whizard trimmer maintenance overview · whizard trimmer maintenance overview proper flex shaft and...

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

http://bettcher.com/whizlube

https://vimeo.com/43684869#




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

https://vimeo.com/43669907




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



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


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





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


New Housing Close-up of ScallopClose-up of ScallopInspect Blade Housing for WearInspect Blade Housing for Wear


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


#Housing 183143

Frame Assembly#

Right Hand 184362#

Left Hand 184363

Flangless Handle

Standard#183142

Serrated#183266

Standard#183141

Serrated #183265

1000/1500M2 Blades


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#




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




48" Series II DuraFlex 183771 183849 183852 183837



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

whizard trimmer maintenance overview · whizard trimmer maintenance overview proper flex shaft and...

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