Baileigh TN-250 User manual

OPERATOR’S MANUAL
TUBE AND PIPE NOTCHER
MODEL: TN-250 (B8500)
© 2015 Baileigh Industrial, Inc.
Rev. 06/2015

Table of Contents
STANDARD TERMS AND CONDITIONS OF SALE........Error! Bookmark not defined.
INTRODUCTION............................................................................................................. 1
GENERAL NOTES.......................................................................................................... 1
SAFETY INSTRUCTIONS .............................................................................................. 2
SAFETY PRECAUTIONS ............................................................................................... 4
TECHNICAL SPECIFICATIONS..................................................................................... 6
FEATURES..................................................................................................................... 6
TECHNICAL SUPPORT ..................................................Error! Bookmark not defined.
UNPACKING AND CHECKING CONTENTS.................................................................. 7
Cleaning ...................................................................................................................... 7
ASSEMBLY AND SET UP .............................................................................................. 9
OPERATION................................................................................................................. 10
Arbor Adapters .......................................................................................................... 11
MATERIAL SELECTION............................................................................................... 12
LUBRICATION AND MAINTENANCE .......................................................................... 12
PARTS IDENTIFICATION DRAWING .......................................................................... 13
Parts Identification List .............................................................................................. 14

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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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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.
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
General precautions are listed on CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
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.
BEWARE OF PIERCING POINTS
NEVER place hands, fingers, or any part of your
body near rotating tools. Hole saws are very sharp
and can quickly pierce your fingers and hands.
Always wear heavy leather gloves when handling
these tools.
ENTANGLEMENT HAZARD – ROTATING SHAFT
Contain long hair, DO NOT wear jewelry or loose fitting clothing.
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.

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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.
1. Only trained and qualified personnel can operate this machine.
2. Make sure any 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. 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.
7. 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.
8. 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.
9. Use eye and ear protection. Always wear ISO approved impact safety goggles. Wear a
full-face shield if you are producing metal filings.
WARNING: FAILURE TO FOLLOW THESE RULES MAY RESULT IN
SERIOUS PERSONAL INJURY

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10. Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or
across a running machine.
11. Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool
or machine when you are tired.
12. 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.
13. 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.
14. Blade adjustments and maintenance. Always keep blades sharp and properly adjusted
for optimum performance.
15. Keep children away. Children must never be allowed in the work area. DO NOT let them
handle machines, tools, or extension cords.
16. 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.
17. 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.
18. Do not cut where the atmosphere might contain flammable dust, gas, or liquid vapors such
as from gasoline.
19. Wear oil-free protective garments such as leather gloves, heavy shirt, high shoes or boots,
cuffless trousers, and a cap.
20. DO NOT touch live electrical components or 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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TECHNICAL SPECIFICATIONS
TN-250
Imperial
Metric
Notching Capacity (OD)
0.5” – 2.5”
12.7mm – 63.5mm
Angle Adjustment
Infinite
Power Requirements
1/2” (12.7mm) Powered Hand Drill
Shipping Dimensions
24” x 12” x 12”
610mm x 305mm x 305mm
Shipping Weight
50 lbs.
23 kgs.
FEATURES
•Solid steel construction
•Grade 8 bolts throughout, ensuring maximum rigidity
•Unique 6 jaw radial vise
•Will notch over 75°
•1-1/4” hardened Thomson shaft with replaceable tips
•Slotted carriage for offset notches (no shims)
•Patent pending
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 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: 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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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.

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ASSEMBLY AND SET UP
1. Install the hand wheel onto the hub
with the supplied 5/16-18 socket
head screws.
2. Attach the pivot block and indicator assembly onto
the vise assembly using the 1/2-13 bolts and the
retaining plate supplied.
3. The pivot block will fit into the machined recess in
the vise assembly plate.
4. The retaining plate will go on the opposite side of
the vise assembly and is there to act as a support
washer so as not to damage the vise plate from
frequent tightening.
WARNING: For your own safety, DO NOT connect a powered drill until
the machine is completely assembled and you have read and understand the entire
instruction manual.

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OPERATION
1. Operating your TN-250 is very easy, but certain steps need to be followed.
2. After your notcher is assembled, it needs to be clamped into a vise or bolted to the side of a
workbench. The main vise plate has a machined step that is designed to make insertion into
vise jaws very easy.
3. Choose a hole saw that matches your materials outside diameter and screw it onto the
threaded stud on the end of the main shaft arbor.
4. If you will be notching on center,
check the height scale on the left
side of the notcher and make
sure the pivot clamp block is in
the zero position. If an offset
notch is required, loosen the two
hex screws using a 3/8 hex key
wrench and adjust it to the
desired offset.
5. Open your vise assembly using
the 3 legged hand wheel and
insert the desired tubing that
needs to be notched. The
amount of tubing protruding past
the vise will be determined by
the angle of notch, and the hole
saw should be slid forward to set that distance.
6. Tighten the material, being careful not to over tighten and crush your tube, as the vise has
supreme holding power.
7. If an angle notch is required, loosen the two hex bolts on the side of the clamp block with a
3/8” hex key. Position the pivot arm to the desired angle. And re-tighten. Angles up to 45
degrees work best using the center slot in the pivot arm, the second slot is used for extreme
angles and for notching on curved tubes as it aides in offsetting further.
8. When the desired angle is set, the aluminum bearing block should be slid as far forward as
possible to the notch, this will make the cutting as rigid as possible. Be sure to tighten the
two hex bolts beneath the aluminum block using a 3/8” hex key.
9. A 1/2” drive electric drill will need to be chucked onto the hexed arbor, and tightened
securely.
CAUTION: Always wear proper eye protection with side shields, safety
footwear, and leather gloves to protect from burrs and sharp edges.

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IMPORTANT: It is recommended to use a drill with a keyed chuck to tighten the
chuck securely onto the hexed arbor. Recheck the chuck periodically to ensure it remains tight
to the hexed arbor. Allowing the chuck to become loose on the hex arbor will accelerate the
wear on the hex drive stud.
10.Insure that the hole saw is not in contact with the material and start the drill.
11.Slowly push the arbor forward allowing the hole saw to do the work, and do not push too
hard.
•Keeping the speed around 250 rpm provides the best combination of saw cut and saw
life.
•In some instances, the hole saw will bottom out requiring the slug to be cut out with a zip
wheel to continue the notch, this is normal with this type of machine. Sometimes the pivot
arm can be swung back 180 degrees to finish a notch, but again probably only up to 45
degrees will this method work.
•Angle notches over 45 degrees should be sawed to the angle first, to remove the majority
of the material.
•Following these simple steps will give you years of trouble free service from your TN-250
notcher.
Arbor Adapters
When setting up the notcher, use the correct arbor to saw adapter to fit the size and manufacturer
of the hole saw being used.
Contact your distributor to order optional or replacement adapters.
Hole Saw End
Arbor End
Standard Adapter.
Used with most hole
saws.
Reducer Adapter.
Used with small hole
saws.
Optional Adapter.
Larger M18 end to fit
certain hole saws
manufacturer saws.

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MATERIAL SELECTION
When selecting materials keep these instructions in mind:
•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
Note: Proper maintenance can increase the life expectancy of your machine.
•Check for any loose or worn parts; contact your dealer for replacement parts.
•Fluid level in aluminum housing should be checked periodically, add 80w gear oil if fluid
levels are low. When completely empty, the aluminum block will hold 1 oz. of oil.
•Replacement seals, bearings, threaded hole saw studs, and drive hexes are all available to
keep your machine running for years.
•Replace the hexed drive stud when it becomes worn.
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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PARTS IDENTIFICATION DRAWING

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Parts Identification List

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Item
Part Number
Description
Qty.
1
ME-TN250-6A016
MAIN FRAME
1
2
ME-TN250-6A009
ACTUATOR PLATE
2
3
ME-TN250-6A011
PIVOT CLAMP BLOCK
1
4
ME-TN250-6A015
ROCKER BLOCK
1
5
ME-TN250-6A021
GRIPPER JAW
6
6
TN250-7A014
SPACER
1
7
ME-TN250-5A001
PIVOT ARM ASSY
1
8
ME-TN250-6A013
BRG BLOCK
1
9
TN250-7A001
SAW ARBOR
1
10
TN250-6A017
DEGREE DISC
1
11
TN250-7A007
TRUNION
1
12
TN250-7A006
VISE SCREW
1
13
ME-TN250-7A008
WHEEL HUB
1
14
M300-6A066
HAND WHEEL
1
15
ME-TN250-6A022
POINTER
1
16
STD.
M8 X 1.25 X 50 HEX FLANGE
7
17
ME-TN250-7A010
DRIVE STUD
1
18
PP-1142
SEAL
2
19
TN250-6A014
BOLT CAP
2
20
NOT INCLUDED
HOLE SAW
1
21
STD.
.25 X 1.25 SLOTTED SPLIT PIN
1
22
STD.
3/8-24 X 5/16 SET SCREW
1
23
Imperial
Adapter, Standard 5/8-18 X 1.25 Set Screw
1
23-A
M600-7A006
Adapter, Reducer 5/8-18 x .5 to 1/2-20 x 1/2
1
23-B
M600-7A009
Adapter, Enlarger 5/8-18 x .5 to M18-1.5 x 10
Optional
24
M12 X 1.75 X 50
SHCS
2
25
M12 X 1.75 X 35
SHCS
2
26
M6 X 1.0 X 10
BUTTON HEAD
3
27
M12 X 1.75 X 45
SHCS
2
28
M8 X 1.25
FLANGED NYLOCK NUT
7
30
STD.
3/16 X 7/8 SLOTTED SPLIT PIN
1
31
M8 X 1.25 X 10
BUTTON HEAD
6
32 M5 X 0.8 X 8 BUTTON HEAD
2

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Item
Part Number
Description
Qty.
33
PP-0196
0.5 ID X 0.625 OD X 0.562 LG
1
34
PP-1141
NEEDLE BEARING
2

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NOTES

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NOTES