Baileigh SH-8003HD User manual

MAINTENANCE / PARTS MANUAL
HYDRAULIC SHEAR
MODEL: SH-8003HD
© 2018 Baileigh Industrial, Inc.
REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL, INC.
IS PROHIBITED. Baileigh Industrial, Inc. does not assume and hereby disclaims any liability for any damage or loss
caused by an omission or error in this Operator’s Manual, resulting from accident, negligence, or other occurrence.
Rev. 11/2018
Baileigh Industrial, Inc.
P.O. Box 531
Manitowoc, WI 54221-0531
Phone: [phone]
Fax: [phone]
[e-mail]

Table of Contents
SAFETY INSTRUCTIONS ..............................................................................................1
SAFETY PRECAUTIONS...............................................................................................3
Dear Valued Customer:...................................................................................................3
Electrical Enclosure Disconnect Switch.......................................................................6
Hazard Signs...............................................................................................................6
MATERIAL SELECTION................................................................................................. 7
MACHINE ADJUSTMENTS............................................................................................7
Blade Clearance..........................................................................................................7
Suggested Knife Clearance.........................................................................................8
REPLACING THE SHEAR BLADES...............................................................................9
To Rotate or Replace the Top Blade.........................................................................10
To Rotate or Replace the Bottom Blade.................................................................... 11
KNIFE BAR WAYS ADJUSTMENT...............................................................................12
LUBRICATION AND MAINTENANCE .......................................................................... 13
Roller Lubrication....................................................................................................... 13
Hydraulic Oil.............................................................................................................. 14
Oil Change and Disposal...........................................................................................14
Storing Machine for Extended Period of Time...........................................................14
HYDRAULIC SCHEMATIC...........................................................................................15
MANIFOLD BLOCK ...................................................................................................... 16
Hydraulic Component Identification........................................................................... 17
ELECTRICAL ENCLOSURE BACK PANEL................................................................. 18
ELECTRICAL COMPONENT IDENTIFICATION ..........................................................19
Electrical Parts List.................................................................................................... 20
Additional Electrical Components..............................................................................20
ELECTRICAL SCHEMATIC (Sheet. 1).........................................................................21
ELECTRICAL SCHEMATIC (Sheet 2)..........................................................................22
ELECTRICAL SCHEMATIC (Sheet 3)..........................................................................23
ELECTRICAL WIRE TERMINALS................................................................................24
MECHANICAL REPLACEMENT PARTS...................................................................... 25
MAIN FRAME PARTS DIAGRAM.................................................................................26
Main Frame Parts List ............................................................................................... 29
HYDRAULIC CYLINDER-PARTS DIAGRAM................................................................ 31
Hydraulic Cylinder Parts List...................................................................................... 32
HOLD DOWN CYLINDER PARTS DIAGRAM..............................................................33
Hold Down Cylinder Parts List...................................................................................33
BACK GAUGE PARTS DIAGRAM................................................................................34
Back Gauge Parts List............................................................................................... 35
TROUBLESHOOTING.................................................................................................. 36

1
1
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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2
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.
HYDRAULIC HOSE FAILURE
Exercise CAUTION around hydraulic hoses in case of a hose or
fitting failure.
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 SHEAR HAZARD
Blade is sharp. Placing hands or fingers near
blade will result in cuts and possibly loss of
fingers or limbs if placed in machine. NEVER
place your hand or any part of your body in this
machine.

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3
Emergency Stop Button
In the event of incorrect operation or dangerous
conditions, the machine can be stopped
immediately by pressing the E-STOP button. Twist
the emergency stop button clockwise (cw) to reset.
Note: Resetting the E-Stop will not start the
machine.
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!
WARNING:FAILURE TO FOLLOW THESE RULES MAY RESULT IN
SERIOUS PERSONAL INJURY

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4
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.
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.Blade adjustments and maintenance. Always keep blades sharp and properly adjusted for
optimum performance.
17.Keep children away. Children must never be allowed in the work area. DO NOT let them
handle machines, tools, or extension cords.
18.Keep visitors a safe distance from the work area.

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5
19.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.
20.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.
21.DO NOT touch live electrical components or parts.
22.Turn off power before checking, cleaning, or replacing any parts.
23.Be sure all equipment is properly installed and grounded according to national, state, and
local codes.
24.Inspect power and control cables periodically. Replace if damaged or bare wires are
exposed. Bare wiring can kill!
25.DO NOT bypass or defeat any safety interlock systems.

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6
Electrical Enclosure Disconnect Switch
The main disconnect switch (P) turns power on to the machine
when in the “ON” position. If the door handle is turned while
the switch is “ON”, a safety catch will prevent the door from
opening.
Hazard Signs
WARNING: Before opening the door to work on electrical circuits, turn
the main disconnect switch “OFF”. Also turn off and Lock Out the electrical supply
source to this machine. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT
IN FATAL OR SERIOUS INJURY.
HAUPTSCHALTER MAIN SWITCH
OFFNEN IN
0-STELLUNG OPEN IN
OFF - POSITION
O
P

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7
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.
MACHINE ADJUSTMENTS
Blade Clearance
1. Allowed the knife bar to slowly drop and the cutting edges to begin to cross / interfere. Check
with a feeler gauge for 0.031” (0.8mm) clearance between blades on the right side.
2. Check the blade clearance from the right to the left as the knife-bar moves downward. The
clearance should be 0.031” (0.8mm) on each side & 0.023” (0.6mm) in the center. The
clearance must be checked at the exact center point of intersection of the blades to obtain
accurate indications.
3. If clearance is not correct loosen the table bolt & move the table in or out. Use the square set
screws to push the table in (= reduce clearance), and the hex socket cap screws to pull the
table out (= increase clearance). Use the control screws alternately so as not to force one
screw against the other & to maintain complete control over the table as all times. Check
clearances after the table bolts have been tightened and the control screws snuggled up to
determine if any settings have changed.
4. To change the clearance as the center of the blade, adjust the nut.
5. This blade clearance checking and adjustment procedures must be followed whenever the
blades are changed or reversed.
6. Check with feeler gauge between the wear plate and the knife bar along the lower gear
surface and top rear surface that a proper clearance has been established.
7. Repeats step 2 through 6 on the L.H. end of the shear.
8. Check blade clearance and adjust it necessary.
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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8
Suggested Knife Clearance
Note: This is a general guide for setting the blade gap. Your specific settings may
change based upon several factors regarding specific material and other machine settings and
conditions. This is based upon a general guideline of blade gap is equal to 6.5%-7% of material
thickness.
Gauge
(ga)
Standard Steel Thickness Aluminum Thickness Knife Blade Clearance
3
0.2391 (6.073mm)
0.2294 (5.827mm)
.010”-.018” (.25-.45mm)
4
0.2242 (5.695mm)
0.2043 (5.189mm)
.009”-.013” (.23-.33mm)
5
0.2092 (5.314mm)
0.1819 (4.620mm)
.009”-.013” (.23-.33mm)
6
0.1943 (4.935mm)
0.162 (4.115mm)
.009”-.013” (.23-.33mm)
7
0.1793 (4.554mm)
0.1443 (3.665mm)
.008”-.011” (.20-.28mm)
8
0.1644 (4.176mm)
0.1285 (3.264mm)
.007”-.010” (.17-.25mm)
9
0.1495 (3.797mm)
0.1144 (2.906mm)
.006”-.009” (.15-.23mm)
10
0.1345 (3.416mm)
0.1019 (2.588mm)
.006”-.009” (.15-.23mm)
11
0.1196 (3.038mm)
0.0907 (2.304mm)
.004”-.008” (.10-.20mm)
12
0.1046 (2.657mm)
0.0808 (2.052mm)
.004”-.008” (.10-.20mm)
13
0.0897 (2.278mm)
0.072 (1.829mm)
.003”-.006” (.076-.152mm)
14
0.0747 (1.897mm)
0.0641 (1.628mm)
.003”-.006” (.076-.152mm)
15
0.0673 (1.709mm)
0.0571 (1.450mm)
.003”-.006” (.076-.152mm)
16
0.0598 (1.519mm)
0.0508 (1.290mm)
.002”-.005” (.05-.127mm)
17
0.0538 (1.367mm)
0.0453 (1.151mm)
.002”-.005” (.05-.127mm)
18
0.0478 (1.214mm)
0.0403 (1.024mm)
.002”-.004” (.05-.10mm)
19
0.0418 (1.062mm)
0.0359 (0.912mm)
.002”-.004” (.05-.10mm)
20
0.0359 (0.912mm)
0.032 (0.813mm)
.002”-.004” (.05-.10mm)
21
0.0329 (0.836mm)
0.0285 (0.724mm)
.002”-.004” (.05-.10mm)
22
0.0299 (0.759mm)
0.0253 (0.643mm)
.002”-.004” (.05-.10mm)
23
0.0269 (0.683mm)
0.0226 (0.574mm)
.001”-.003” (.025-.076mm)
24
0.0239 (0.607mm)
0.0201 (0.511mm)
.001”-.003” (.025-.076mm)

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9
REPLACING THE SHEAR BLADES
The blades on the Baileigh shear have multiple usable edges. If you have not already used both
cutting edges on the top blade you can rotate it end for end to expose a sharp edge. The bottom
blade has four usable edges. After all edges have been used, the blade can be reground or
replaced. Contact Baileigh Industrial at (920.684.4990) for replacement blades.
BLADE CARE
Like all power shears, this machine has high-carbon / high-chrome alloy tool steel blade with
cutting edges on the bottom blade and two edges on the top blades are quickly and easily
reversible when one edge is dull. The multiple shearing edges prolong blade lift considerably.
•Never permit the blade to rub each other.
•Lubricate the blade with light oil when shearing stainless steel or galvanized material. Brush
oil on the lower blade; the upper blade will pick up oil during the shearing cycle.
•Keep the blade sharp. Turn or change blades as soon as a burr is noted on the sheared
stock. It is to recommend that a spare set of blades be held in stock so as not to impair
production during grinding.
•When all edges have been used, it will be necessary to have the blade ground. The blades
should be ground so that the variation is no greater than 0.025mm within 3048mm and
0.05mm from the end to end.
•When re-installing re-ground blades, install shim stock under the lower edge to bring the
blade up flush with the table.
WARNING:The shearing blade poses an amputation hazard. Make sure
no body part or clothing is near the specific hazard. Failure to follow this warning
could result in severed or crushed fingers.

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10
To Rotate or Replace the Top Blade
1. Raise the blade to the up position.
2. Shut down and lockout power to the machine.
3. Remove the yellow safety guard.
4. Remove the shadow wire to avoid breaking it, before
changing the blade. Loosen the center bolts of both
brackets and the outside setscrews to relieve tension
on the wire. (fig. 5)
5. CAUTION: ALWAYS WEAR LEATHER GLOVES
WHEN HANDLING THE BLADE. Remove the
capscrews and washers that hold the blade in place.
6. Turn the blade end for end if the other side is sharp,
or replace the blade with a new one.
7. When the blade is in position, secure with the bolts
and washers.
8. Re-attach the shadow wire. Adjust so that the wire is taut and as close to the blade as
possible without touching.
9. Re-mount the yellow safety guard!
10.Set the blade gap arm to the 3/16” (4.76mm) setting, start the
machine, and lower the top blade until it overlaps the bottom
blade along the full length. The gap should measure .60mm
or .023” along the full length. (The blades must be parallel.)
11.The blade gap adjustment setscrews are shown in (fig. 6).
These were preset at the factory. ADJUST ONLY IF
ABSOLUTELY NECESSARY!
CAUTION: Always wear proper eye protection with side shields, safety
footwear, and leather gloves to protect from burrs and sharp edges.
Keep hands and fingers clear of the shearing blade and clamping cylinders.
figure 5
loosen
figure 6

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11
To Rotate or Replace the Bottom Blade
1. Raise the blade to the up position.
2. Shut down and lockout power to the machine.
3. Unbolt and remove the 2 ball transfer tables and the squaring arm. This will allow access to
the rest of the bottom blade bolts. (fig. 7)
4. CAUTION: ALWAYS WEAR LEATHER GLOVES WHEN HANDLING THE BLADE. Remove
the capscrews and washers from the front of the machine that hold the blade in place while
the blade is removed from the back.
5. Turn the blade if you have not already used all four cutting edges, or replace the blade with a
new one.
6. When in position, secure the blade with the bolts and washers.
7. Mount the 2 ball transfer tables and the squaring arm.
8. Set the blade gap arm to the 0.1875” (4.76mm) setting, start the machine, and lower the top
blade until it overlaps the bottom blade along the full length. The gap should measure 0.023”
(0.60mm) along the full length. (The blades must be parallel.)
9. There is no adjustment for the lower blade.
CAUTION: Always wear proper eye protection with side shields, safety
footwear, and leather gloves to protect from burrs and sharp edges.
Keep hands and fingers clear of the shearing blade and clamping cylinders.
figure 7
Squaring Arm
Transfer
Table

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12
KNIFE BAR WAYS ADJUSTMENT
The ram ways are adjustable to affect the wear that will occur during gears of service. The
adjustment will only be required about every five (5) years, unless the shear is allowed to
operate unleveled which causes a twisting action and premature ways wear.
The proper running clearance is 0.0015”-0.0019” (0.038-0.05mm) and should be maintained at
all times in order to get the maximum life from the blades & quality work from the shear.
The adjustment procedure is as follows:
1. Disconnect electrical power from the machine.
2. Loosen the lock nuts on the three square head set screw located at the front gib area of r.h.
end heading.
3. Run center set screw in tight to take up excess clearance.
4. Run in the top and bottom screws until they strike the wear plate, the back off 1/16 of turn
and tighten lock nuts.
5. Take off on the center set screw until it comes in line with the top and bottom screws, tighten
lock nuts.

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13
LUBRICATION AND MAINTENANCE
Daily Maintenance
•Check daily for any unsafe conditions and fix immediately.
•Inspect the power plug and cord.
•Check the foot switch cable for any loosening or damage.
•Check hydraulic hoses and fittings for leakage.
•Keep area around machine clear of debris.
•Check that all nuts and bolts are properly tightened.
Weekly Maintenance
•Make sure proximity switches and limit switches are secure and adjusted properly.
•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.
Note: Proper maintenance can increase the life expectancy of your machine.
Roller Lubrication
Lubricate the machines roller wheels monthly or as necessary using the
grease gun provided. There are two grease fittings on each side, at the
back of the shear. Also make sure there is adequate grease on the
surfaces that the wheels ride on.
The blade gap adjustment chains and sprockets need to be oiled
periodically. They are located between the rollers at each end of the
machine.
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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14
Hydraulic Oil
The hydraulic oil is the primary medium for transmitting pressure and also must lubricate the
running parts of the pump.
After installation of the machine and before machine startup, bring the oil level up to 90% of
capacity. Verify that the ram is in the upper most position to prevent overfilling of the tank.
A shortage of hydraulic oil can cause hydraulic system breakdown and damage to major
mechanical parts due to overheating.
1. Use hydraulic oil #46 or #68 SHELL BRAND or an equivalent with similar specifications.
(Based upon location temperature and availability.)
2. Keep hydraulic reservoir filled to 90% of capacity.
3. DO NOT rely totally on the oil gauge as they can sometimes indicate an incorrect level
reading. Do a visual inspection with the oil fill cap removed as well.
4. A shortage of hydraulic oil will cause hydraulic system breakdown to major mechanical
components due to overheating.
5. Change the hydraulic oil every 12 months along with the oil filter.
Oil Change and Disposal
Change the oil in the hydraulic tank after the first 6 months, and every 12 months after that.
Clean the filter basket located under the fill cap before refilling the tank.
Capacity of the oil tank is approx. 34 gallons. (128.7 liters) max. Required oil capacity is 27.5
gallons (104 liters).
Used oil products must be disposed of in a proper manner following your local regulations.
Air bleed for hydraulic hold down cylinders. If hold down cylinders
don’t all function the same, there might be air in the line.
Storing Machine for Extended Period of Time
If this machine is to be inactive for a long period of time, prepare the
machine as follows:
•Disconnect the electrical supply from the power panel.
•Clean and grease the machine.
•Cover the machine.

15
15
HYDRAULIC SCHEMATIC

16
16
MANIFOLD BLOCK

17
17
Hydraulic Component Identification
Item
Description
Part No.
1
Motor 15hp (11.2kw), 480V, 3ph, 60hz
HP*4P
2
Pump
VQ15-19-F-RRL-03
3
Strainer
MF-08
4
Check Valve
CV13A2050N
5
Relief Valve
RVCA LAN
6
SGREN-IN Solenoid Valve
SV08-21
7
Solenoid Valve
DG4V-3-7C
8
Solenoid Valve
DG4V-3-6C
9
Modular Pilot Operated Check Valve
MPC-02W
10
Logic Valve
LODC XDN
11
Logic Valve
LODC XDN
12
Logic Valve
LOFC XDN
13
Counter Balance Valve
CBEA LHN
14
Check Valve
COFA XCN
15
Check Valve
CODA XCN
16
SGREN-IN Solenoid Valve
SV10-23
17
Pressure Gauge
AT-63mm*280Kg
18
Hydraulic Cylinder
145mm dia.
19
Hydraulic Cylinder
130mm dia.
20
Hold-Down Cylinder
20mm dia.
21
Air Breather
HY-08
22
Oil Level w/Thermometer
LG-5A

18
18
ELECTRICAL ENCLOSURE BACK PANEL