INSTRUCTION BULLETIN & MAINTENANCE MANUAL FOR WHIRLWIND WHIRLWIND MODEL NO.: WHIRLWIND SERIAL NO.: MANUFACTURE DATE: DISTRIBUTOR PURCHASED THROUGH:

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1 INSTRUCTION BULLETIN & MAINTENANCE MANUAL FOR WHIRLWIND WHIRLWIND MODEL NO.: WHIRLWIND SERIAL NO.: MANUFACTURE DATE: DISTRIBUTOR PURCHASED THROUGH: (IF ANY) MADE IN THE USA BY CTD MACHINES 2300 E. 11th Street Los Angeles, CA Tel (213) FAX (213) World Wide Web:

2 Set-up and Maintenance Instructions for Whirlwind ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ This machine, like every Whirlwind, was tested under power prior to shipment. Nothing but the best components and raw materials were used in its construction. Like any quality tool, it must be properly maintained to give peak performance. The Operator s Manual addresses a few pre-operational tests which should be performed regularly. Any malfunctions should be corrected immediately. A number of safety devices, such as the extended blade guard and side covers, are on this machine. These devices are for the protection of the operator. CAUTION: THESE DEVICES MUST NOT BE REMOVED OR TAMPERED WITH. CAUTION: NEVER PUT FINGERS UNDER GUARD / CLAMP. Set-Up Instructions for Whirlwind ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 1. Position machine and bolt to floor. If infeed and outfeed table are to be used, these should be aligned with saw top and fence. After alignment is satisfactory, bolt table legs to floor. 2. Have a certified electrician bring in power, connect machine and check voltage level. Rotation of motor should be checked while electrician is present. This should be done prior to blade installation. An arrow indicating proper rotation is affixed to the arbor access cover. All wiring must conform to the National Electrical Code, state law and O.S.H.A. Power Requirements 7.5H.P. 10H.P. 15H.P. Voltage Phase Full Load (AMPS) Connect air line to the air cut-off valve on the machine table top (1/4 inch female pipe thread). Pressure gauge on the regulator should indicate 90 PSI. Adjust as needed. CAUTION: DO NOT OPERATE SAW WITH LESS THAN 60 P.S.I. The air cut-off valve is provided so the air supply to the machine can be turned off when the saw is not in use. This valve also bleeds the system and allows the guard / clamp to lower. This is a worthwhile safety feature and its use should be encouraged by supervisors. Page 2

3 SAFETY NOTE: An airline interlock has been provided with this machine. This interlock must be locked when performing any maintenance or repair work. 4. A 4 inch dia. dust chute has been provided at the back of the saw. This outlet makes it easy to hook your saw up to a dust collection system. We suggest a minimum of 400 C.F.M. for dust collection. Adequate hose must be provided to allow for the movement of the guard / clamp while the saw is cycling. 5. Install saw blade. Loosen both bolts on side blade cover and swing clear. Remove front blade access door. Slide blade through blade access slot. Verify that tips will be turning in the proper direction for cutting. Tighten arbor bolt after installing the blade. Left hand saws use right hand threads on arbor bolt. Right hand saws use left hand threads on arbor bolt. Replace door and blade access cover. 6. Check work area to be sure it is clear. Turn air cut-off valve to the on position. The guard / clamp should come up quickly. CAUTION: DO NOT PUT FINGERS UNDER GUARD / CLAMP OR SENSOR. Place a piece of material under the guard / clamp. Turn the air cut-off valve to the off position. The guard / clamp should lower onto the material. Adjust the guard / clamp so it will clear the material by approximately 1/4 when air pressure is restored. This is done by turning the large hand knob at the rear of the guard / clamp. Clockwise rotation lowers the guard / clamp. Counter clockwise rotation raises the guard / clamp. CAUTION: DO NOT PUT FOOT INTO FOOT VALVE AREA UNTIL READY TO CUT. 7. After adjusting the guard / clamp height, turn the air cut-off valve to the on position. Operate the 2 hand control and hold it. Saw should clamp material, and blade should come up and make cut. If the machine is installed with a two hand control, you will have to activate the two hand control unit properly to actuate the saw head. Blade should lower back into base and the guard / clamp should release material when the 2 hand control is released. The automatic retract feature should also be checked at this time. Again, with the guard / clamp adjusted and with material in place, depress two hand control and then quickly release it. The saw should immediately return to the at rest position. 8. Installation of your Whirlwind cut-off saw is now complete. Prior to putting the saw into production, have every operator read and understand the Operator s Manual. It is suggested that you document this training and have all operators sign a statement that they have read and understand the instructions. Should you have any questions or comments on this machine, please feel free to give us a call. 9. Your machine is standard with a two hand control for the safety of the operator. The foot pedal controls the clamp and simultaneously charges the two hand control. Without the pedal being depressed, the two hand control will not operate. Once the pedal is depressed and the clamps is set, the two hand control can be operated to actuate the saw head. During the actuation cycle of the saw head, the pedal can be released without the clamps releasing because the two hand control now has control over the saw head and the clamps. Both will release if the two hand control buttons are released. Page 3

4 Diagram F Vertical Clamp Assembly Removing Material From the Blade: If the machine is stalled while cutting, immediately shut saw off and disconnect power. NEVER attempt to free the blade while the motor is still on. If a piece is bound on the blade, do not attempt to raise the material out of the blade. Instead, tap the piece down on both sides of the blade with light pressure until the piece has freed the blade. Cutting Wood: While wood is generally soft and simpler to cut than aluminum, it requires that the material be held in place as the blade passes through the material. CTD suggests using a Carbide Blade with Alternate Top Bevel (AT) for lighter wood sections and picture frame mouldings. This type of blade gives the finest of finishes. No ONE blade will cut all material perfectly. High lacquers or jesso covered moulding may require a special modified blade for best results. Consult factory. Never use a wood blade to cut aluminum, as it will chip and fracture the carbide tips of the blade. Cutting Plastic; High Lacquers,or jesso Mouldings: Plastic can be cut as easily as wood on the Whirlwind class Saws. H.L. & Jesso Mouldings can quickly dull carbide blades ground for wood. It is important to clamp the material as close as possible to the blade and support it by use of fixtures. CTD offers Horizontal and Vertical Clamps for this application. Additional tooling may be required. Cutting Aluminum: As with cutting any material, it is important that aluminum be clamped properly. Precision blades are required for accurate cutting. CTD suggests and uses a Triple Chip Grind on all its non-ferrous Carbide Blades. When cutting aluminum, or other non-ferrous materials, it is essential that the blades be lubricated with a Sawblade Lubrication System or other blade lubricating system for the finest finish. See Sawblade Lubrication System on the next page for more details. Page 4

5 Combination Blades: Any combination blade is basically an aluminum cutting blade. Significant blade life in between sharpenings will be lost if a blade is used for cutting both aluminum and wood. The amount of production for either wood or aluminum should be the determining factor in the assessment of the particular blade type to be used. Please consult factory. Sawblade Lubrication System: The Sawblade Lubrication System is used when cutting aluminum or other non-ferrous materials. This system normally uses a Water Soluble Oil mixture of 10 parts water to one part oil. The system operates by siphoning the lubrication up the line to the spray nozzle. Any air leak will cause inconsistent fluid flow to the spray nozzle. BE SURE your fluid is free from chips and other debris. A fluid container supplied with the machine contains a One-Way Check Valve, Part No. B3P96 at the end of the clear fluid line. This check valve helps to hold the lubrication in the line. However, after a couple of minutes, the lubrication or oil will backflow into the container. Priming of the system may be necessary if the machine has been standing without use. The system may be shut off by closing the toggle valve next to the vacuum pump. The fluid must be clean or the Vacuum Pump will clog. CTD Bio Lubrication System: The CTD biodegradable lubrication system operates by pulse spraying a minute amount of biodegradable lubricant directly on to the saw tooth of the blade in time-measured increments. The majority of the lubricant then dissipates with the heat of the cutting action. Chips coming off the blade are hot and dry, and are more easily collected. (See specific instructions included with system.) Page 5

6 Air Supply: The air supply must be turned off and all electrics disconnected before making adjustments on the power feed. A working pressure of 75 PSI (pounds per square inch at 5.4 kg/cm2) is required. An industrial-type compressor of at least 5 CFM (cubic feet per minute) is recommended. An additional 3 CFM is required for Spray Mists. A conveniently located valve should be supplied by the user to shut off the air line. Arms should be raised or lowered by hand when setting up machine. The machine must use clean, filtered air. The speed of descent of the saw head will vary if the air pressure varies. FR: An Air Filter/Regulator installed ahead of the air inlet to the machine. This system helps prevent foreign material from entering the system. The FR is comprised of two different components. 1. The Air Filter Bowl is located on the left side and is provided with an automatic drain. This collects and then releases foreign matter and condensation collected by the air filter. 2. The Pressure Regulator, which is located on top of the air filter, controls the amount of air pressure allowed into the system. An operating pressure of kg/cm2 is required. (This is set at the factory.) All air cylinders on the saw are Lubed for Life; and do not require a lubricator. AIR FILTER REGULATOR Trouble Shooting the Pneumatic System for Downfeed of Saw Head: If the Air Feed no longer has smooth action, check the Hydrocheck oil level. See separate instructions on Hydrocheck.. If there is no Speed Control, the Hydrocheck may need oil. Consult factory. If air is leaking from the bottom of the cylinder, replace Cylinder with Part No. B3P306 or P/N B3P Way Valve: The 4-Way Valve is the main control, five port valve located on the right wall of the floor stand. If the saw is sticking in the up or down position, the spool located in the valve probably is not shifting from side to side as necessary. This condition is caused by unclean air passing through the system. The internal parts become gummed up, and the air pressure can no longer shift the spool. A broken spring in the valve is another common cause. A 4-Way Valve Repair Kit, P/N B3P76 is available for the valve. Air Hold Down Clamps for the Material: Both Horizontal Air Vises or Vertical Air Clamps are available and can be purchased as an optional accessory. Page 6

7 Hand Valve: The foot valve actuates the clamps into position. Once the foot pedal is depressed, the Two Hand Anti-Tie Down Control is energized and ready to activate. As soon as the Two-Hand Control buttons are depressed, the clamp pressure will be maintained by Limit Valve #1, P/N B3P50. Speed Control of Blade Movement: The up and downstroke speed of the blade is controlled by air flow controls. The Upstroke Control Valve, P/N B3P60 is located on either side of themachine or in fron depending on the machine. Simply rotate head of valve and adjust in to slow down, or out to speed up. If not equipped with a hydrocheck, the down speed is regulated by a flow control valve (P/N B3P60) near the base of the main cylinder. Preventative Maintenance: The Whirlwind Series machines are relatively easy machines to operate and maintain. Following is a weekly check list of General Maintenance items. The best preventative maintenance advise is to CLEAN THE MA- CHINE DAILY, especially around the pivot points on the machine. Lubrication and Adjustments of Bearings: NO LUBRICATION OR ADJUSTMENTS ARE REQUIRED. All CTD cut-off saws are assembled using sealed, prelubricated ball bearings. The spindle and pivot assembly are constructed using preloaded belleville springs. These springs eliminate the need for adjustments of bearings and also greatly increase the life of the bearings. General Maintenance Weekly Check List: Always disconnect electrical power and air supply. 1. Keep machine clean especially around pivot bracket and pivot bearings. 2. Blow off and clean around the cylinder 3. Check Air Filter Bowl for water and condensation build up. 4. Remove any scrap pieces and dust build up from inside floor stand. 5. Check monthly: A. For excessive belt wear B. Make sure motor pulley set screws are tight. Repair and Service: Always use CTD factory authorized replacement parts and consult factory before making any repairs or adjustments which may be unclear. Fence Alignment and 45 Angle Adjustment of Blades: All machines are preset at the factory for perfect 90 and 45 miter cuts. If any adjustments are necessary: 1. Check alignment of fences Use a two foot steel scale or quality precision straight edge and lay flat on table base. Butt edge against fence bracket and long mea-suring gage (if purchased). Touch the outside corner of the straight edge. If one side of the straight edge pulls away from the fence, then the long fence gage is not in alignment with the Right Fence, P/N 400M05. all surfaces of dirt or dust, and re-assemble as before (see Diagrams A & B on Pages No. 3 & 4). 2. Re-align right fence to left fence with your straight edge. Once you are sure both fences are in alignment, you now have a reference point to check your 45 miter. Page 7

8 Whirwind Series Air/Pneumatic System: The air pneumatic system on the Whirlwind series Models are simple to use and understand, and easy to operate. The main components of the air system are shown below in the Air Circuit Piping Diagram. The system operates using a Two-Hand Anti-Tie Down Control for safety. Included with the air pneumatic system are the main drive Cylinder and Valves, an Air Filter/Regulator, and one Vertical Pneumatic Clamp. The Vertical Clamp are actuated at the same time as the saw head (via the Two-Hand Control, P/N B3P110) or prior to the activation of the saw head via a Hand Valve, P/N B3P75 (recommended for safety) which in turn energizes the Two-Hand Control. The two hand buttons must be depressed at the same time for the saw head to travel downwards. The system operates by pushing the foot Valve, P/N B3P75. This gives a signal to the Shuttle Valve, P/N B3P86 to allow air to pass to the Two Hand Anti- Tie Down Control, P/N B3P110. By depressing both palm buttons simultaneously (at the same time), a signal is given to the main 4-Way Control Valve, P/N B3P73 to change direction allowing air to pass to the main drive Cylinder, P/N B3P306 for 16 machines, P/N B3P308 for 20 machines, and a Hydrocheck for precision controlled downstroke. The Cylinder pushes the saw head down. The speed of descent is controlled by the Hydrocheck, P/N B3P146 for 16 machines, and P/N B3P148 for 20 machines located next to the Cylinder. By releasing the Two-Hand palm buttons, air is shut off to the main 4-Way Valve, it shifts direction and the main drive cylinder reverses. Page 8

9 Electrical Installation: The WHIRLWIND Series Up-Cut Saws use 7.5 H.P. three phase 3450 RPM, 60 HZ TEFC (totally enclosed fan cooled) or 10 H.P. three phase 3450 RPM motors on a NEMA 213T or 215T Frame. The blade runs at approximately 3200 RPM for an 18 blade. An optional motor is 15 H.P. Electrical installation should be performed by a qualified and certified electrician. A lock-out or disconnect switch is located on the magnetic starter between your main electrical panel and the machine. This disconnect switch is used to shut off power to the machine and should be used whenever the blades are changed or at any time the machine is serviced and the blade is exposed. A Magnetic Starter (OSHA required) is standard on the machine. The starter protects the motor from overheating and will not allow the motor to restart itself after power outages or undervoltage situations. Electrical Installation of Power to Starter by a Qualified Electrician: All wiring from the motor to the starter has been completed and tested at the factory several times. The voltage has been clearly tagged. DO NOT CONNECT ANY VOLTAGE THAT IS DIFFERENT THAN THE TAGGED VOLT- AGE, AS THIS MAY CAUSE SEVERE DAMAGE AND DANGER. Consult the factory if any changes are needed. Bring power lines to the top of the Magnetic Starter. Use dust proof connectors if available. Three Phase Motors: Connect incoming power line leads to L1 (line 1), L2, and L3. (See Wiring Diagram for Three Phase Motors below.) Green ground wire must be grounded to enclosure. Be sure to check rotation as polarities may be different. The blade must rotate down and to the rear on the underside of the blade (see Diagram D on Page No. 4). If a change in rotation is necessary, reverse any two of the incoming power wires. Example: If the blades are running backwards and incoming wires are connected White L1, Black L2, and Red L3, switch the Black wire with the Red so that Black is connected to L3 and Red is connected to L2. This will change the motor to rotate properly. Wiring Diagram for Magnetic Starter Page 9

10 Troubleshooting Guide for Whirlwind Cut-Off Saws Cut Off Electricity and Lock Out Disconnect Box Before Working on Saw. PROBLEM CAUSE CHECK ========================================================================================== Air on, but guard A. Air pressure too low A. Must be full regulated at inlet of cylinder. does not move up. (90 P.S.I.) B. Guard binding at table B. Apply lubricating oil. Check movement top or cylinder pin. of guard with air off; should be firm, but free Guard is up, foot A. Foot pedal valve faulty. E. Remove pedal & inspect. Replace pedal. valve is depressed, clamp does not clamp Guard is up. Foot A. Shock absorber is locked up A. Disconnect lower end of shock absorber. valve is depressed. Check for freedom of movement. clamps clamp, two hand control is depressed but blade B Check for foeign matter lodged between doesn t come up. clevis and yoke. B. Mechanical binding. C. Check for lose air lines, faulty button valves, or logic unit. C. Faulty two hand control components. D. Pilot valve problem. D. Check for constant air flow at pilot valve mufflers All other valves. A. Pilot valve A. Remove, clean & inspect. Piston must move freely in housing. Housing shouldn t show excessive wear. B. Cylinder. B. Cylinder should extend and retract freely. If not, or if air leaks out end of cylinder, disassemble & inspect piston & bore. Replace seals & apply pneumatic grease. Troubleshooting Guide for Whirlwind Cut-Off Saws Cut Off Electricity and Lock Out Disconnect Box Before Working on Saw. PROBLEM CAUSE CHECK ========================================================================================== Slow cycle. A. Clogged muffler on pilot valve. A. Remove muffler. Clean with solvent or replace muffler. B. Dust or contaminants in top B. Remove cap, clean & inspect. of pilot valve. C. Water in cylinder. C. Clean and inspect. D. Speed adjustment knobs D. Re-adjust speed adjustment knobs. in too far. counter-clockwise to speed up cycle Page 10

11 NOTES: 1. Closely examine rubber seals for damage. 2. Repair kit available for cylinder and some valves. Please call us for availability and pricing. 3. Do not allow sawdust or any foreign matter to enter valves or hoses while the machine is being serviced. 4. Do not remove or tamper with any safety devices. Electrical Problems ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 1. If reset button must be depressed to re-start machine: A. Check wire connections of magnetic starter. B. Check wire to motor. C. Check incoming wire, connections and voltage. D. Verify correct coils for voltage are installed. 2. If machine does not re-start by depressing start / stop button: A. Check wire connections on start / stop switch. B. Follow these wires to box and check connections at box. C. Depress the center of the contactor to verify motor and overload operations. D. Check contactor coil for continuity and operations. Pneumatic Operation of Whirlwind Cut-Off Saws ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ The Whirlwind cut-off saw is a semi-automatic cut-off saw using a pneumatic cylinder and valves to operate each cycle. Incoming air is first cleaned and dried in the filter, regulated from line pressure to 90 PSI. Regulated pressure is then taken to two locations: The foot valve and the pilot valve. Note: Whirlwind saws use a dry air system. DO NOT add lubricant to the air system. The saw will return to idle i.e. guard up, blade down if the 2 hand control is released. The pilot valve does two things. First it directs the regulated air pressure to either end of the cylinder, depending on its position. Second, it exhausts the opposite end of the cylinder. The speed of the cylinder s actuation is determined by the rate of exhaust flow. This flow is adjusted by flow control valves for each direction. These valves are located on the right side of the machine (silver knurled knobs). The upper knob controls the speed up, and the lower knob controls the down speed. Turn the knobs clockwise to slow the travel. When the saw is not in use, the air cut-off valve must be turned to the Air Off position to bleed the system for safety. Page 11

12 Changing V-Belts on Whirlwind Cut-Off Saws ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 1. Loosen four bolts which mount the motor to the table top and slide the motor forward. (W222) unbolt the motor/slide at the top and drop slowly backware to service blet or motor. 2. Remove shock clevis from yoke. Note: Counter-balance spring must also be removed. 3. Remove belt access cover on side of saw. Using access hole, remove two bearing hanger bolts. 4. On left hand saw, loosen two bolts which mount the left hand bearing hanger to the table top. Note: On a right hand saw, loosen bolts which hold right hand bearing hanger. 5. On left hand saw, remove two bolts which mount the right hand bearing hanger. Note: On a right hand saw, remove bolts which hold left hand bearing hanger. 6. On left hand saw, swing right hand bearing hanger down and remove V-belts. Opposite on RH saw. 7. Install new V-belts and reassemble. If desired, an extra set of V-belts can be looped around the yoke and tied out of the way. This will make the next belt change much easier. 8. Pulleys must be parallel within 1/32 of an inch. 9. V-belt tightness should be 5/32 inch deflection with three (3) pounds of pressure. 10. Note: Improper alignment or tension will result in excessive wear on V-belts or bearings. SUGGESTED MAINTENANCE: 1. Check filter/regulator daily for moisture in bowl. Drain as needed. If your air is fairly moist, an air Dryer is highly recommended. Valves that fail due to excessive moisture are not covered under warranty. Note: Whirlwind saws use a dry air system. DO NOT ADD ANY LUBRICANTS TO AIR SYSTEM. 2. Lubricate external moving parts with lubricating oil. 3. Check V-belts and tighten if necessary. (See item 9 above.) 4. Keep inside of machine free of excessive sawdust or aluminum chips. Special attention should be given to keeping foot valve area clean. 5. Keep saw blades properly sharpened. Carbide tipped blades are highly recommended. CTD Machines maintains these blades in stock at very reasonable prices. Page 12

13 WHIRLWIND 218

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15 TERMS: 30% deposit required with order, balance due prior to shipment. Order cancellations subject to restocking charge. All prices F.O.B. Los Angeles, CA Plant. All shipments are made on a freight collect basis. Specifications and prices subject to change without notice. Prices do not include special tooling. Model and serial number are required when placing parts orders. Installation and/or set up is not included. Lease/purchase programs are available through a third party. Motor Warranty: Motors which fail during the warranty period of one (1) year must be returned to an authorized Baldor Service Representative for examination to determine whether the failure was caused by manufacturing. In the event a replacement is required before factory examination, a motor will be sold at the list price. If the factory authorizes replacement, CTD will credit customer s account for the replacement cost. All motors are shipped F.O.B. CTD, Los Angeles, CA Plant. Guarantee: CTD warrants that their cut-off machines and accessories are free from defect of material, workmanship, and title, and are of the kind of quality indicated and described in applicable specifications. The foregoing warranty is exclusive and in lieu of all other warranties, whether written or oral. CTD s obligation under the foregoing warranty is limited to the repair or replacement (at CTD s option) of the part which is defective in materials or workmanship for a period of one (1) year from the date of shipment to the original purchaser, whether for warranties, negligence, or otherwise, shall not in any way include consequential damages, or costs of removing or re-installing the products. All parts and machines are shipped F.O.B. CTD, Los Angeles, CA Plant. CTD MACHINES 2300 E. 11th Street Los Angeles, CA Tel (213) FAX (213) World Wide Web: ctdsaw@ctdsaw.com Page 13