BETTCHER INDUSTRIES Operating Instructions & Parts List Manual
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Operating Instructions & Parts List for
Manual # 188000
Issued : September 1, 2009
TMC #754
For Assistance, Write:
BETTCHER INDUSTRIES INC.
P.O. Box 336
Vermilion, Ohio 44089-0336
U.S.A.
Phone: 440/965-4422
Phone: 800/321-8763
Fax: 440/965-4900
www.bettcher.com
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® AirMax MACH 3 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 your Regional Manager, or by contacting:
BETTCHER INDUSTRIES, INC.
P.O. Box 336
Vermilion, Ohio 44089-0336
U.S.A.
Telephone : 440/965-4422
(In The U.S.A.) : 800/321-8763
Fax : 440/965-4900
www.bettcher.com
The Information Provided In These Operating Instructions Is Important To Your
Health, Comfort And Safety.
For Safe And Proper Operation, Read This Entire Manual Before Using This
Equipment.
Copyright 2009 By Bettcher Industries, Inc.
All Rights Reserved.
Original Instructions
Page i
Table of Contents
Section 1……………Safety and Ergonomics
Section 2……………Designated Use
Section 3……………Unpacking and Installation
Section 4……………Instructions for Operation
Section 5……………Maintenance
Section 6……………Cleaning
Section 7……………Service Parts
Section 8……………Contact and Document Information
Safety and Ergonomics
Manual No. 188000
September 1, 2009
Safety and Ergonomics
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
1-1
Section 1
Safety and
Ergonomics
NOTICE
The manufacturer assumes no liability for any unauthorized
changes in operating procedures or for unauthorized changes or
modifications made to the design of the machine or any factoryinstalled safety equipment, whether these changes are made by
the owner of this equipment, by his employees, or by service
providers not previously approved by Bettcher Industries, Inc.
CONTENTS OF THIS SECTION
Safety Recommendations and Warnings ............................................................................... 1-2
Safety Features ...................................................................................................................... 1-6
Ergonomic Features ............................................................................................................... 1-6
Additional Features ................................................................................................................. 1-6
Safety and Ergonomics
1-2
Safety and Ergonomics
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
W A R N I N G
THE MANUFACTURER ASSUMES NO LIABILTY FOR ANY
UNAUTHORIZED DESIGN CHANGES, MODIFICATION,
OR USE OF PARTS NOT SUPPLIED BY THE MANUFACTURER
OR
THE USE OF PARTS NOT DESIGNED FOR USE ON THAT
SPECIFIC MODEL, INCLUDING CHANGES IN OPERATING
PROCEDURES MADE BY THE OWNER OR ANY OF HIS
PERSONNEL.
THE USE OF PARTS OTHER THAN THOSE LISTED IN THE
PARTS LIST FOR THE SPECIFIC MODEL MAY CAUSE BLADE
LOCK-UP RESULTING IN AN UNSAFE OPERATING
CONDITION.
W A R N I N G
SHARP BLADE MAY CAUSE INJURY !
Safety Recommendations and Warnings
Whizard® AirMax MACH 3 Trimmers are used for removal of fat and tissue, the recovery of
lean meat from bone, and as a universal cutting tool in industry. Any use in applications other
than those for which the Whizard® trimmer was designed and built may result in serious injuries.
Safety and Ergonomics
Manual No. 188000
September 1, 2009
Safety and Ergonomics
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
1-3
W A R N I N G
SHARP BLADES MAY CAUSE CUT INJURY!
FOR PROPER PROTECTION OF HANDS, A PROTECTIVE
GLOVE SHOULD BE USED WHEN OPERATING THIS
EQUIPMENT AND DURING THE HANDLING OF THE BLADES.
METAL MESH GLOVES ARE RECOMMENDED FOR THE “NON-
KNIFE” HAND.
W A R N I N G
KEEP HANDS AWAY FROM MOVING BLADES!
W A R N I N G
IF AT ANY TIME THIS MACHINE DOES NOT APPEAR TO
OPERATE NORMALLY OR EXHIBITS A MARKED CHANGE IN
PERFORMANCE, IT SHOULD BE IMMEDIATELY SHUT DOWN,
DISCONNECTED FROM THE AIR SUPPLY, AND TAGGED AS
“UNSAFE” UNTIL SUCH TIME AS PROPER REPAIRS ARE
MADE AND THE MACHINE AGAIN OPERATES NORMALLY.
Safety Recommendations and Warnings (Continued)
Whizard® AirMax MACH 3 Trimmers have been designed to obtain the highest possible degree
of safety. The trimmer contains a sharp knife blade. Handle this equipment with caution, as you
would any sharp object. In particular, read and apply the following safety recommendations:
Warnings identify conditions that can cause serious bodily injury to the user.
Cautions identify conditions that are important to the operation, care and maintenance of the
machine.
Safety and Ergonomics
1-4
Safety and Ergonomics
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
W A R N I N G
HEARING LOSS MAY OCCUR!
ALWAYS OPERATE WITH HOSE AND MUFFLER ATTACHED.
W A R N I N G
SHARP BLADE MAY CAUSE INJURY!
ALWAYS DISCONNECT AIR SUPPLY PRIOR TO
SERVICINGUNIT.
W A R N I N G
LONGORREPEATEDUSEOFVARIOUSPOWERTOOLS
VIBRATINGEXCESSIVELYISSUSPECTEDOFCONTRIBUTING
TOCERTAINHAND,WRISTORFOREARMDISORDERSIN
SUSCEPTIBLEINDIVIDUALS.IFEXCESSIVEVIBRATION
OCCURS,ITISANINDICATIONTHATTHEREAREWORN
PARTSTHATNEEDREPLACEMENT.
Safety Recommendations and Warnings (Continued)
Safety and Ergonomics
Manual No. 188000
September 1, 2009
Safety and Ergonomics
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
1-5
W A R N I N G
IFYOURTRIMMERDEVELOPSUNUSUALVIBRATION,DONOT
CONTINUETOUSEITWITHOUTFIRSTUNDERTAKING
CORRECTIVEACTIONASOUTLINEDINTHEFAULTAND
DETECTIONSECTIONOFTHISOPERATINGINSTRUCTION.
C A U T I O N
USEONLYREPLACEMENTPARTSMANUFACTUREDBY
BETTCHERINDUSTRIES,INC.
USEOFSUBSTITUTEPARTSWILLVOIDTHE
WARRANTYANDMAYCAUSEINJURYTOOPERATORSANDDAMAGETO
EQUIPMENT.
Safety Recommendations and Warnings (Continued)
Safety and Ergonomics
1-6
Safety and Ergonomics
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
Safety Features
Two-handed start-up prevents the tool from being started accidentally.
The air supply is disconnected from the motor when the run lever is released.
Ergonomic Features
Right and Left-Handed – The Whizard®AirMax MACH 3 Trimmers have been
manufactured in both right and left-handed configurations.
Optional Thumb Support - A thumb support is available to ensure a proper and comfortable
fit while providing added control and stability of the tool during use.
Additional Features
The hose assembly swivels for easier trimmer rotation and operator comfort.
The hose is ten feet (3.05 m) long to allow for greater operator mobility.
Designated Use
Manual No. 188000
September 1, 2009
Designated Use
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
Whizard® AirMax MACH 3 Trimmers are made for several recommended operations. Assure
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 350 / 360
Model 620
Designated Use
Manual No. 188000
September 1, 2009
Designated Use
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
2-3
BEEF
POULTRY
PORK
Upgrading Retrim
Fat Trimming of Turkey
Thighs
Trimming of Turkey Skins
Fat Trimming of Pork Loins
Upgrading Retrim
POULTRY
PORK KILL
PORK CUT
Turkey Thigh Knuckles
Trim Pork Snouts
Trim Pork Trachea
Trim Pork Heads
Remove Lean from Neck
Bones of Heavy Hogs
Remove Tails from Heavy
Hogs
Removing 99% Picnic Muscle
from Bellies
Removing Pork Tenderloins
INDUSTRIAL
Foam Industry
POULTRY
Turkey Thigh Trim
BEEF BONING/FABRICATION
Removing Lean from Fat Generated in Fabrication
PORK CUT
PORK KILL
FOAM INDUSTRY
Remove Diaphragm Lean
Removal of Picnic Hearts
Remove Cheek Meat
Remove Blood Clots from
Jowls
Remove Defects
Flash Trimming
Recommended Operation (Continued)
Model 625
Model 500
Model 505
Model 750
Designated Use
2-4
Designated Use
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
PORK KILL
HAM PROCESSING
BEEF
Removing Leaf Lard
External Ham Defatting
Internal Ham Defatting
Defat Pork Loins
Remove Oyster Meat
Recover Lean from Fat
Trim Lean from Rib Caps
Trim Beef Tripe
Unpacking and Installation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
W A R N I N G
SHARPBLADESMAYCAUSECUTINJURY!
UNPACKTHEWHIZARDTRIMMERCAREFULLY.
Part
Number
Description
173226
Filter Regulator Lubricator (FRL) Kit
100655
Special Stone
100641
Special Steel
103603
Pint of Oil
113326
Planetary Gear Grease Gun (Needle-Nose)
184134
Spanner Wrench
184128
Hex Wrench
184282
4 oz. Tube of Max-Z-Lube
And one of the following:
143631
14 oz. Cartridge of Special Whizard® Grease
100608
8 oz. Tube of Special Whizard® Grease
Safety First
Included with your Machine – (Small Whizard® AirMax MACH 3
Tools)
Models: 350, 360, 620, 625, 500, 505
Unpacking and Installation
Manual No. 188000
September 1, 2009
Unpacking and Installation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
3-3
Part
Number
Description
173226
Filter Regulator Lubricator (FRL) Kit
100660
Special Stone
100642
Special Steel
103603
Pint of Oil
113326
Planetary Gear Grease Gun (Needle-Nose)
184134
Spanner Wrench
184128
Hex Wrench
184282
4 oz. Tube of Max-Z-Lube
And one of the following:
143631
14 oz. Cartridge of Special Whizard® Grease
100608
8 oz. Tube of Special Whizard® Grease
Included With Your Machine – (Large Whizard® AirMax MACH 3
Tools)
Models: 750, 850, 880-B, 880-S, 1850, 1880, 1000, 1300, 1400, 1500
Unpacking and Installation
3-4
Unpacking and Installation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
Part
Number
Description
113326
Planetary Gear Grease Gun (Needle-Nose)
184134
Spanner Wrench
184128
Hex Wrench
184325
Hex Wrench – 3/32”
184437
Hex Wrench – 9/64”
184282
4 oz. Tube of Max-Z-Lube
Included With Your Machine – (TRIMVAC® Tools)
Models: TRIMVAC® 18AMX and TRIMVAC® 45AMX
Unpacking and Installation
Manual No. 188000
September 1, 2009
Unpacking and Installation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
3-5
THIS PAGE INTENTIONALLY LEFT BLANK
Unpacking and Installation
3-6
Unpacking and Installation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
Installation
The workstation 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 Whizard
®
AirMax MACH 3 Trimmer 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.
Air Supply
A clean, dry, lubricated air supply is critical to proper operation. The filter, regulator and
lubricator (FRL) unit, furnished with your complete Whizard® AirMax MACH 3, should be
mounted horizontally at the air supply outlet and in such a position as to be easily reached for
draining the filter bowl and refilling the lubricator. The filter bowl should be drained, and the
lubricator refilled, daily.
IMPORTANT: Be sure the air supply is a constant 90 pounds per square inch (6.2 bar) and the
volume is a minimum of 14 cubic feet per minute (396 liters per minute) per unit.
Supply Line:
Use a 2 inch to 6 inch (5 cm to 15 cm) pipe for the air supply.
All air outlet drops should be connected to the top of the main air supply line to
minimize the possibility of moisture and dirt reaching the motor.
Drops should be at least:
¾ inch (2 cm) pipe for one (1) tool.
1 inch (2.54 cm) pipe for two (2) tools.
1 ¼ inch (3.18 cm) pipe for three (3) tools.
A FRL should be used for each tool. Do not run multiple tools off of a single
FRL.
All air outlets should be located close enough to the operator’s work station so that
additional hose is not required.
Unpacking and Installation
Manual No. 188000
September 1, 2009
Unpacking and Installation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
3-7
Air
Compressor
Air Dryer
To
Tool
¾” Drop
(2 cm)
1” Drop
(2.54 cm)
1 ¼ ” Drop
(3.18 cm)
Accumulator
Tank
FRL
Water Trap Drain
Installation (Continued)
Instructions for Operation
Manual No. 188000
September 1, 2009
Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
4-1
Section 4
Instructions for
Operation
CONTENTS OF THIS SECTION
Optional Thumb Support ........................................................................................................ 4-2
Power Unit / Head Assembly - Attachment and Adjustment ................................................... 4-3
Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
NOTE
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® AirMax MACH 3 handles because
the gloves may become slippery.
Optional Thumb Support
Your Whizard® AirMax MACH 3 Trimmer 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.
Instructions for Operation
Manual No. 188000
September 1, 2009
Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
4-3
W A R N I N G
SHARPBLADESMAYCAUSEINJURY!
Power Unit / Head Assembly - Attachment and Adjustment
The Whizard® AirMax MACH 3 Trimmers 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 align the blade with the
product, while maintaining a comfortable position for the operator’s wrist.
The position that is selected should be based on the individual workstation, product, and
operator. To determine the proper position, it will be necessary to observe the operator while
trying various positions. Select the position which is most comfortable to the operator.
Note that left-handed tools are available for left-handed users. Do not assign a right-handed tool
to a left-handed user.
Instructions for Operation
4-4
Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
Thumb
Support
Tab
Frame
Notches
Spacer Ring
Small End
Frame
Power Unit / Head Assembly - Attachment and Adjustment
(Continued)
Step 1:
Select the spacer ring or optional
thumb support.
If a spacer ring is used: Slide the
spacer ring onto the frame, small
end first.
If an optional thumb support is used: The thumb support should be positioned on the
opposite side of the grease cup.
Align the thumb
support tab with a notch
on the underside of the
frame and slide the
thumb support onto the
frame.
The frame is designed
with multiple
notches to allow
the thumb support
to be adjusted to the
most comfortable
position for the
operator.
Instructions for Operation
Manual No. 188000
September 1, 2009
Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List
4-5
Pin
Short
Groove
Notches
Frame
Power
Unit
Hex
Wrench
Frame
Attachment
Screw
Power Unit / Head Assembly - Attachment and Adjustment
(Continued)
Step 2:
While holding the
Whizard® AirMax
MACH 3 frame, align
the pin in the power
unit with one of the
notches on the frame.
The frame is designed
with multiple notches
to allow the head to be
adjusted to the most
comfortable position
for the operator.
For the initial
adjustment position, the
short groove on the
power unit should be
facing up. See illustration at right.
Step 3:
Insert the attachment screw in
the frame.
Tighten the attachment screw
FIRMLY, using the supplied
hex wrench.
NOTE: Recommended torque of
115-140 lb-in (13-16 N-m).
Instructions for Operation
4-6
Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List
Manual No. 188000
September 1, 2009
Bearing
Frame
Flat
Frame
Bearing
Flat
Drive
Adapter
Retaining
Ring
Power Unit / Head Assembly - Attachment and Adjustment
(Continued)
Step 4: Install Drive Adapter
Insert the drive adapter and align
the square end with the square hole
in the power unit.
The drive adapter should drop in
with no force required.
The retaining ring will sit flush
against the attachment screw when
properly aligned.
Step 5: Install Bearing
Slide the handpiece bearing into
the frame bore, aligning the
bearing flat with the frame flat.
The bearing should go in with
minimal effort and not require
pressing.
Do not force the bearing into the
frame. If the bearing does not go
in easily, check frame and
bearing for damage or build-up.
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