4. Shrinking as well as most of the shaping functions
will take time to learn and control. To practice
shrinking, use 3003-H14 .059 wall aluminum. This
is a good material to learn on because it shapes
easily and is more forgiving. To shrink start feeding
the metal in slowly controlling the shrink by your
foot control; slowing as you pull out not to flatten
the edge too much.
5. The hammer mode is also used for planishing.
Install the flat top die and the 6000R x 1000F lower
hammer die. This die has a contact patch of 1”
diameter. Install the tools following the same steps as before. Adjusting the stroke will give
different results. Shortening the stroke will allow different speed settings, faster speeds can
be achieved by finding the “sweet spot”, just before the spring begins to float. The
combinations of stroke / speed / down feed are almost endless.
6. These dies can be used for planishing as well as stretching. The flat top die is used for most
of the stretching applications except for aggressive doming. The rubber die can be installed
on either the top or bottom depending on your application.
WARNING: The tools on this machine should never come in contact with
each other, if they do, machine damage will occur.

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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.
LUBRICATION AND MAINTENANCE
•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.
•Grease the fittings every month with two pumps from a standard grease gun.
•Check for any worn or damaged parts and replace immediately.
•Check and fill oil cup as needed. Use AW-46 hydraulic oil.
Note: Proper maintenance can increase the life expectancy of your machine.
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.
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.

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PLATE ASSEMBLY

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UPPER / LOWER RAM ASSEMBLY

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SPROCKET ASSEMBLY