whizard trimmer maintenance overview - nemco - dk · pdf filewhizard trimmer maintenance...
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Whizard Trimmer Maintenance OverviewWhizard Trimmer Maintenance Overview
Proper flex shaft and casing maintenance is critical to good trimmer performance and parts life. These critical parts lubricated before first use and cleaned and re-lubricated after every 20 hours of use.
Clean and Inspect Flex Shafts Remove the flex shaft from casing and wipe with a clean cloth. Inspect the flex shaft for wear, broken wires, kinks, or corrosion.
Also inspect the ferrule for wear.
Note: Broken flex shaft wires will lead to flex shaft and casing failure.
#WhiZLube Heavy Duty Lubricant (Part 185548) Place a quarter size portion of WhiZLube in the palm of your
hand. Apply an even coating of the lubricant along the entire length of the flex shaft.
Reassemble the shafts into the casings.
#WhiZLube Aerosol (Part 173519) Lay a group of flex shafts on a covered surface and generously
spray them lengthwise. Be sure to turn the flex shafts to ensure total coverage.
If lubricating only one, an alternate method is to hold the casing with one hand and spray the flex shaft while it is being inserted into the casing.
For Maximum Flex Shaft and Casing Performance Clean and lubricate after every 20 hours of operation. Do not use flex shaft washers. Avoid contact with mineral oil. WhiZLube aerosol or gelUse only Bettcher . Do NOT use any
other grease!
Do not over bend, kink, or knot casings. Keep Series II
casings upright and straight when not in use.
With a small portion of WhiZLube in your hand, apply an even coat along the entire length of the flex shaft.
Gel MethodGel Method
Clean flex shaft with a clean cloth.
Gel MethodGel Method
12.05.2012
t h e P i o n e e r i n T r i m m i n g
AerosolMethod
Lay a group of flex shafts on a covered surface and generously spray them length wise.
Flex Shaft & Casing Maintenance
How to videoon Lubrication
Rinse & Dry: Rinse and completely dry all parts.
Sharp blades may cause cut injury! Keep hands away from blades! For proper protection of hands, protective cut resistant gloves should be used when cleaning equipment and during the handling of the blades.
Clean: Rinse: Immediately after use. 1. 3.
5.Clean Handle & Frame: Remove handle and clean all surfaces of handle and frame.
4.
Soak: Use 2 oz per gallon of Extra Cleaner of warm water ... soak for 30 minutes.
2.
Case Part #184331
WARNING!
Cleaning – Completely Disassemble & Clean
Any blade that passes through the gauge is worn.Replace Blade.
Simply drop a blade into the gauge.
Part Number Model Number
163917 350 / 350M2163918 360 / 360M2 • 350M2 Low Profile163923 620173576 620M2163924 625 / 625M2173577 620M2 Low Profile163919 500163920 500M2 / 505 / 505M2173575 500 Low Profile / 500M2 Low Profile
163922 560 / 564 / 564M2163925 750 / 750M2173578 750M2 Low Profile163926 850 / 880 / • 850M2 / 880M2163927 1850 / 1880 / • 1850M2 / 1880M2163928 1000–1500 / • 1000M2–1500M2
Blade Wear Gauge - Simple Go / No Go TestBlade Wear Gauge - Simple Go / No Go Test
Compressed Air Helps
#Case 1843314 gallons and pump
#Gallon 184332
Whizard Cleaning Tools Kit #184334
How to videoon Lubrication
When the ‘key' or notch area is worn or damaged, the blade housing will not be secured. This poorly seated housing moves, causing the trimmer to run rough and rapid parts wear.
Replace the frame when worn or damaged.
Deteriorated frame causes the pinion to be exposed and the housing is unsupported. Replace frame.
Examine the FrameExamine the Frame
New Frame
Inspect Frame for Wear
Worn Frame
Damaged, tapered key - Replace.
Note: Defined alignment key.
GoodGoodGoodGood
ReplaceReplace
Inspect Frame for WearClose-up of Alignment ‘Key’ or notch
Inspect Parts and Re-AssembleInspect Parts and Re-Assemble
®Whizard Trimmer – 620M2
Please review Operating Instructions for complete instructions and safety information.Please review Operating Instructions for complete instructions and safety information.
Flanged Bearing
183060#
Pinion183365#
HandleSpacer Ring#183120
Cover183356#
Handle#Grease Cup Assembly 163263
#Bulb 163265#Washer 123523#Retainer Ring 163266#Base & Fitting 163269
-{
Standard #183605
Low Profile #183353
Standard#183354
Serrated #185787
625M2 Blades
620M2 Blades
Bearing Removal Tool Kit
#Part 184983
Bearing Removal Tool
Push Rod
625M2 Cover withSteeling Device
183368#
625M2 Cover withSteeling Device &
Depth Gauge 185979 #
Inspect PinionInspect PinionCheck for rounded or broken teeth. When re-placing the pinion also replace the bearing.
Damaged teeth caused by worn parts or improper housing adjustment.
Normal wear pattern. Replace pinion and bearing.
Frame Assembly#183866 R#183867 L
Cover Retaining #Screw (2) 183376
HandleRetaining
Knob183086
#
Housing{ Off-Set 185606#
Center Split 188078#
Depth Gauge Only
#185689
Deteriorated frame causes the pinion to be exposed and the housing is unsupported. Replace frame.
Examine the FrameExamine the Frame
Depth Gauge–Skin#Open 183076
Cover with Steeling Device
#183056
Cover Retaining #Screw 183654
(2) used
Blade Housing#183070
Damaged, tapered key - Replace.
Note: Defined housing alignment key.New Frame
Worn Frame
GoodGoodGoodGood
ReplaceReplace
When the ‘key' or notch area is worn or damaged, the blade housing will not be secured. This poorly seated housing moves, causing the trimmer to run rough and rapid parts wear.
Replace the frame when worn or damaged.
Inspect Frame for Wear Close-up of Alignment ‘Key’ or notch
Please review Operating Instructions for complete instructions and safety information.Please review Operating Instructions for complete instructions and safety information.
Depth Gauge–Beef#Closed 183075
®Whizard 750M2/850M2 – 880M2/1880M2
Standard #183071
Serrated #185619
#183072
1850/1880M2 Blades
Serrated#183289
Standard #183073
850M2 Blade
750M2 Blades
Inspect Parts and Re-AssembleInspect Parts and Re-Assemble
Inspect PinionInspect PinionCheck for rounded or broken teeth. When re-placing the pinion also replace the bearing.
Damaged teeth caused by worn parts or improper housing adjustment.
Normal wear pattern. Replace pinion and bearing.
Frame Assembly#183896 R#183897 L
Thumb Support#163207
HandleRetaining Knob
183086#
Bearing#183060
Pinion#183063
-{#Medium Grease Cup 173191
#Bulb & Washer 173208 #Retainer Ring 173190 #Base & Fitting 173187
Deteriorated frame causes the pinion to be exposed and the housing is unsupported. Replace frame.
New Housing Close-up of ScallopClose-up of ScallopInspect Blade Housing for WearInspect Blade Housing for Wear
Examine the FrameExamine the Frame
Worn Housing
Good
Replace
Good housings have large defined scallops. Note: Defined scallop on the back wall.
Upper scallop is completely worn away.Replace when scallops are worn away.
GoodGood
ReplaceReplace
®Whizard Trimmer - 1000M2 Series
Please review Operating Instructions for complete instructions and safety information.Please review Operating Instructions for complete instructions and safety information.
#Housing 183143
Frame Assembly#
Right Hand 184362#
Left Hand 184363
Flangless Handle
Standard#183142
Serrated#183266
Standard#183141
Serrated #183265
1000/1500M2 Blades
Inspect Parts and Re-AssembleInspect Parts and Re-Assemble
1300 /1400M2 Blades
Cover with Steeling Device#1000 / 1500M2 183163 #1300 / 1400M2 183164
#Cover WITHOUT Steeling 185552
Flanged Bearing#183060
Pinion#183154
Handle Spacer
RingDepth Gauge
#183160
Depth Gauge#183159
HandleRetaining Knob183086#
Inspect PinionInspect PinionCheck for rounded or broken teeth. When re-placing the pinion also replace the bearing.
Damaged teeth caused by worn parts or improper housing adjustment.
Normal wear pattern. Replace pinion and bearing.
Cover Retaining #Screw (2) 183654
#Medium Grease Cup 173191#Bulb & Washer 173208
#Retainer Ring 173190 #Base & Fitting 173187
-{
Proper Housing Adjustments
The correct blade housing adjustment is critical for proper trimmer operation. If the housing is too tight the trimmer may overheat. The motor-driven flex shaft and casing may be dam-aged, and parts life will be reduced. If the housing is adjusted too loose, it may cause rough operation and gear damage. Here's a procedure to help you get it right:
Tighten Blade Housing: Begin by threading both screws in the pinion cover. Then tighten the right cover screw. Next, secure the left cover screw— then loosen the left screw a half turn to allow for blade and housing adjustment.
Blade Adjustment: Gently pry the housing open (see Image 1) until the blade has a slight amount of side clearance in the housing in the direction of the arrow shown in Image 2 and the blade rotates freely. A slight amount of clearance is all that is needed. Finally, tighten both cover screws to the recommended torque and recheck the blade clearance and rotation.
Recommended Torque: 30 - 35 lb. in. (3,4 - 4,0 N-m)
Important: Make sure the blade is free to move in the housing. If the blade does not move freely, it may cause the trimmer to perform poorly or overheat.
With the left screw loosened, gently pry the housing open if the blade is not moving freely.
The blade should turn freely with a slight amount of clearance in the direction shown by the arrow.
Right
Left
Image 1. Loosen Blade
Housing
Image 2. Check blade for clearance and rotation.
1000~1500M2#183154
620M2A#183367
Angled Head Trimmer
500/564M2620/625M2#183365
350/360M2440M2
#183651
750/850M2880/1880M2
#183063
Series II PinionsSeries II Pinions
Begin by making sure the cover is tightened securely … that is, the cover retaining screws are tightened properly (very tight).
The “best practice” to secure the pinon cover and housing is to use a torque limiting T-handle tool (Bettcher Part #183898) to secure the housing quickly and properly.
Using a straight-blade screwdriver, slowly apply pressure to the housing. If the housing moves easily without much pressure, the cover is worn. It should be replaced, as it can no longer secure the blade and housing and may become a safety issue in addition to running rough.
If the blade housing does not move easily unless a lot of pressure is applied, then the cover is still good and has useful life.
That's all there is to it! By using this simple test, you should improve Trimmer performance and lower maintenance costs.
You may also view a video clip demonstrating these test procedures. To view the video go to:
Begin with a properly tightened cover using the Bettcher Torque Limiter
30 - 35 lb. in (3,4 - 4,0 N-m)
Cover Wear TestingSimple test to determine the time to replace.
Apply gentle pressure, if the housing moves, the cover is worn.
The cost of a T-handle torque limiter is about the same as a new pinion cover, so it makes sense to invest in this tool to ensure all Trimmer parts are properly assembled for maximum life and performance.
Additionally, many maintenance pros find that using the T-handle torque limiter is faster, easier and more precise than using a straight blade screwdriver.
Torque Limiting T-Handle: A Key Part of Your Toolkit
Torque Wrench KitPart #183900
Part # Description183900 Kit 183900
183898 Torque wrench
183899 Socket ¼” 6 pt
183901 Socket 5/16” 6 pt
183902 Extension ¼” x 3” long
Damage occurs when the housing is pried without first loosening the cover screw (red arrow).
LoosenFirst
!
Preventing Cover Damage
www.bettcher.com/pinion-cover
Handle Diameters and Part Numbers
Large1.69”
42,9 mm
XX Small1.23”
31,2 mm
Flangless Non-DisconnectQuick-Disconnect
X Small1.28”
32,5 mm
Small1.39”
35,3 mm
Medium1.44”
36,6 mm
Series II Small #183767Requires XX-Small Spacer #163313
Series II Medium #183768Requires XX-Small Spacer #163313
Post Handle Kit#183620
Micro-BreakStrap
Thumb Support#163207
Handle Spacer Ring#183120
Handle Spacer Ringfor Only XX-Small
#163313
HandleRetaining Knob
#183086
Aluminum Handle-Small
Aluminum Handle-Medium
Flanged Non-Disconnect Handles Flangeless
183040 Large (Green) 183918
183041 Medium (Blue) 183919
183042 Small (Grey) 183920
183043 X-Small (Turquoise) 183921
183511
183588
XX-Small with Spacer (Tan)
XX-Small no Spacer (Tan)
183935
183922
Flanged Disconnect Handles Flangeless
183045 Large - Disconnect (Green) 183937
183046 Medium - Disconnect (Blue) 183938
183047 Small - Disconnect (Grey) 183939
183048 X-Small - Disconnect (Turqoise) 183940
183512
183589
XX-Small - Disconnect with Spacer
XX-Small - Disconnect no Spacer
183942
183941
505M2 / 625M2
Open-Style Depth Gauge
Closed-Style Depth Gauge
Trimmer Part #
880M2B 1830751880M2* 1830771500M2 183160
Trimmer Part #
880M2S 1830761400M2 1831591932M2 1851161942M2 185116
Closed style depth gauge for defatting T-bones.
*Heavy-Duty Thick Design
Series II Depth Gauges
850 / 880M2 #173347850 / 880M2 #173347
1400 / 1500M2 #173348 1400 / 1500M2 #173348
The inner disk can be flipped: metric on one side and US inches on the other.
Setting FixtureSetting Fixture
Trimmer Part #
625M2
505M2 - 1 Screw505M2 - 2 Screw
185979
183705188083
Series II Disc Gauges
Disc1000M2-N
Assembly Kit
#184365
Disc850M2-S
Assembly Kit
#183801
Disc1300M2-S
Assembly Kit
#183794
Disc – Skin
Disc – Skin
Disc – Skin
Disc – Skin
Trimmer Kit # Diameter (cm)
850M2-S 183801 8,01000M2-S 183792 10,91300M2-S 183794 9,81000M2-N 184365 10,4
Disc1000M2-S
Assembly Kit
#183792
183787
183619
184367
183789
183790
Disc1300M2-F
Order Kit#183795
Disc1000M2-F
Order Kit#183793
Trimmer Trimmer Part #Part # Dia (cm) Dia (cm)
1000M2-F 183793 10,41300M2-F 183795 9,5
Disc – Fat Disc – Fat
Lubricants for Better Performance and Tool Life
WhiZLube Solid designed especially for flex shafts
WhiZLube aerosol penetrating formula for flex shafts
MaxZLube High Performance Lubricant for AirMax gear head
LubricantPart
Number Quantity Lubricant Type Applications
163329
100608
24 pack - 8 oz. Tubes
8 oz. Tube Solid Lubricant
(Use Grease Gun*)Modular, UZ, Series II & AirMax™ Trimmers
Fills the grease cup and lubricates blade, housing,pinion and bearing.
143631 14 oz. Cartridge Solid Lubricant
Use Standard Grease Gun(Not supplied by Bettcher)
®AirShirz : Lubricates drive roller and servo link.
16332825 pack - 14oz.
Cartridges UZ: lubricates gear head assembly.
100640 35lb. Bucket
185546 4 oz. Tube Solid Lubricant
185548 12 oz. Cartridge Solid Lubricant
Casing Maintenance Kit
(WhizLube™ Spray)
173519 11.25 oz. Aerosol Aerosol Lubricant
Series II flex shafts: Lubricate
103603
185617
Pint Bottle
Gallon Jug
Liquid
AirMax™ & UZ Trimmers: Lubricates air motors
FRL (Filter, Regulator, Lubricator): Fills up the FRL.
184282 4 oz. TubeSolid Lubricant
High Speed/High Performance AirMax™: Lubricates gear head assembly & general use
Grease Gun 113415Accessory for Filling
Whizard Grease CupsFor use with Special Grease 8 oz. Tube (#100608)
Planetary Gear
Grease Gun113326
#113326
Needle NoseAccessory
Use with 4 oz. Tube (#184282) & 8 oz. Tube (#100608).
AirMax™ & UZ Trimmers: Lubricates planetary gears
®: AirShirz lubricates drive roller and servo link
Whi Lube
Heavy-Duty Lubricant
Heavy-Duty Lubricant
SPECIAL
GREASE
M A X L U B EH IGH PERFORMANCE LUBRICANT
Food GradeMultipurpose
Lubricating Oil
H-1: Lubricants approved for incidental food contact that may safely
be used on machinery used for producing, manufacturing, packing,
processing, preparing, treating, packaging, transporting or holding food.R E G I S T E R E D
Actual Casing Measurement48” Casing = 46 5/8” [118.4 cm]60” Casing = 58 5/8” [149 cm]84” Casing = 81 7/8” [208 cm]
Driver Assembly 5 ½” [14 cm]
®Casings are an important part of your Whizard Trimming System. To help get the most out of your casings, here are some tips that will make it easier to order the correct replacements, keep maintenance costs low by removing the driver assembly, and some tips on lubrication for longer casing and flex shaft life.
Quick-Disconnects A spring-loaded lever that fits inside the handle instantly stops the trimmer when-ever an operator's hand-grip is released.
(not included in measurement)
Measure from red arrow to red arrow
Series II DuraFlex Casings
Casing Flex Shaft Only Only
Non-Disconnect Assembly
Disconnect Assembly
Includes Driver Assy
Includes Driver Assy
Includes Driver Assy
Includes Driver Assy
48" Series II DuraFlex 183771 183849 183852 183837
60" Series II DuraFlex 183772 183850 183853 183838
84" Series II DuraFlex 183773 183851 183854 183839
Series II DuraLite™ Casings
Casing
Only
Non-Disconnect Assembly
Disconnect Assembly
48" Series II DuraLite™ 183491 183856 183859 183661
60" Series II DuraLite™ 183492 183857 183860 183662
84" Series II DuraLite™ 183493 183858 183861 1838320.1
87
”F
lexs
ha
ftD
iam
ete
r
0.2
50”
Fle
xsh
aft
Dia
mete
r
Includes Driver Assy Includes Driver Assy
How to Order Series II Casings
Casings may be ordered with or without the driver assembly. The driver assembly is easily removed with an adjustable wrench and fitted onto a new casing. Here is how to measure and identify your casing …
Flex Shaft Only
DisconnectDriver Assembly
Non-DisconnectDriver Assembly
Lever #183108
Lever Collar#183110
Latch Collar#183111
When replacing a Series II casing, the driver assembly may be removed and used on the new casing. To remove driver assembly:
Hold the worn casing end in vise. Unscrew the drive end assembly, turning counterclockwise, using
the wrench flats on the drive end assembly. Remove the washer and latch collar from casing. Discard the old casing, but reuse the driver assembly on the new
casing.
Assembling the Driver Assembly to the Casing Slide casing latch collar and washer on to new casing end.
® Clean threads of new casing and apply Loctite #242 Threadlocker. Verify small casings are marked with ‘S’ for small. Thread drive end assembly on to the new casing and tighten with a
wrench while holding casing in hand.
Caution: DO NOT hold the new casing in a vise or use pliers as damage will occur. It is not necessary to over-tighten this joint.
Grease flex shaft with Bettcher WhizLube™ and install in casing.
Use an adjustable wrench to remove the driver assembly from the
casing.
Casing Driver Assembly
TrimVac Sharpener & SteelSharp blades increase productivity and performance.
17
8
2
3
4
5
6
Complete Assembly
Item # Description Part # Qty
1 TrimVac 18AMX Sharpener 184377
2 Sharpening Rod 183893 1
3 Guide 184379 1
4 Socket Head Cap Screw 122510 2
5 Spring Pin 122409 3
6 Steeling Rod 163124 2
7 Set Screw 120092 3
8 Steeling Asm. Ball Tip 184423 1
LatchCollar #183111
PlasticWasher#123314
Casing
Save money by reusing thedriver end assembly.
Drive End Assembly Complete
(Tube, Spring, Driver)
Large Complete #183099Small Complete #183503
SS
The small sized driver is marked with a letter ‘S’ for use with small size casings.
Driver Assemblies
Large #183101
Small #183502
Driver - Tube & Spring Onlyfor Large & Small #183129
Broken wire.Replace flex shaft.
Rounded ferrule.Replace flex shaft.
New flex shaft.
Worn ferrule and corrosion.Replace flex shaft.
Mineral oil causes casing to swell.
Nicked casing.
Melted casingcaused by a kink.
Break.
Common Flex Shaft and Casing Failures
Motor adapters should be changed at least once a year. If motors are used for two shifts per day, adapters should be changed every six months.
Adapters are inexpensive and easy to replace. Simply unscrew the Quick Disconnect and swap out the adapter. Care should be taken not to over torque the Quick Disconnect.
Motor Adapters
New flex shaft.
Worn flex shaft.
UltraDrive
UN-84Motor
1/2” 3/8”
Motor Adapters Part Number
UN-84 Motor # 143077
UltraDrive™ Motor # 163400
UltraDrive
UN-84Motor
Drive Adapter#163400
UltraDrive
Drive Adapter#143077UN-84
Quick Disconnect
#163190
The E-Z Edge or Edge Master may be fixed to a table or other work station for more convenient sharpening or steeling.
Sharpens & Steels Trimmer Blades
Mounting BlockE-Z Edge or EdgeMaster
#173090
C
Bottom View
Close-Up
Step 1: With the trimmer running, place the E-Z Edge locator over the blade housing.
Step 2: While holding the E-Z Edge Sharpener firmly down on the blade housing, slide the sharpen-ing rod against the blade for a few seconds, with very light pressure.
Step 3: Slide blade against the steeling rod for a few seconds, with very light pressure and you’re done!
Step 1: With the trimmer running, place the trimmer inside the locator. Make sure the blade is centered between the two rods.
Step 2: Rest the blade flat on the two rods with a very light pressure.
Step 3: Slide blade against the steeling rod for a few seconds, with very light pressure and you’re done!
Easy to Train, Easy to Use
Top View
Flat Blades
Straight Blades
Top View
All trimmers should be disassembled, cleaned, and lubricated after every 8 hour shift. Flex shafts and casings should be cleaned and lubricated after every 20 hours of use.When these procedures are followed, the estimated parts life, based upon single shift use is indicated below:
Place a mark in the proper box to indicate when a part was changed
Whizard Trimmer Maintenance Log
Proper Motor Mounting Height for a Flat Surface
All Motors
28”71 cm
40”102 cm
40”102 cm
28”71 cm
All Motors
Mount motors behind worker.
XBad
Excessive curves
accelerate wear!
Eliminate droopy flex shafts.
Motor position for left- or right-hand dominance.
Right Hand
Left Hand
P a r t P a r t Dec.Dec.Jan.Jan. Nov.Nov.MayMay Jun.Jun. Jul.Jul. Aug.Aug. Sep.Sep. Oct.Oct.FebFeb Mar.Mar. Apr.Apr.
Pinion
Flex Shaft
Blade
Blade Housing
Bearing
Casing
X
WeeksWeeks
Blade 3 - 4
Flex ShaftBlade Housing 8 - 10
CasingPinion Gear 6 - 8
Bearing 10 - 12
WeeksWeeksP a r t P a r t P a r t P a r t
6 - 8
12 - 16
Whizard Trimmer and AirShirz are registered trademarks of Bettcher Industries. US and International patents. © 2012 Rev. C Order: TS-1001 A4
www.bettcher.com
Headquarters: 6801 State Route 60 • Birmingham, OH 44889 Tel: (440)965-4422 • (800)321-8763 • Fax: (440)965-4900 • E-mail: [email protected] @WhizardTrimmer