Whirlwind 216 User manual

STANDARD EQUIPMENT :
• 10 HP Baldor TEFC Motor
208 / 230 / 460 / 3/ 60
• 3 Premium V-Belts
• Filter, Regulator, Coalescing Filter w. Gauge
• Magnetic Starter
In Nema 12 Box
with Low
Vo ltage Controls
• Tempered Chrome-
Maly Spindle
• Heavy Steel Spindle Housing
• 4" Cast Aluminum Dust Chute
•
Air Supply Lock-Out
OPTIONAL EQUIPMENT:
• 20" A.TB . or T.C.G. Systi-Matic Blades
• Spray
Mist for Metal and Plastic Use
• Electric Delete Credit
• 15 HP Baldor TEFC Motor
• 7 1/ 2 HP Single Phase Motor
ELECTRICAL (Amps)
Current 230 Vo lt s
Motor Running
26 Amps
Service Current
50 Amps
460 Volts
13 Amps
25 Amps
-- -- MATERIAL FLOW
2 1/4" cast i ron
table top
ACCESS DOOR WITH
AUTOMATIC ELECTRIC
INTERLOCK
4 INCH EXHAUST
FITTING IN BACK --
SPECIFICATIONS:
• Blade Size: 20 " x 1" Bore
• Blade Speed: Approx. 3,
165 RPM
• Cycle Speed: Up to 40 I Minute
•
Air Cylinder: 2" x 12"
• C.F.M. Approx.
1.96 -SCFM 12.65
• Table Height: 36 3/ 4 Inches
• Floor Space:
26 " x 33 1/ 2 Inches
• Made With Pride
in the U.S. A.
CAPACITY:
• 1 x 18 , 2 x 16 , 3 x 14 , 4 x 12
• 5 x 10 and 6 x 8
HEIGHT ADJUSTMENT KNOB TO
ADJUST CLEARANCE BETWE EN
-- LUMBER AND GUARD/CLAMP
(S HOULD BE 1/4 INCH)
AIR CUT-OFF VALVE W. LOCK-OUT
RECESSED TOP FOR
OPERATOR'S HANDS
MAGNETIC STARTER
IN NEMA 12 BOX
LO W VOLTAGE
CONTROLS
ONE PIECE
1/4" STEEL PLATE:
ALL 4 CORNERS BENT
AIR H OSE FOR
CLEARING CHIPS
MODEL 216 LEFT HAND SAW

Whirlwind Inc.
4302 Shilling Way Dallas, TX USA 75237
[phone] Fax [phone]
www.whirlwindsaws.com
Whirlwind Model 216 Cut-Off Saw Owner's Manual
Table of Contents
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General Safety Rules .........................................................................................................Page 01
Cover Page ........................................................................................................................Page 02
Set-Up Instructions .................................................. .. ............... ... .. ......... .. .........................Page 03
Fence Combination Guidelines .. ...................................... .. ......................................... ... .... Page 05
Trouble Shooting Guide .....................................................................................................Page 06
Adjustment of Valves .........................................................................................................Page 07
Instructions for Changing V-Belts ..... .... ........................... ... ............. .. ... ................... .. ..... ... Page 08
Suggested Maintenance ............................... ... ... ...... ... .. ................. .. ........................... .. .... Page 08
Warranty ................................................. .. ......... .. .................................. .. ..... .. ............. .. . ... Page 09
Assembly Drawing ......... .. ..................................................................................................Page 10
Diagram
of Cylinder ... . ... ............. .. ..... .. ....... ... .. ... .. .......................................................... ... Page 12
Final Assembly Checklist .. ......... .. ...................... .. ...................... ... ...................... ... ... .. .. .....Page 13
Brochure Model 216 Cut-Off Saw .................................. .. ..................................... ... .. ... ......Page 15
Material Handling Equipment Flyer ........
... .. ... ... ........................... .. .......... .. ... ....... .. ... .........Page 16
Safety Guide for-Carbide Tipped Blades ............................................... .. ......................... .. Page 17
Specifications on Compressed Air Filter I Regulators .................................. ... .. ..... ... .. ...... Page 18
Specifications on Coalescing Filters ................................................................................. Page 19
Whirlwind Return Policy .. .. .. .......... .. ... .. ...................................... .. ....... .. .. .. ........:................Page 20
Double Palm Button Controls .......................
... .. ... ........ .. .......... ... .... .. ... ... .. ...... .. ................ Page 21
R081303

General Safety Rules for Whirlwind.Cut-Off Saws
+++++++++++++++++++++++++++++++++++++++++++++++++++
1. READ AND UNDERSTAND THE OPERATING INSTRUCTIONS BEFORE OPERATING SAW.
2. If
you are not THOROUGHLY familiar with the operation of the equipment you are assigned to ,
ask your supervisor. instructor or other qualified person for further instruction.
3.
DO NOT operate any piece of equipment while under the influence of any type of medication,
alcohol or drugs.
4. ALWAYS wear eye protection (safety glasses or a face shield).
5. Remove loose clothing, tie, rings, watch and otherjewelry, and roll up shirt sleeves prior to
operating machinery. DO NOT wear gloves while operating machinery.
6. GUARDS must be in place and used at all times.
7. CAUTION: Never put hands under yellow guard I clamp.
8. ALWAYS use a "push stick" or air gun to clear away chips and sawdust.
9. AVOID awkward operations and hand operations where a sudden slip or loss
of balance could
cause your hand to move into the blade area.
10 . DO NOT work with lumber that is too large or too small to handle safely.
1
1. Make all adjustments to machine with air and electrical power OFF.
12. DISCONNECT the saw from all power sources (air and electrical) and wait for blade to come to a
COMPLETE STOP before making repairs or performing routine maintenance.
13 . NEVER attempt to free a stalled saw blade without first turning electrical power and air OFF.
14 . SHUT OFF all power sources (air and electric) and clean the machine before you leave i t.
15 . CHECK SAW prior to operation for any damaged parts. Report any problems to your supervisor.
16. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN 0.FF POWER (air and electric).
Don 't leave saw until it comes to a complete stop.
1
7. IF IN DOUBT as to what you should do, call WHIRLWIND INC. The telephone number is located
on the Air Cut-Off Valve Caution Label.
SAFETY FIRST!

Cover Sheet
Whirlwind Model 216 Pneumatic Cut-Off Saw
============================================================================
Before we get started, we would like to thank you for your purchase of a Whirlwind Model 216 Cut-
Off Saw . We realize we have a lot of competition out there and we truly appreciate your business.
In preparing this manual we've tried to provide the answers to most problems that might arise.
However, if we've missed something, please give
us a call. You should also be aware that an
operator's manual has been provided with the machine. We encourage you to have each and every
operator spend a few minutes to become familiar with
it.
This machine, like every Whirlwind, was tested under power for 4-5 hours 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 perform at its best. The operator's manual gives instructions
on a few pre-operational tests. These tests should be performed at the beginning of each shift. If any
malfunction
is noted, it should be corrected immediately.
Numerous safety devices are installed
on this machine for the protection of your operators.
These devices must not be removed or tampered with.
CAUTION: NEVER PUT FINGERS UNDER GUARD I CLAMP.
Again, we would like to thank you and welcome you to the large family
of Whirlwind customers.
We'
re confident you'll be impressed with our products and our service. With proper maintenance,
your Whirlwind Model 216 should provide many years
of excellent service.
For your records, please fill in the followi
ng informati on :
Date machine purchased ________ _
Seri
al number
-----------
Model number -216
Page 02 R081303

Set-Up Instructions for Whirlwind Model 216 Cut-Off Saw
============================================================================
1. Position machine and bolt to floor. If infeed and outfeed tables are to be used, these should be
aligned with saw fence and table top.
When alignment is satisfactory, bolt table legs to floor.
2. Have a certified electrician bring in power , connect machine, and check voltage. Rotation of
motor should be checked while electrician is present. This should be done prior to installation
of the blade. An arrow indicating proper rotation has been provided on the arbor access cover.
All wiring must conform
to the National Electric Code , O.S.H.A. and local standards .
Power Requirements
Voltage 230
Phase 3
Service Current (Amps) 50
Motor Running Current ( Amps ) __ 26
or 460
3
25
13
3. Connect air line to the air cut-off valve on the machine table top ( 1/4" female pipe thread ).
Pressure gauge on the regulator should read 90 PSI.
CAUTION:
DO NOT OPERA TE MACHINE WITH LESS THAN 60 PSI.
This machine is equipped with a filter, regulator and coalescing filter system for incoming air.
DO NOT ADD OIL TO THE AIR SYSTEM.
The air cut-off valve is provided so t hat when the saw is not in use, this valve can be closed.
This cuts off air supply, bleeds system and allows the guard/clamp to lower. Use of this safety
feature should be encouraged
by all supervisory personnel. A lock-out is also provided on this
valve. ·
4. A 4" dia. exhaust fitting has been provided at the rear of the machine. This fitting allows easy
installation into dust collection systems.
Adequate hose must be provided to allow for the
movement of
th e guard while the machine is cycling. -
Page 03 R081303

Model 216 Set-Up Instructions (Cont'd.)
============================================================================
5. Install blade on saw . The model 216 uses a 20" x 1" blade. Loosen bottom bolt and remove
top bolt from bl
ade cover on front of machine. Loosen bolt on arbor access cover and swing
cover cl
ear . S li de blade through the blade access slot and position on arbor. Verify rotation
with arrow on arbor access
cover . Tighten arbor bolt through arbor access hole. Left hand
saws use right hand threads on arbor bolt. Right hand saws use l
eft hand threads. Replace
access cover
6. Check work area to be sure it is clear. Turn air cut-off valve to the "ON" position. The guard I
clamp will come up quickly.
CAUTION: DO
NOT PUT FINGERS UNDER GUARD I CLAMP .
Depress the green
"START" button on the start I stop switch to turn on the motor. Making
sure that nothing is in the blade path , depress the palm buttons. Saw should cycle once.
For cutting, the guard I clamp should be adjusted to clear material by about 1/4 inch. This
clearance is adjusted by turning the hei
ght adjustment knob. This is the cast aluminum knob
located just behind
the guard/clamp. Turn the knob clockwise to decrease the size of the
opening. To increase the size
of the opening, turn the knob counter clockwise. This adjust-
ment
is quick and easy when air to the machine is off.
7. After adjusting the guard I clamp height, turn the air cut-off valve to the "ON" position. Verify
there is nothing in the blade path. Quickly press and release the palm buttons. Guard I
clamp should begin to clamp and then quickly retract. If
saw does not perform in this manner . ·
call us immediately. Palm buttons must be depressed
throughout the cutting cycle. After the
cut is completed, you
must release the buttons before beginning another cycle.
CAUTION: DO
NOT PUT HANDS ON PALM BUTTONS UNTIL YOU ARE READY TO CUT.
8. Installation of your Whirlwind Model 216 Cut-Off Saw is now complete. Have every operator
read
and understand the operator's manual prior to putting this machine into production.
Sh
ou ld you have any quest ions or comments on our products, please give us a call. Our
phone
nu mber is proudly displayed on the air c ~t - o ff valve caution l abe l.
Page 04 R081303

Fence Configurations for Various Material Sizes
============================================================================
Maximum Material Widths Using Various Fence Inserts
Std. +
Material Std Std + Std + Std + Std + 2 SMX-40A-1
Thickness Only
SMX-42A SMX-40A-1 SMX-40A-2 SMX-40A-1 SMX-40A-2
1"
2"
3"
4"
5"
6"
18 17 16
15
14 13
16 15
14
13
12
14 13
12 11
12
11 10
10 9
8
Note: Various fence combinations will satisfy more than one cut width requirement.
For example, the set-up using the standard fence and one
SMX-40A-2 will cut 4 x 12, 3 x 13, .
2 x 14 and 1 x 15.
SMX-42A -- 1 inch wide fence insert can only be used in combination with the standard
fence (SMX-38A). Two 1/4 -
20 x 1" long socket head cap screws are required for attachment.
SMX-40A-1- -- 2 inch wide fence insert can be used alone, in combination with thestandard
fence or combined with the standard fence and another 2 inch or 3 inch insert. Three 3/8 -16
x 1" long hex head bolts and special thick washers are required to mount each insert.
SMX-40A-2 -- 3 inch wide fence insert can be used alone, in combination with the standard
fence or combined with the standard
fence and one 2 inch insert. Three 3/8 -16 x 1" long hex
head bolts and special thick
washers are required for mounting.
Page 05 R081303

Troubleshooting Guide for Whirlwind Model 216 Cut-Off Saw
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Electrical Problems
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1. If reset button must be depressed to re-start machine:
A Check wires
on magnetic starter.
B. Check wires
to motor.
C. Check incoming wire connections and voltage.
D. Verify correct heaters are installed.
2. If machine re-starts by depressing start/stop button:
A. Check wires to start/stop switch.
B. Check wires to door interlock switch.
C. Follow these wires to box and check connections at box.
NOTE:
1. Closely examine all rubber seals for damage while disassembling valves.
2. Repair kits are available for cylinder and pilot valve.
3. Do Not allE:lw 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.
Page 06 R081303

Adjustment of Valves for Whirlwind Model 216 Cut-Off Saw
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Your Whirlwind model 216 cut-off saw was run-in for 4 - 5 hours and then adjusted to factory
specifications. The double palm manifold requires
no adjustment and all other valves should be
adjusted properly. Adjustments to cycle speed may be made for various applications. This adjust-
ment
is outlined below.
CAUTION: CUT OFF ELECTRICITY & LOCK OUT DISCONNECT BOX BEFORE ADJUSTING
VALVES.
Cycle speed
is adjusted by two alien cap adjustment screws located on the pilot valve. The upper
screw adjusts the speed of the cylinder expanding. The lower screw adjusts the speed of the cylinder
contracting. The speed ofthis expansion and contraction should be equal. The model 216 saw
should be adjusted to cycle 40 times per minute without lumber under the guard. When the saw
is
cutting lumber, cycle speed will increase. This is due to the fact that the guard is traveling less
distance. Maximum cycle time while cutting
is approximately 40 cuts per minute.
NOTE: Exceeding 40 cuts per minute may reduce the life of the machine.
Page 07 R081303