TECHNICAL BETTCHER LARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC. REV. June 28, 2012
Information in this document is subject to change without notice.
No part of this document may be reproduced or transmitted in any form or any
means, electronic or mechanical, for any purpose, without the express written
permission of Bettcher Industries Inc.
Written permission to reproduce in whole or part is herewith granted to the legal
owners of the Whizard Trimmer with which these Operating Instructions have
been supplied.
Operating Instructions in other languages are available on request. Additional
copies of Operating Instructions are available by calling or writing the local
Representative or by contacting :
BETTCHER INDUSTRIES INC.
6801 State Route 60
Birmingham, Ohio 44889
U.S.A.
Telephone : 1-440-965-4422
(In The U.S.A.) : 1-800-321-8763
Fax : 1-440-965-4900
The Infomation Provided In These Operating Instructions Are
Important To Your Health, Comfort And Safety. For Safe
And Proper Operation, Read This Entire Manual
Before Using This Equipment.
Copyright 1999 By Bettcher Industries, Inc.
All Rights Reserved
Original Instructions
Page i
TECHNICAL BETTCHER LARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC. REV. June 28, 2012
Table Of Contents
SECTION 1.0 Machine Specifications 1
SECTION 2.0 Designated Use 1
2.1 Warning 1
2.2 Recommended Operation 2
SECTION 3.0 Function 5
3.1 Machine Function Description 5
3.2 Safety Recommendations And Warnings 5
SECTION 4.0 Safety Features 7
SECTION 5.0 Ergonomics & Environment 8
5.1 Ergonomic Features 8
5.2 Noise And Vibration Levels 8
SECTION 6.0 Unpacking 9
6.1 Safety First 9
6.2 Included With Your Machine 9
SECTION 7.0 Installation 9
SECTION 8.0 Instructions For Operation 10
8.1 Optional Thumb Support And Handle Size Selection 10
8.2 Handle - Assembly & Adjustments 10
8.3 Proper Use/Operating Procedures 16
8.4 Fault Detection And Correction 22
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TECHNICAL BETTCHER LARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC. REV. June 28, 2012
Table Of Contents
(Continued)
SECTION 9.0 Maintenance 24
9.1 Disassembly Of Handpiece 24
9.2 Daily Inspections & Maintenance 27
9.3 Blade Sharpening 34
9.4 Assembly 35
9.5 Preventative Maintenance 39
SECTION 10.0 Cleaning 40
10.1 Periodic Cleaning During Use 40
10.2 Daily Cleaning 40
10.3 Cleaning Solutions 40
SECTION 11.0 Spare Parts List 41
11.1 Head Assembly - 750M2 42
11.2 Head Assembly - 850M2 44
11.3 Head Assembly - 880M2-B 46
11.4 Head Assembly – 880M2-S 48
11.5 Head Assembly - 1850M2 50
11.6 Head Assembly – 1880M2 52
11.7 Head Assembly - 1000M2 54
11.8 Head Assembly - 1300M2 56
11.9 Head Assembly - 1400M2 58
11.10 Head Assembly - 1500M2 60
11.11 Head Assembly - 1930M2 62
11.12 Head Assembly - 1932M2 64
11.13 Head Assembly - 1933M2 66
11.14 Head Assembly - 1940M2 68
11.15 Head Assembly - 1942M2 70
11.16 Head Assembly - 1943M2 72
Page iii
TECHNICAL BETTCHER LARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC. REV. June 28, 2012
Table Of Contents
(Continued)
11.17 Flex Shaft & Casing 74
11.18 Post Handle (Optional) 76
11.19 Optional Equipment Available 78
Lubrication and Lubrication Equipment 78
Optional Blades 78
Blade Sharpening and Steeling Equipment 78
Covers and Depth Gauges 78
Tools 79
Cleaning Equipment 79
Cleaning Solution 79
11.20 Handle Options 79
SECTION 12.0 About These Operating Instructions 80
12.1 Other Languages 80
12.2 Document Identification 80
12.3 Software & Duplication 80
SECTION 13.0 Contact Addresses & Phone 81
Page iv
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 1.0 Machine Specifications
Bettcher Modular Series II Whizard tools are highly effective for use in the meat industry,
designed with the highest possible standards for safety, ergonomics and production. These
versatile machines, with their carefully engineered and durable cutting edge, bring uniformity and
consistent yield control to all operations. This Operating Instruction covers the following models:
Modular Series II Whizard tools are used for removal of fat and tissue, the recovery of lean meat
from fat, and as a universal cutting tool in the meat industry. Any use in applications other than
those for which the Whizard trimmer was designed and built may result in serious injuries.
WARNING
THEMANUFACTURERASSUMESNOLIABILITYFORANY
UNAUTHORIZEDDESIGNCHANGES,MODIFICATIONS,ORUSEOF
PARTSNOTSUPPLIEDBYTHEMANUFACTURER
OR
THEUSEOFPARTSNOTDESIGNEDFORUSEONTHATSPECIFIC
MODEL,INCLUDINGCHANGESINOPERATINGPROCEDURESMADEBY
THEOWNERORANYOFHISPERSONNEL.
THEUSEOFPARTSOTHERTHANTHOSELISTEDINTHEPARTSLIST
FORTHESPECIFICMODELMAYCAUSEBLADELOCK-UPRESULTING
INANUNSAFEOPERATINGCONDITION.
Page 1
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
2.2 Recommended Operations
Modular Series II Whizard tools are made for several recommended operations. Ensure that you
are using the correct tool for your specific application. The following recommendation list is not
intended to be a total and comprehensive listing, but is offered as a guide. Additional applications
are possible.
MODEL 750M2
PORK CUT PORK KILL FOAM INDUSTRY
Remove diaphragm lean
Removal of picnic hearts
External defat of hams
External defat of pork shoulders
- Ribs
Defat navels (Pastrami)
MODEL 1400M2 WITH ADJUSTABLE DEPTH GAUGE
PORK PROCESSING
Defatting:
- Whole Hams
- Shoulders
- Canadian Backs
Removing Beater Marks
Scraping Leaf Lard
BEEF PROCESSING
Carcass hair & dirt removal
Defatting:
- New York strips & sirloin butts
- Rounds and ribeyes
MODEL 1500M2 WITH ADJUSTABLE DEPTH GAUGE
PORK PROCESSING
Removing skin patches from bellies
Defatting:
- Whole Hams
- Pork Loins
BEEF SLAUGHTER
Defatting hot beef externally
Hair and dirt removal
Page 3
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
2.2 Recommended Operations (Continued)
MODEL 1930M2
BEEF SLAUGHTER
Defatting Hot Beef
MODEL 1932M2 WITH ADJUSTABLE DEPTH GAUGE
BEEF PROCESSING
Defatting Strips
MODEL 1933M2 WITH ADJUSTABLE DISC GAUGE
BEEF PROCESSING
Defatting Strips
MODEL 1940M2
BEEF SLAUGHTER
Defatting Hot Beef
MODEL 1942M2 WITH ADJUSTABLE DEPTH GAUGE
BEEF PROCESSING
Defatting Strips
MODEL 1943M2 WITH ADJUSTABLE DISC GAUGE
BEEF PROCESSING SALMON PROCESSING
Defatting Strips Slicing
Page 4
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 3.0 Function
3.1 Machine Functions
Modular Series II Whizard tools are durable and efficient, promoting higher yields for
meat and poultry trimming. The Modular Series II Whizard tools are superbly designed
for ease of handling while reducing operator fatigue. Modular Series II Whizard tool
blades maintain accurate and continued sharpness.
A vertically hung motor drives a flexible shaft. The flexible shaft drives a rotating blade in
the handpiece via a gear and pinion. The force to cut through meat and fat is now provided
by the drive motor and no longer by the worker. Forces applied by the worker are greatly
reduced and limited to guiding the rotating knife blade.
3.2 Safety Recommendations And Warnings
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
Modular Series II Whizard tools have been designed to obtain the highest possible
degree of safety. The Trimmer contains sharp knife blades. Handle this equipment with
caution as you would with any sharp object. In particular, read and apply the following
safety recommendations :
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
PROPERPROTECTIONOFHANDS,APROTECTIVE
FOR
GLOVESHOULDBEUSEDWHENOPERATINGTHIS
EQUIPMENTANDDURINGTHEHANDLINGOFBLADES.
METALMESHGLOVESARERECOMMENDED
THEFREEHAND.
FOR
Page 5
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
3.2 Safety Recommendations And Warnings (Continued)
WARNING
KEEPHANDSAWAYFROMMOVINGBLADE!
WARNING
ALWAYSTURNOFFTHEMOTORANDPLACETHEHANDPIECEINTHE
HANGERBRACKET.NEVERLAYTHEHANDPIECEDOWNONTHE
WORKSTATIONORLETITHANGFREEBYTHEFLEXSHAFTCASING.
NEVERPLACETHEHANDPIECEINTHEHANGERWHILETHEBLADEIS
STILLREVOLVING!
WARNING
ALWAYSDISCONNECTTHEPOWERANDREMOVETHETOOLFROM
THEFLEXSHAFTCASINGPRIORTOSERVICING!
WARNING
IFATANYTIMETHISMACHINEDOESNOTAPPEARTOOPERATE
NORMALLYOREXHIBITSAMARKEDCHANGEINPERFORMANCE,IT
SHOULDBEIMMEDIATELYSHUTDOWN,UNPLUGGED,ANDTAGGEDAS
"UNSAFE"UNTILSUCHTIMEASPROPERREPAIRSAREMADEANDTHE
MACHINEAGAINOPERATESNORMALLY.
WARNING
AFTERSERVICEOFTHEUNIT,ALWAYSCHECKTOENSURETHATTHE
BLADEISFREETOROTATEINTHEMACHINEPRIORTOSTARTING.IF
THEBLADEDOESNOTROTATEFREELY,ITMAYCAUSETHE
HANDPIECETOROTATEINTHEHAND.
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TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
3.2 Safety Recommendations And Warnings (Continued)
All Modular Series II Whizard tools have been designed for use with an optional
Disconnect which will stop blade rotation when the trigger/lever is released. This
trigger/lever has been designed in such a way that minimal grip force is required for
operation, using three fingers.
Page 7
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 5.0 Ergonomics And Environment
5.1 Ergonomic Features
Handles – X-Small, Small, Medium, and Large Handle sizes are available to help improve
the operator’s grip and comfort. Fitting the correct size handle to the worker's hand is a
very important step. The Modular Series II Whizard tools have been manufactured in
both right and left handed configurations. All handles are also available without flanges, to
allow for more freedom of movement where space is limited.
Optional Thumb Support - An adjustable Thumb Support is available to ensure a proper
and comfortable fit while providing added control and stability of the tool during use.
Whizard Hand Strap - This Strap has been designed to allow the user to relax the fingers
between work cycles while maintaining control of the Trimmer.
NOTE: The Whizard® handstrap can not be
used with the flangeless handles.
5.2 Noise And Vibration Levels
The force to cut through meat and fats is now provided by the drive motor and no longer
by the worker. Forces applied by the worker are greatly reduced and limited to guiding the
rotating knife blade.
The noise emission value is less than 70 dB(A)
Vibration of the handpiece is less than 1 m/sec2
No negative side effects have been reported.
Page 8
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 6.0 Unpacking
6.1 Safety First
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
UNPACKTHEWHIZARDTRIMMERCAREFULLY.
6.2 Included With Your Machine
The following parts are included with each Modular Series II Whizard tool. Please
check when unpacking and advise your local Bettcher Industries representative if the
delivery is incomplete.
Part Number Description Qty.
100642 Whizard® Special Steel 1
100660 Special Stone 1
113415 Grease Gun (for 8 oz. tube of Whizard® Grease) 1
100608 8 oz. Tube Whizard® Grease 1
143631 14 oz. Cartridge of Special Whizard® Grease 1
183130 Operating Instructions and Spare Parts List 1
SECTION 7.0 Installation
The work station for each operator should be designed so that the operator's movements in
performing the job are natural and easy. A sideways sweeping motion with the Modular
Series II Whizard tool is preferable to a reaching motion. Long reaching motions and
high muscle strain should be avoided if possible. Also, a proper working height is needed
to avoid excessive shoulder and back exertion. Refer to the Whizard Motor Manual for
instructions on the proper placement and installation of the motor.
Page 9
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 8.0 Instruction For Operation
8.1 Optional Thumb Support And Handle Size Selection
Your Modular Series II Whizard® tool has been supplied with a spacer ring and an optional thumb
support. If using the optional thumb support, the operator’s thumb should be fully supported and
rest comfortably in the support. The thumb support has been optimized to fit most hands
comfortably.
Fitting the correct size handle to the grip of an operator’s hand is a very important step when
trying to reduce risks associated with cumulative trauma disorders. The Trimmers are
available in right and left handed configurations. Once it has been determined that an operator
is right or left handed and the appropriate model of Trimmer has been selected, choosing the
proper handle size can be accomplished in the following manner. The handles have been
color-coded for size as follows:
Tan
Turquoise
Grey
Blue
Green
Here is a very simple procedure to determine correct handle size:
STEP 1 - Assemble four (4) knives each with a different size handle. (See Section 8.2 for
complete assembly instructions).
STEP 2 - Allow the user to hold the knife and apply the grip pressure normally used during
the job operation.
If the operator normally wears a glove, this process
should be done with the glove(s) used in normal operation.
We do not recommend the use of Nitrile gloves in direct
contact with the Whizard® handles because
the gloves may become slippery.
The operator should choose the handle that is most comfortable. Allow the operator to work
with this handle on a tool for several days. If the operator is not comfortable with the handle
selection, try a different size.
XX-Small
X-Small
Small
Medium
Large
NOTE
Page 10
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.1 Optional Thumb Support And Handle Size Selection (Continued)
Short
Groove
8.2 Handle - Assembly And Adjustment
The Modular Series II Whizard tools have been designed to allow the head of the tool to
be rotated relative to the handle. In this way, the tool can be adjusted to position the blade
properly to the product while the handle can be set to allow the operator to have a
comfortable position for the wrist.
The position which is selected will vary based on the individual work station, product, and
operator. To determine the proper position, it will be necessary to observe the operator
while trying various positions. Select the position in which the operator's wrist appears to
maintain the most neutral position and which is comfortable to the operator.
Note that left handed heads are available for left handed users. Do not assign a knife
designed for a right handed person to a left handed user. Possible exposure to increased
muscle stress may result.
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TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.2 Handle - Assembly And Adjustment (Continued)
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
STEP 1
Pick up the Whizard Trimmer
Pick up a spacer ring or optional thumb support
If the optional thumb support is used, align the
thumb support tab with one of the notches
on the underside of the frame
The optional thumb support should be located
on the opposite side of the grease cup
Frame
Notches
STEP 2
While holding the Trimmer, pick up a handle and align the four (4) handle tabs with the four
notches located on the threaded portion of the frame tube
Firmly push the handle towards the bottom of the spacer ring or optional thumb support, and
align the handle tabs with the notches on the front of the tube as shown
For the initial adjustment position, the short groove on the handle should be on top, as shown.
STEP 3
Screw on the handle retaining knob.
Tighten firmly, but take care not to overtighten or the handle will be damaged.
Short Groove
Optional
Thumb Support
Handle
Tabs (4)
Handle
Retaining
Knob
Frame Tube Threads
Frame Notches
Page 12
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.2 Handle - Assembly And Adjustment (Continued)
The Whizard Hand Strap has been designed to allow the user to relax the fingers of the
hand between work cycles while maintaining control of the Trimmer.
NOTE: The Whizard® handstrap can not be
used with the flangeless handles.
Installation Of The Hand Strap
Remove the grease cup from the tool.
Push the grease cup thread through the round grommet end of the strap. Be sure that
the ribbed surface of the strap is on top as shown.
Reinstall the grease cup.
Weave the end of the strap down and back up through the slots in the flange of the
handle. The strap may be pulled through the slots to adjust for size.
An optional secondary strap has been provided with your Modular Series II Whizard
tool. To install the secondary strap :
Weave the secondary strap end through the opposite handle slots similar to the method
used to install the primary hand strap.
Bring the loose end of the strap across the tool and snap closed.
Primary
Hand
Strap
Optional
Secondary
Hand Strap
Page 13
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.2 Handle - Assembly And Adjustment (Continued)
The Disconnect Casing
Connect the casing to the Bettcher Industries motor as described in the motor manual.
Hold the trimmer in the hand you will use in operation, and with the other hand, grasp the
casing and push it into the end of the tool through the handle retaining knob.
Push the casing in until the latch catches the casing.
The disconnect lever rotates freely around the handle.
Align the disconnect lever in the notched-out area of the handle. Slightly open the fingers on
the hand holding the trimmer. Push the casing inward and hold the lever down in the handle
groove with the normal operating hand.
Check to see that the lever is seated completely flat within the groove.
Release the lever and the casing should pop out and stop the blade from turning. The motor
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.2 Handle - Assembly And Adjustment (Continued)
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
WHILEWEARINGAPROTECTIVEGLOVE,ALWAYSCHECKTOENSURE
THATTHEBLADEISFREETOROTATEINTHEMACHINEPRIORTO
STARTING.IFTHEBLADEDOESNOTROTATE,ITMAYCAUSETHE
HANDPIECETOROTATEINTHEHAND.
With the handpiece held in your operating hand, stand at your normal work position and
move your hand and the handpiece over your normal work area to check that there are no
binds or sharp bends in the flex shaft and casing assembly.
With your other hand, turn on the motor switch. While the blade is rotating, press the
rubber cap of the grease cup on the handpiece with your thumb. Press only until a light
coating of lubricant appears on the blade in the gear tooth area.
During daily use, the grease cup rubber cap should be depressed every 30 minutes. Refill
when empty.
WHIZARD SPECIAL GREASE COMPLIES WITH
USDA H1 STANDARDS FOR USE IN FEDERALLY
INSPECTED MEAT AND POULTRY PLANTS AND IS
AUTHORIZED BY AGRICULTURE AND AGRI-FOOD CANADA
FOR USE IN FOOD PLANTS.
DO NOT USE A SUBSTITUTE TYPE LUBRICANT.
USE OF SUBSTITUTE LUBRICANTS COULD
RESULT IN DAMAGE TO THE UNIT.
Prior to placing the tool in operation, refer to the guidelines for tool adjustment and handle
size selection. It is critical to use the proper size handle and that the tool be properly
adjusted in order to gain the full benefit of the
Modular Series II Whizard tool design
concept.
You are now ready to put the Modular Series II Whizard® tool into operation.
Page 15
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.3 Operating Procedure
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
NEVER
ALWAYS
Always hold the handpiece of the Modular Series II Whizard® tool with your thumb
extended. Let the handpiece rest naturally in the palm of the hand in a relaxed manner.
Each person should be allowed to hold the handpiece in a position that is most comfortable
to them.
The most-used motion is a long sweeping or gliding stroke across the trimming surface.
Hold the blade surface as flat to the trim surface as possible. A scooping action, such as
dipping ice cream, should be used around the vertebra.
On flat bones, such as backbones or blades, use a long, quick gliding stroke.
During the cutting operation do not try to pull the blade out of a cut. Let the blade do the
work as you would any other cutting tool. Finding the proper angle for Whizard
trimming will become easy after experience and use of the tool.
As with any meat cutting tool, your speed and efficiency is only as good as the blade
sharpness.
In order to achieve maximum unit and operator efficiency, it is recommended that sharp
blades be installed at each shift break. For this reason, it is suggested that extra blades be
kept on hand. For example, if 4 units are being used and there are 3 shift breaks, 16 blades
would be required. This would provide a sharp blade for start up and one for each break.
When following this procedure, steeling of the blade is virtually eliminated, and blades
need only be sharpened once a day with the use of a Whizard Model 210 Universal Blade
Sharpener, Bettcher® AutoEdge, or by hand stoning.
If blades are not changed at each shift break, it may be required to steel the blade.
HOLDTHEPRODUCTBEINGTRIMMEDINYOURHAND.
LAYTHEPRODUCTFLATONTHEWORKSURFACE.
Page 16
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.3 Operating Procedure (Continued)
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
PROPERPROTECTIONOFHANDS,APROTECTIVEGLOVE
FOR
SHOULDBEUSEDWHENOPERATINGTHISEQUIPMENTAND
DURINGTHEHANDLINGOFBLADES.
ALWAYS
DISCONNECTTHEPOWERANDREMOVETHETOOLFROM
THEFLEXSHAFTCASINGPRIORTOSERVICING.
For Models 880M2-S&B,1880M2, 1400M2, 1500M2, 1932M2 and 1942M2 Only :
These tools are equipped with an adjustable Depth Gauge for setting a controlled product trim
thickness. The Depth Gauge can be adjusted for cuts up to ¼” thick. A Depth Gauge Setting
Device is also available. To adjust depth :
Hold the handpiece with the blade facing downward.
Loosen the attachment screws at the base of the plastic depth gauge.
Adjust the gauge setting by sliding it up or down to the desired height.
Retighten the attachment screws.
Depth Gauge Adjustment Range :
Slide to Adjust
Moving Up = Thicker Cut
Moving Down = Thinner Cut
Attachment
Screws
Model 880M2-B Model 1400M2
Page 17
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.3 Operating Procedure (Continued)
Optional Adjustable Fat (F) and Skinner (S) Disc Gauges
(850M2, 1000M2, 1300M2, 1933M2 and 1943M2):
Hold the handpiece with the blade facing
downward.
Adjustments – Turn the adjustment knob
clockwise for a thicker cut, or counterclockwise
Adjustment
Blade
Disc
Knob
Attachment
Screws (2)
for a thinner cut. Take care not to turn too far
as the depth control hub may disengage from
the shaft.
Model 1000M2-S
WARNING
SHARP BLADES MAY CAUSE CUT INJURY!
OR PROPER PROTECTION OF HANDS,APROTECTIVE GLOVE SHOULD
F
BE USED WHEN OPERATING THIS EQUIPMENT AND DURING THE
HANDLING OF BLADES.
LWAYS DISCONNECT THE POWER AND REMOVE THE TOOL FROM THE
A
FLEX SHAFT CASING PRIOR TO SERVICING.
Steeling For All Models Except 750M2:
Use the Whizard Special Steel anytime you feel the edge of the blade needs to be raised for
better cutting action.
Use the Whizard Special Steel against the flat ground surface on the outside surface of the
blade. Be sure to hold the "steel" flat and across the centerline of the blade to prevent "rounding
off" or rolling of the edge.
The inside edge of the blade should be steeled only with the Special Steeling Device mounted on
the inside diameter of the blade housing. This is accomplished as follows :
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TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.3 Operating Procedure (Continued)
Hold the Whizard Special Steel on the bottom edge of the blade and the handpiece in your
normal operating hand with the blade down, or away from you.
With your thumb, lightly push down on the push button of the steeling device. DO NOT hold
the steeling device against the rotating blade steadily, but rather lightly contact the blade edge.
Whizard
Special Steel
Push Button
Special Steeling
Device
While steeling the inside edge,
use the Whizard Special Steel
to steel the bottom edge.
Models 850M2/880M2-S&B/
1850M2and 1880M2
Whizard
Special
Steel
Whizard
Special Steel &
Push Button
Models 1000M2/1300M2/1400M2/1500M2
Replace or sharpen the blade (see Section 9.3 for complete instructions) if this procedure does not
improve the cutting action.
Steeling For Models 750M2 Only :
Use the Whizard Special Steel any time you feel the blade needs to be raised for better cutting
action. Be sure to hold the steel at the actual angle of the blade edge. Running the steel at an angle
greater than the factory ground angle will round over the edge and make resharpening more
difficult.
Cross-Section View Of Steeling
Inside Blade Edge
Cross-Section View Of Steeling
Outside Blade Edge
Whizard Special Steel
Use the steel lightly and always make the last pass of the steel on the blade on the inside surface of
the blade.
Page 19
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.3 Operating Procedure (Continued)
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
PROPERPROTECTIONOFHANDS,APROTECTIVE
FOR
GLOVESHOULDBEUSEDWHENOPERATINGTHIS
EQUIPMENTANDDURINGTHEHANDLINGOFBLADES.
ALWAYS
DISCONNECTTHEPOWERANDREMOVETHETOOL
FROMTHEFLEXSHAFTCASINGPRIORTOSERVICING.
The Modular Series II Whizard tools have been designed in such a way as to allow the blades to
be quickly removed and reinstalled.
Blade Changing
Hold the tool in your hand.
Loosen only the left cover retaining screw (Item #1)
With a screwdriver held in the opposite hand, insert the screwdriver in the housing slot (Item
#2). Note: The 1000M2-1500M2 tools have two slots in the housing. Using the frame as the
support point (Item #3), spread open the housing. The blade should fall out.
NOTE:
A slight tension on the left cover screw will allow
To Re-Install The Blade :
Turn the tool over so the blade side is up.
Spread open the blade housing with a screwdriver.
Insert a new blade in the housing.
Loosen the left cover screw so the housing will close.
Adjust the housing for proper running clearance. The blade should turn freely with a slight
side-to-side motion. This leaves room for the grease.
B
E CERTAIN THAT THE BLADE IS FREE TO ROTATE IN THE HOUSING.IF THE BLADE DOES NOT
TURN FREELY
Tighten the left cover screw to 35 in-lb. (4 N-m). Use of the Bettcher torque wrench kit is
recommended.
Re-check the running clearance.
, IT MAY CAUSE THE TOOL TO ROTATE IN THE HAND.
the blade housing to stay open on its own.
NOTE:
Leave a slight tension on the left cover screw
so the blade housing will stay open on its own.
Page 20
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.3 Operating Procedure (Continued)
To Re-Install The Blade : (Continued)
If the blade is too tight in the housing, adjustments can be made by loosening the left cover
retaining screw and slightly spreading open the housing. Check again for proper running
clearance. Retighten the left cover retaining screw.
If the blade is too loose in the housing, adjustments can be made by slightly loosening the
left cover screw and squeezing the housing lightly.
Check the housing for proper running clearance and retighten the left cover screw to
35 in-
lb. (4 N-m). Use of the Bettcher torque wrench kit is recommended.
#2
Housing Slot
#3
Frame
Support
Point
#1
Left Cover
Retaining
Screw
#2
#1
#3
Page 21
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.4 Fault Detection And Correction
PROBLEM PROBABLE CAUSE REMEDY
Inside bore of handpiece frame worn out Replace frame
Worn handpiece bearing Replace
Worn pinion gear Replace
Worn teeth on blade or pinion gear Replace
Handpiece
Vibration
Handpiece
Hot
Adjust blade housing. If still
Blade too loose in blade housing
too loose, try a new blade in
the housing.
Blade too tight in the housing Adjust blade housing
Inside of flex shaft casing worn Replace casing
Clean flex shaft and casing as
No lubrication on flex shaft or casing
described in Section 9.2 and
relubricate properly
Clean corrosion from the
Pinion gear tight in handpiece bearing
handpiece bearing and
lubricate
Blade tight in blade housing Adjust blade housing
Handpiece bearing not installed correctly
(No clearance between face of pinion gear
and blade housing) causing mechanical
bind
Reinstall bearing correctly.
With handpiece removed
from flex shaft, you should
be able to rotate the blade
freely by hand.
Page 22
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
8.4 Fault Detection And Correction
PROBLEM PROBABLE CAUSE REMEDY
Rapid Flex Shaft
Wear or Breakage
Dull Blade
Optional Thumb
Support Rotates
Improper cleaning and lubrication of flex
shaft and casing.
Inside of flex shaft casing worn, allowing
flex shaft to “wind-up” inside the casing
Refer to Section 9.2
Replace flex shaft casing
With handpiece removed
Mechanical bind in handpiece
from flex shaft, blade should
rotate freely by hand.
Correct any mechanical bind.
Sharpening can best be
accomplished by use of a
Improperly sharpened blades will cause
loss of production, increase wear of parts,
and operator fatigue
Whizard® Model 210
Universal Blade Sharpener,
or Bettcher® AutoEdge.
However, the blades can be
sharpened by hand. See
Section 9.3
Anti-rotation rib has broken off Replace
Spring Lost from
Flex Shaft Casing
Blade Skips or
Will Not Rotate
Refer to note in section 11.5
Improper Assembly
flex shaft and casing of
service parts list for assembly
instructions
Handpiece bearing too tight Check/Replace bearing
Flex shaft worn Replace shaft
Motor Adapter worn Replace adapter
Loose ferrule on shaft Replace shaft
Page 23
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 9.0 Maintenance
9.1 Disassembly Of Handpiece
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
PROPERPROTECTIONOFHANDS,APROTECTIVE
FOR
GLOVESHOULDBEUSEDWHENOPERATINGTHIS
EQUIPMENTANDDURINGTHEHANDLINGOFBLADES.
ALWAYS
DISCONNECTPOWERANDREMOVETOOLFROM
FLEXSHAFTCASINGPRIORTOSERVICING.
To remove the casing from the handpiece, push the metal plate on the handle retaining knob in
and the tool should pop off.
Removal Of The Blade From The Tool :
Hold the tool in your hand.
Loosen only the left cover retaining
screw (Item #1)
With a screwdriver held in the opposite hand, insert the screwdriver in the housing
slot (Item #2). Note: The 1000M2-1500M2
tools have two slots in the housing. Using
the frame as the support point (Item #3),
spread open the housing. The blade
should fall out.
Unscrew the grease cup.
Removal Of The Handle From The Tool :
Remove the handle retaining knob by turning counterclockwise.
While holding the trimmer, pull the handle and align the four (4) handle tabs with the four
notches located on the threaded portion of the frame tube.
Pull the handle off the tube.
Remove the handle spacer ring or optional thumb support.
#2
#3
#1
Page 24
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.1 Disassembly Of Handpiece (Continued)
Removal/Disassembly Of The Depth Gauge From The Cover:
Loosen the two attachment screws located inside the depth gauge. It is not necessary to
remove the screws.
Slide the gauge upward until the depth gauge clamps come out of the cover plate grooves.
Cover
Plate Grooves
Cover
Plate
Grooves
Depth
Gauge
Clamps
Depth
Gauge
Clamps
Model 880M2-B
Attachment Screws
(2)
Depth Gauge
Model 1400M2
Attachment Screws
(2)
Depth Gauge
Cover Plate
Grooves
Depth Gauge
Attachment Screws (2)
Model 1000M2-F
Removal Of The Blade Housing And Cover:
Loosen cover retaining screws until the cover is free.
NOTE:
Pinion
Cover Plate
Frame
The screws will stay in the frame.
Remove the blade housing.
Pull the pinion out of the frame.
Blade
Housing
Cover Retaining
Screws (2)
Page 25
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.1 Disassembly Of Handpiece (Continued)
Removal Of The Bearing From The Frame :
The bearing is pulled out from the
front of the tool.
Use a screwdriver to reach into the
bearing and catch the bearing
grease groove.
While pulling upward, try to rotate
the bearing back and forth. Since
the bearing is not a press-fit, this
will work in most cases.
If the bearing will not come out, it
may be necessary to run a tap
into the bearing and pull on the
tap. If this is done, then the
Bearing
bearing must be replaced due
to damage.
The handpiece is now completely disassembled except for the cover retaining screws and
finger guard.
Finger Guard
(For Models 750M2 -1880M2 Only)
Cover Retaining Screws
NOTE:
The cover retaining screws do not normally need to removed. If they do need to be
removed, turn the screw while pulling down to engage the thread in the frame.
Page 26
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.2 Daily Inspections & Maintenance
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
ALWAYSDISCONNECTPOWERANDREMOVETHETOOLFROMTHE
FLEXSHAFTCASINGPRIORTOSERVICING.
See Disassembly And Reassembly of Handpiece
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
AFTERSHARPENING,ALLABRASIVEDUSTMUSTBECOMPLETELY
REMOVEDFROMTHEHANDPIECE.DISASSEMBLETHEUNITAND
CAREFULLYWASHEACHPIECEWITHHOT,SOAPYWATERANDA
SMALLBRUSH.
Be Sure To Clean All Lubricant Out Of The
Inside Of Handpiece. Rinse And Dry Each Piece.
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
DONOTADJUSTHANDLEORTHUMBSUPPORTWITHTHETRIMMER
RUNNINGORWITHBLADEINSTALLED.
Blade
Inspect the cutting edge height with Bettcher Blade Gauge.
Check for worn or chipped teeth.
Check for damage to the cutting edge.
Page 27
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.2 Daily Inspections & Maintenance (Continued)
Blade Housing Wear – For Models 750M2-1880M2
Inspect the inner diameter of the housing for wear.
Look for evidence of the blade rubbing the outer wall of the housing.
When holding the housing with a new blade installed, if the split in the housing touches the other side,
and the blade is still loose, the housing needs to be replaced. If a gap is seen, the housing is
acceptable.
Housing is Acceptable
Gap –
No Gap - Housing is Not
Acceptable
Blade Housing Wear – For Models 1000M2-1500M2
Inspect the inner diameter of the housing for wear.
When the housing wears to a point where the segments (grooves) are gone, the housing needs to be
replaced.
Segments
Page 28
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.2 Daily Inspections & Maintenance (Continued)
Pinion Gear
Check for worn or chipped teeth. Worn out teeth are indicated by rounded off and pointed tops on the teeth.
Bearing
Install a new pinion and move the pinion side to side.
If the bearing feels egg-shaped, it should be replaced.
As a rule of thumb, the bearing should be replaced at 500 hours of use or sooner.
Cover Plate
Look for signs of corrosion or wear on the cover.
Pay special attention to the area covering the gear teeth.
If the edge of the cover is worn, exposing the pinion and blade teeth, the cover should be replaced.
Hand Strap
Inspect the strap for hardening and cracks.
If any fibers, cuts, or cracks are showing, the strap should be replaced.
Knob
Inspect for cracks.
Make sure spring tension in the metal plate is adequate.
Make sure the metal plate is clean and moves freely.
Frame
Inspect the frame surfaces where the housing mounts.
Look for corrosion and any nicks or burrs that may prevent proper housing seating.
Inspect the housing locating key for damage.
Steeling Device
Inspect the surface condition of the carbide steel. If chipped or cracked it should be replaced.
Make sure the steeling device and the plunger are free to move.
The plunger and steel should be cleaned and oiled with mineral oil in order to keep free movement
and prevent build-up of dirt.
Depth Gauge and Depth Gauge Clamps
Inspect the depth gauge for wear or damage.
Make sure the depth gauge clamps are not bent.
Page 29
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.2 Daily Inspections & Maintenance (Continued)
Flex Shaft And Casing
Bearing
Inspect the casing for any cracks, tears, or
other wear. If any damage is found, replace
the casing.
Remove the flex shaft from the casing and
check for any flex shaft damage, such as
broken wires or kinking. If any damage is
detected, replace the flex shaft.
Reinsert the flex shaft into the casing, making
certain the flange of the flex shaft is pressed
against the bearing inside the casing.
Check the extension of the flexible shaft
driver at the motor end. The flexible shaft
driver should extend past the motor end
fitting. If the shaft extends less than 5/64”,
replace the casing.
Motor End
Fitting
Flex Shaft
Driver
Casing
Page 30
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
When the casing needs to be replaced, the drive end assembly may be retained and reused.
Hold the casing (#1) in a vise.
Unscrew the drive end assembly (#4) by turning counterclockwise using the wrench flats on the drive
end assembly.
Unscrew and remove the nylon washer (#3), casing latch collar (#2) or lever mounting collar (#5)
from the casing.
Discard the casing but retain and reuse the drive end assembly (#4), the nylon washer (#3),
the casing latch collar (#2) – or the lever mounting collar (#5) and disconnect lever (#6).
7
1
2
5
3
4
6
To Reassemble the Drive End Assembly to a New Casing
If using the casing disconnect, place the disconnect lever (#6) onto the lever mounting collar (#5).
Slip the casing latch collar (#2) or lever mounting collar (#5) with disconnect lever (#6) onto the new
casing.
Thread the nylon washer (#3) onto the new casing.
Clean the threads of the new casing assembly and apply Loctite #242 Threadlocker or equivalent.
Screw the drive end assembly (#4) on the new casing.
Tighten by hand and then with a wrench while holding the casing by hand.
NOTE:
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.
Page 31
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.2 Daily Inspections & Maintenance (Continued)
Drive End Assembly Inspection And Replacement
Removal of the driver assembly
With one hand, pull the spring (#1) back to expose the knurled cap (#2) at the end of the tube.
Using the other hand, grip the knurled cap (#2) with a pair of pliers.
Using a 7/16” open end wrench, hold the flats on the drive end assembly (#3) and turn the knurled cap
(#2) counterclockwise.
Unscrew the knurled cap (#2) until the threads are free from the tube.
Pull the driver assembly (#4) out of the tube.
NOTE: Never use pliers on the tube as damage to the internal parts may occur.
3
1
2
4
Inspection of the driver assembly (See Figure Below)
Wipe off excess grease.
Inspect the split bearing (#5) for wear or damage. Replace if required.
Slide the knurled cap (#6) forward against the driver (#7).
Wiggle the bushing (#8) sideways to check for excessive movement. Movement
should be minimal.
7
6 8
5
Slide the bushing (#8) and washer (#9) forward
toward the driver (#7). If the gap is 1/16” or
greater, the driver should be replaced.
9
10
Check the coupling cross pin (#10). If there is any free play or movement, replace the driver
assembly.
Page 32
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.2 Daily Inspections & Maintenance (Continued)
Drive End Assembly Inspection And Replacement
Replacement of the Driver Assembly
Clean the threads on the tube and knurled cap.
Apply Whizard special grease to split bearing (#3) and bushing (#2).
Apply a small amount of Loctite #242 Threadlocker or equivalent to the threads on the
knurled cap (#1).
Pull the spring (#4) on the drive end assembly back with one hand and insert the driver
assembly in the tube.
Push in and tighten the knurled cap until it is flush with the end of the tube. Pliers may be
used for this however it is not necessary to tighten beyond hand tight.
Allow ½ hour dry time for the threadlocker before the assembly is put in service.
1
2
3
4
Replacement of the Split Bearing (#3)
Remove the driver assembly as described above.
Insert a small screwdriver into the split in the bearing.
Spread the bearing and slide over the shoulder on the driver.
Clean the surface of the coupling and apply Whizard special grease.
Hold the bearing with the inside cone facing the end of the coupling.
Push the bearing on until it snaps into position.
Install the driver assembly as described above.
Page 33
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.3 Blade Sharpening – Daily
CORRECT POSITION OF
STONE OR STEEL FOR
SHARPENING
BLADE CUTTING EDGE
WARNING
AFTERSHARPENING,ALLABRASIVEDUSTMUSTBECOMPLETELY
REMOVEDFROMTHEHANDPIECE.DISASSEMBLETHEUNITAND
CAREFULLYWASHEACHPIECEWITHHOT,SOAPYWATERANDA
SMALLBRUSH.
WARNING
SHARPBLADESMAYCAUSECUTINJURY!
FORPROPERPROTECTIONOFHANDS,APROTECTIVEGLOVESHOULD
BEUSEDWHENOPERATINGTHISEQUIPMENTANDDURINGTHE
HANDLINGOFBLADES.
The blade should be stoned or sharpened on a Whizard Model 210 Universal Blade
Sharpener or Bettcher® AutoEdge at the end of each work day. Be sure to clean the blade
first to remove all grease or meat particles which could coat the stone and greatly reduce its
effectiveness. In the event the stone becomes coated, simply scrub it using hot, soapy
water.
HAND STONING – Models 850M2/880M2/1000M2-1500M2/1850M2/1880M2:
With the motor running, apply the flat side of the stone to the outside of the blade as shown
in the illustration. The stone should be applied with the flat part of the stone resting on the
flat part of the blade edge to be ground, using a "back and forth" motion.
Use the Special Whizard steel to finish sharpening as described in the Operating Section.
Page 34
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
Prior to assembly, be sure all parts are clean and have been inspected for wear per Section 9.2.
Handpiece Bearing Installation
Bearing
Push the handpiece bearing in
the frame bore and align the
bearing flat with the frame flat.
The bearing should go in with
Cover
Plate
minimal effort and not require
pressing.
Do not force the bearing in. If
it does not go in, check frame
Cover
Retaining
Screw
and bearing for damage or
build-up.
Frame
Pinion Installation
The pinion should fit freely into
Blade Housing
Pinion
the bearing.
Blade Housing And Cover Plate Installation
Set the blade housing on the frame and put the cover plate on.
While holding the cover plate firmly against the housing and frame start the two cover
retaining screws.
Tighten the screws lightly.
Page 35
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.4 Assembly Of Handpiece (Continued)
Grease Cup
Pick up the Whizard Trimmer
Pick up a spacer ring or optional thumb support
If the optional thumb support is used, align the thumb
support tab with one of the notches on the underside of
the frame
The optional thumb support should be located on the
opposite side of the grease cup
Frame
Notches
While holding the Trimmer, pick up a handle and align the four (4) handle tabs with
the four notches located on the threaded portion of the frame tube
Firmly push the handle towards the bottom of the spacer ring or optional thumb support,
and align the handle tabs with the notches on the front of the tube as shown
For the initial adjustment position, the short groove on the handle should be on top, as
shown.
NOTE: The handle can be adjusted to suit the operator and the work station by pulling the
handle back away from the frame and re-locating it on another set of notches on the frame
tube.
Screw on the handle retaining knob.
Tighten firmly but take care not to overtighten or the handle will be damaged.
Optional
Thumb
Support
Short Groove
Handle Tabs (4)
Page 36
Frame Tube Threads
And Notches
Handle
Retaining
Knob
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.4 Assembly Of Handpiece (Continued)
Installation Of The Hand Strap And Grease Cup
Push the threaded end of the grease cup through the round grommet end of the strap.
Be sure that the ribbed surface of the strap is on top as shown.
Reinstall the grease cup.
Weave the end of the strap down and back up through the slots in the flange of the
handle. The strap may be pulled through the slots to adjust for size.
An optional secondary strap has been provided with your Modular Series II Whizard
tool. To install the secondary strap :
Weave the secondary strap end through the opposite handle slots similar to the method
used to install the primary hand strap.
Bring the loose end of the strap across the tool and snap closed.
Optional
Secondary
Hand Strap
Primary
Hand
Strap
Page 37
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.4 Assembly Of Handpiece (Continued)
Installation Of The Depth Gauge
(For 880M2-S&B, 1880M2, 1400M2, 1500M2, 1932M2 and 1942M2 Only)
Cover Plate
Grooves
Slide the depth gauge downward
along the cover plate grooves until
the depth gauge clamps catch in
Depth
Gauge
Clamp
position.
Final height adjustment can be
made after the blade is installed.
Attachment
Screws (2)
Tighten the two attachment screws.
Model 880M2-B
Depth Gauge
Attachment
Screws (2)
Cover Plate
Grooves
Depth
Gauge
Model 1400M2
Depth
Gauge
Clamp
Installation Of The Adjustable Disc Gauge
(For 850M2, 1000M2 and 1300M2)
Slide the depth gauge downward along the
Cover
Plate
Grooves
cover plate grooves until the depth gauge
clamps catch in position.
Final height adjustment can be made after
the blade is installed.
Tighten the two attachment screws.
Attachment
Screws (2)
Model 1000M2-F
Page 38
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
9.4 Assembly Of Handpiece (Continued)
Installation of the Blade :
Turn the tool over so the blade side is up.
Spread open the blade housing with a screwdriver.
NOTE:
Leave a slight tension on the left cover screw so the blade housing will stay open on its own.
Insert a new blade in the housing.
Loosen the left cover screw so the housing will close.
BE CERTAIN THAT THE BLADE IS FREE TO ROTATE IN THE HOUSING.IF THE BLADE DOES NOT
ROTATE FREELY
Adjust the housing for proper running clearance. For more information, refer to section 8.3,
Operating Procedures.
, IT MAY CAUSE THE TOOL TO ROTATE IN THE HAND.
9.5 Preventive Maintenance
CAUTION
USE ONLY BETTCHER WHIZLUBE
At least once each week, more frequently for multi-shift operation, the flex shaft casing should be
cleaned, inspected and lubricated as follows:
Exterior Of Casing – Clean the exterior of the casing with a mild detergent. For best results, use
Whizard® EXTRA Heavy Duty Cleaner, diluted according to the directions on the container.
Flex Shafts - Clean the shaft after 20 hours of operation by wiping off the old grease with a dry
cloth. Avoid the use of any liquids on the shaft. Spray the shaft with a generous amount of
Bettcher WhizLube as it is pushed back into the casing. Inspect the casing support for wear,
cracks, or chips.
CAUTION
DO NOT USE ANY HYDROCARBON SOLVENTS OR MINERAL OIL ON, OR IN, THE
CASING.
Page 39
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 10.0 Cleaning
CAUTION
CASINGS,FLEX SHAFTS, AND HANDPIECES SHOULD BE REMOVED
RIOR TO AREA CLEANUP.
P
10.1 Periodic Cleaning During Use
Remove meat particles and rinse with warm soapy water. Wash the Whizard Trimmer
with warm cleaning solution. For best results, clean the Whizard® Trimmer with E
XTRA
Heavy Duty Cleaner, diluted according to the directions on the container. Rinse
thoroughly with water.
10.2 Cleaning After Daily Use
Disassemble and clean thoroughly daily.
Remove the blade and blade housing and clean them with a brush and cleaner. For best
results, clean the Whizard® Trimmer with E
XTRA Heavy Duty Cleaner, diluted according
to the directions on the container. Rinse thoroughly with water and dry.
Remove the hand strap from the handpiece per the instructions in Section 9.2 Clean these
in warm soapy water.
Before assembly, rinse well with clean water, dry, and assemble per instructions in Section
9.4.
10.3 Cleaning Solutions
Avoid the use of aggressive cleaning products as they will damage the aluminum handle
assembly.
Page 40
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 11.0 Spare Parts List
Bettcher Industries, Inc. proudly manufactures
quality parts for your Bettcher equipment.
For optimum performance of your Bettcher
equipment, use only parts manufactured by
Bettcher Industries, Inc.
Page 41
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
11.1 Head Assembly – 750M2
2
3
1
13
11
4
10
12
5
6
8
7
9
Page 42
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
11.1 Head Assembly – 750M2
ITEM DESCRIPTION
Handpiece Assembly (Includes the Head Assy. Plus Items 1, 2 (Flanged Only), 11, 12, 13)
XX-Small 183722 184580 183724 184581
X-Small 183386 184582 183390 184583
Small 183387 184584 183391 184585
Medium 183388 184586 183392 184587
Large 183389 184588 183393 184589
Disconnect Handpiece Assembly (Includes the Head Assy. Plus Items 1, 2 (Flanged Only), 11, 12, 13)
XX-Small 183721 184806 183723 184807
X-Small 183378 184808 183382 184809
Small 183379 184810 183383 184811
Medium 183380 184812 183384 184813
Large 183381 184814 183385 184815
Head Assembly (Includes Items 3 - 10) 183021 183022
Thumb Support (Gray)
See Section 11.20 for Handle Options
163207 163207
Page 69
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
11.15 Head Assembly – 1942M2
1
2
14
3
12
13
4
11
5
6
7
8
9
10
Page 70
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
11.15 Head Assembly – 1942M2
ITEM DESCRIPTION
Handpiece Assembly (Includes the Head Assy. Plus Items 1, 2 (Flanged Only), 12, 13, 14)
Small 185106 184714 185109 184715
Medium 185107 184716 185110 184717
Large 185108 184718 185111 184719
Disconnect Handpiece Assembly (Includes the Head Assy. Plus Items 1, 2 (Flanged Only), 12, 13,
14)
Small 185100 184940 185103 184941
Medium 185101 184942 185104 184943
Large 185102 184944 185105 184945
Head Assembly (Includes Items 3 – 11) 185114 185115
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
11.18 Post Handle (Optional)
8
6
9
2
5
3
4
10
1
Page 76
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
11.18 Post Handle (Optional) (Continued)
ITEM DESCRIPTION
1 Clamp Ring 183621 1
2 Post 183622 1
3 Hex Washer Head Bolt 183623 1
4 Hex Flange Nut 183633 1
5 Handle (Extra Small) 183043 1
6 Arm Rest Assembly 183624 1
UNIVERSAL POST HANDLE KIT
183620
QTY.
7
8 Knob Assembly 183626 1
9 45º Elbow 183631 1
10 Grease Fitting 102273 1
Arm Rest Strap
Assembly
183630 1
Page 77
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
11.19 Optional Equipment Available
Lubrication and Lubrication Equipment
Part Number Description
173519 Duralite® Casings Maintenance Kit (WhizLube Spray)
100608 8 oz. Tube Whizard® Grease
143631 14 oz. Cartridge of Special Whizard® Grease
163328 25 pack – 14 oz. Cartridges of Whizard® Grease
100640 35 Pound Bucket of Whizard® Grease
113415 Grease Gun (for 8 oz. tube of Whizard® Grease)
163267 Large Grease Cup (Optional)
102273 Grease Fitting
183631 Elbow - Body
Large (Green) 183040 183918 183045 183937
Medium (Blue) 183041 183919 183046 183938
Small (Gray) 183042 183920 183047 183939
X-Small (Turquoise) 183043 183921 183048 183940
XX-Small (Tan)
(With Spacer Ring)
Aluminum Handles Flanged Flangeless
183511 183935 183512 183942
Disconnect
Flanged
Disconnect
Flangeless
Small (With Spacer Ring) - - - 183767
Medium (With Spacer Ring) - - - 183768
Contact Your Whizard Salesperson For Information About Our Ergonomic Manual Now
Available.
Page 79
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 12.0 About These Operating Instructions
12.1 Other Languages
Translations into any of the languages used in the European Union are available at
cost price upon request. Call or write the local Distributor or contact Bettcher
Industries.
12.2 Document Identification
Copies of this Operation Instruction may be ordered by quoting the Document ID as listed
below :
Document ID:Manual #183130
Document Description:
Operating Instructions and Spare Parts List for
Large Modular Series II Whizard
Tools
Issued:November 15, 1999
Operating Instructions for other Whizard Trimmer Models may be requested by quoting
the model designation of the tool as shown on the identification plate on the
Whizard
Trimmer.
12.3 Software And Duplication
For more information, contact your local Representative or :
Bettcher Industries
Administrative Assistant/Engineering
Department
P.O. Box 336
Vermilion, Ohio 44089
USA
Page 80
TECHNICAL BETTCHERLARGE MODULAR SERIES II WHIZARD
MANUAL INDUSTRIES, INC.REV. June 28, 2012
SECTION 13.0 Contact Addresses And Phone
For additional information, technical support and spare parts, contact your local
Representative, Distributor, or Bettcher Representative :
United States of America
Bettcher Industries Inc.
6801 State Route 60
Birmingham, Ohio 44889
U.S.A.
Tel: +1-440-965-4422
Fax: +1-440-965-4900
Brazil
Bettcher do Brasil Comércio de Máquinas Ltda.
Av. Fagundes Filho, 145 Cj 101/102 - São Judas
São Paulo - SP
CEP 04304-010 - BRAZIL
Tel: +55 11 4083 2516
Fax: +55 11 4083 2515