BETTCHER INDUSTRIES Whizard AirMax MACH 3 Operating Instructions & Parts List Manual

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: [phone]
Phone: [phone]

Fax: [phone]

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 : [phone]

(In The U.S.A.) : 800/321-8763

Fax : [phone]

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

SERVICING UNIT.

W A R N I N G

LONG OR REPEATED USE OF VARIOUS POWER TOOLS

VIBRATING EXCESSIVELY IS SUSPECTED OF CONTRIBUTING

TO CERTAIN HAND, WRIST OR FOREARM DISORDERS IN

SUSCEPTIBLE INDIVIDUALS. IF EXCESSIVE VIBRATION

OCCURS, IT IS AN INDICATION THAT THERE ARE WORN

PARTS THAT NEED REPLACEMENT.

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

IF YOUR TRIMMER DEVELOPS UNUSUAL VIBRATION, DO NOT

CONTINUE TO USE IT WITHOUT FIRST UNDERTAKING

CORRECTIVE ACTION AS OUTLINED IN THE FAULT AND

DETECTION SECTION OF THIS OPERATING INSTRUCTION.

C A U T I O N

USE ONLY REPLACEMENT PARTS MANUFACTURED BY

BETTCHER INDUSTRIES, INC.

USE OF SUBSTITUTE PARTS WILL VOID THE

WARRANTY AND MAY CAUSE INJURY TO OPERATORS AND DAMAGE TO

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

2-1

Section 2

Designated Use

CONTENTS OF THIS SECTION

Recommended Operation ................................................................................................................... 2-2

Model 350 / 360 ................................................................................................................. 2-2

Model 620 .......................................................................................................................... 2-2

Model 625 .......................................................................................................................... 2-3

Model 500 .......................................................................................................................... 2-3

Model 505 .......................................................................................................................... 2-3

Model 750 .......................................................................................................................... 2-3

Model 850 / 1850 ............................................................................................................... 2-4

Model 880-B / 1880 with Adjustable Depth Gauge ............................................................. 2-4

Model 880-S with Adjustable Depth Gauge ........................................................................ 2-4

Model 1000 ........................................................................................................................ 2-5

Model 1300 ........................................................................................................................ 2-5

Model 1400 with Adjustable Depth Gauge ......................................................................... 2-5

Model 1500 with Adjustable Depth Gauge ......................................................................... 2-6

Model TRIMVAC® 18AMX ................................................................................................. 2-6

Model TRIMVAC® 45AMX .................................................................................................. 2-6

Designated Use

2-2

Designated Use
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009
BEEF

PORK

POULTRY

 Cartilage Removal
 Liver Spotting
 Bone Trimming
 Strip Intestine

 Button Bones
 Bone Trimming
 Spotting Livers / Removing

Gall Sacks

 Turkey Breast
 Turkey Necks
 Chicken Backs
 Turkey Thighs
 Turkey Cage
 Oil Sacks

BEEF KILL/OFFAL

POULTRY

PORK KILL/OFFAL

 Removing Lean from

Heads

 De-Veining Livers

 Removing Lean from Turkey

Carcasses

 Removing Lean from Turkey

Necks

 Removing Oil Sacks

 Removing Eyelids
 Cleaning Stick Wounds
 Removing Eardrums
 Removing Lean from Heads
 Spotting Livers / Removing

Gall Sacks

BEEF BONING / FABRICATION

PORK CUT

 Removing Lean from Bones, Especially:

- Neck Bones - Atlas Bones

- Chine Bones from Strips or Rib Eyes

- Pelvic Bones / Aitch Bones

- Rib Cages

- Blade Bones

- Strip Bones

- Feather Bones

 Trimming Neck Bones
 Removing Lean from Bones
 Removing Tails

Recommended Operation

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

POULTRY

 Defatting Turkey Skins
 Defatting Turkey Thighs

BEEF BONING/FABRICATING

 Removing Dirt and Hair

- Slaughter Floor

- Prior to Loading

- Upon Receiving

- Prior to Fabrication

 Final Trim on Primal Fat Shaping

PORK

POULTRY

BEEF

 Remove Skin or Hair

Patches

 Trimming Pork Loins and

Canadian Backs

 Internal and External

Defatting of Hams

 Defatting Turkey Thighs

 Removing Membranes and

Light Fat Covering from Top
Rounds, Bottom Rounds,
Briskets and Cube Steak
Material

Recommended Operation (Continued)

Model 850 / 1850

Model 880-B / 1880 with Adjustable Depth Gauge

Model 880-S with Adjustable Depth Gauge

Designated Use

Manual No. 188000
September 1, 2009

Designated Use
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

2-5

PORK CUT

BEEF SLAUGHTER

 Defat Hams, Picnics and Butts
 Removing Lean from:

- Picnic Face

- Fat Backs

- Clear Plates

- Bootjack

 Jowls Shoulder End of Belly
 Belly (Wire Muscle – Pickle Pocket)
 Plate Trim

 Defatting Hot Beef Externally & Internally
 Kidney Fat, Heart Fat, Pelvic Fat & Cod Fat

BEEF KILL

BEEF BONING / FABRICATION

HAM BONING

 Pizzle Cord Removal
 Removing External Fat

 Primal Fat Shaping :

- Strips

- Sirloin Butts

- Ribs

 Defat Navels (Pastrami)

 External Defat of Hams
 External Defat of Pork

Shoulders

PORK PROCESSING

BEEF PROCESSING

 Defatting

- Whole Hams

- Shoulders

- Canadian Backs

 Removing Beater Marks
 Scraping Leaf Lard

 Carcass Hair & Dirt Removal
 Defatting

- New York Strips & Sirloin Butts

- Rounds and Ribeyes

Recommended Operation (Continued)

Model 1000

Model 1300

Model 1400 with Adjustable Depth Gauge

Designated Use

2-6

Designated Use
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009
PORK PROCESSING

BEEF SLAUGHTER

 Removing Skin Patches from Bellies
 Defatting

- Whole Hams

- Pork Loins

 Defatting Hot Beef Externally
 Hair and Dirt Removal

BEEF and PORK SLAUGHTER

 Removal of Spinal Column

BEEF and PORK SLAUGHTER

 Internal Defatting

Salmon and Whitefish Processing

 Frame Scraping

Cheese Processing

 Remove Mold

Recommended Operation (Continued)

Model 1500 with Adjustable Depth Gauge

Model TRIMVAC® 18AMX

Model TRIMVAC® 45AMX

Unpacking and Installation

Manual No. 188000
September 1, 2009

Unpacking and Installation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

3-1

Section 3

Unpacking and

Installation

CONTENTS OF THIS SECTION

Safety First ............................................................................................................................. 3-2

Included with your Machine – (Small Whizard® AirMax MACH 3 Tools) ................................. 3-2

Models: 350, 360, 620, 625, 500, 505 ............................................................................... 3-2

Included With Your Machine – (Large Whizard® AirMax MACH 3 Tools) ............................... 3-3

Models: 750, 850, 880-B, 880-S, 1850, 1880, 1000, 1300, 1400, 1500 ............................ 3-3

Included With Your Machine – (TRIMVAC® Tools) ................................................................ . 3-4

Installation .............................................................................................................................. 3-6

Unpacking and Installation

3-2

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

SHARP BLADES MAY CAUSE CUT INJURY!

UNPACK THE WHIZARD TRIMMER CAREFULLY.

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

Hose Assembly Attachment ..................................................................................................4-10

Starting the Trimmer with Standard Hose Assembly .............................................................4-11

Starting the Trimmer with Quick-Start Hose Assembly ..........................................................4-12

Depth Gauge Adjustment ......................................................................................................4-13

Tool Operation .......................................................................................................................4-15

Blade Steeling .......................................................................................................................4-16

Blade Changing .....................................................................................................................4-19

Instructions for Operation

4-2

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

SHARP BLADES MAY CAUSE INJURY!

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.

Instructions for Operation

Manual No. 188000
September 1, 2009

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

4-7

Pinion

Bearing

Cover

Plate

Cover
Retaining

Frame
Blade Housing

Power Unit / Head Assembly - Attachment and Adjustment

(Continued)

Step 6: Install Pinion

 Insert the pinion into the bearing bore.
 The pinion should go in with minimal

effort and not require pressing.

 Do not force the pinion into the

bearing. If the pinion does not go in
easily, check bearing and pinion for
damage or build-up.

 The pinion should sit flush against the

bearing. If the pinion does not, rotate
the pinion to seat it flush with the
bearing.

STEP 7: Install Cover And Blade

Housing

 Set the blade housing on the

frame and place the cover plate
over the blade housing.

 While holding the cover plate

firmly against the housing and
frame, start the two cover
retaining screws.

 Thread the cover retaining

screws in, leaving a slight
tension to allow for blade
adjustment.

Instructions for Operation

4-8

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Left Cover
Retaining
Screw

Pivot Support

Point

Housing

Slot

Screwdriver

Left Cover
Retaining
Screw

Screwdriver

Power Unit / Head Assembly - Attachment and Adjustment

(Continued)

NOTE: Leave a slight tension on the

left cover retaining screw so the
blade housing will stay open on its own.

Step 8: Install Blade

 Holding the tool blade side up, pry

open the blade housing with a
screwdriver.

 Insert a new blade into the

housing.

 Loosen the left cover retaining

screw to allow the housing to
close.

 Tighten the right cover retaining

screw.

 With left cover retaining screw ½

turn loose, adjust housing for proper fit.

 Gently pry the housing open until the blade

rotates freely and has enough clearance
to allow the blade to move forward and
backward in the housing. Only a slight
amount of movement is necessary.

 Tighten the cover retaining screws to the
 recommended torque.

NOTE: Recommended torque of 30-40 lb-in
(3.4-4.5 N-m).

IMPORTANT: Be sure that the blade is free to move
in the housing. If the blade does not move freely, it
may cause the trimmer to overheat.

Instructions for Operation

Manual No. 188000
September 1, 2009

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

4-9

Model Shown is

880-B

Depth Gauge Assembly

Depth Gauge
Mounting
Screws

Cover

Power Unit / Head Assembly - Attachment and Adjustment

(Continued)

Step 9: Install Depth Gauge (Optional)

 Loosen depth gauge mounting screws.
 Slide depth gauge onto the cover.
 Adjust the depth gauge to the desired height.
 (See Depth Gauge Adjustment for more information)
 Tighten the depth gauge mounting screw(s).

Instructions for Operation

4-10

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Hose

Assembly

Power Unit

Pin (2)

Groove

(2)

Power Unit

Lever

Hose Assembly

Hose Assembly Attachment

Step 1:

Align the pins in the hose assembly with the
grooves on the power unit.

Step 2:

 Slide the power unit into the hose

assembly

 Rotate the power unit 90°
 Lever will rotate toward the bottom

of the tool.

Instructions for Operation

Manual No. 188000
September 1, 2009

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

4-11

Hose
Assembly

Power Unit

Flange

Hose Clamp

Push

Power Unit

Lever

Lever

Starting the Trimmer with Standard Hose Assembly

 Hold the power unit and push the flange

and or hose clamp of the hose assembly
toward the power unit.

 Hold the lever against the power unit to

keep the trimmer running.

 Release the lever to turn the trimmer off.

Instructions for Operation

4-12

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Lever

Power Unit

Lever

Lever

Safety

Power

Unit

Hose
Assembly

Starting the Trimmer with Quick-Start Hose Assembly

 Fold the safety into the lever.

 Hold the lever against the power unit to

keep the trimmer running.

 Release the lever to turn the trimmer off.

Instructions for Operation

Manual No. 188000
September 1, 2009

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

4-13

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 BLADES.

ALWAYS DISCONNECT THE TOOL FROM THE AIR SUPPLY

PRIOR TO SERVICING.

Slide to Adjust

Moving Up = Thicker Cut

Moving Down = Thinner Cut

Depth Gauge
Mounting
Screws

Depth Gauge
Mounting

Screws

Depth Gauge Adjustment

Models 880, 1880, 1400, 1500 and optional 505:

These models 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 the depth:

 Hold the handpiece with the blade facing downward.
 Loosen the depth gauge mounting screw(s).
 Adjust the depth gauge setting by sliding it up or down to the desired height.
 Retighten the depth gauge mounting screw(s).

Depth Gauge Adjustment Range:

Model 880 Whizard® AirMax MACH 3 Model 1400 Whizard® AirMax MACH 3

Instructions for Operation

4-14

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

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 BLADES.

ALWAYS DISCONNECT THE TOOL FROM THE AIR SUPPLY

PRIOR TO SERVICING.

Adjustment

Knob

Depth Gauge Adjustment (Continued)

Optional Adjustable Fat (F) and Skinner (S) Disc Gauges for the 850, 1000 and
1300

 Hold the handpiece with the blade facing

downward.

 Adjustments – Turn the adjustment knob

clockwise for a thicker cut, or
counterclockwise for a thinner cut.

Important: Take care not to turn the
adjustment knob too far as the disc may
disengage from the shaft.

Instructions for Operation

Manual No. 188000
September 1, 2009

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

4-15

W A R N I N G

SHARP BLADES MAY CAUSE CUT INJURY!

NEVER HOLD THE PRODUCT BEING TRIMMED IN YOUR

HAND.

ALWAYS LAY THE PRODUCT FLAT ON THE WORK SURFACE.

Tool Operation

Always hold the handle of the Whizard® AirMax MACH 3 Trimmer with your thumb extended.
Let the handle rest naturally in your 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-commonly 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 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® AirMax MACH 3
trimming will become easier as the operator gains experience using 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 minimized, and blades need only be
sharpened once a day with the use of a Whizard Model 210 Universal Blade Sharpener,
Whizard Model 214 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.

Instructions for Operation

4-16

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

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 BLADES.

ALWAYS DISCONNECT THE TOOL FROM THE AIR SUPPLY

PRIOR TO SERVICING.

Cross-Section View of

Steeling Outside Blade Edge

Cross-Section View of

Steeling Inside Blade Edge

Blade Steeling

Steeling For Models: 350, 500, 620 and 750:

 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.

Whizard Special Steel

 Use the steel lightly and always make the last pass of the steel on the inside surface of the

blade.

 Steeling can be accomplished with much greater consistency with the use of the specially

designed Whizard® EdgeMaster™ Steels. See Section 7; Blade Sharpening and Steeling
Equipment, or contact your Regional Manager or Bettcher Industries, Inc. for more
information.

 Replace or sharpen the blade if this procedure does not improve the cutting action.
 The Whizard

quickly removed and reinstalled.

®

AirMax MACH 3 Trimmers have been designed to allow the blades to be

Instructions for Operation

Manual No. 188000
September 1, 2009

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

4-17

Whizard® Special

Steel

*Note: Do not
touch the steel to
the blade.

Whizard® Special

Steel

Blade Steeling (Continued)

Steeling for Model: 360

 Steel the outside edge of the blade by laying the special Whizard

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.

 Steel the inside of the blade by placing the cone shaped tip of the Whizard

on the inside edge of the blade. Do not touch the blade with the shaft of the Whizard®
special steel.

®

steel flat against the

®

special steel

Instructions for Operation

4-18

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Push Button

Steeling
Device

Whizard®

Special Steel

Model 880-B Whizard

®

AirMax MACH 3 Shown

Push Button

Steeling
Device

Whizard®

Special Steel

Model 1400 Whizard

®

AirMax MACH 3 Shown

Blade Steeling (Continued)

Steeling for Models: 505, 625, 850, 880, 1850, 1880, 1000, 1300, 1400 and 1500

 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 :

 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.

 At the same time, lightly push down with your thumb on the push button, holding the

steeling device lightly against the blade edge for several blade rotations.

Instructions for Operation

Manual No. 188000
September 1, 2009

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

4-19

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 BLADES.

ALWAYS DISCONNECT THE TOOL FROM THE AIR SUPPLY

PRIOR TO SERVICING.

Left Cover
Retaining
Screw

Screwdriver

Blade Changing

The Whizard® AirMax MACH 3 Trimmers have been designed to allow the blades to be quickly
removed and reinstalled.

To Change the Blade

 Loosen only the left cover retaining screw.

NOTE: Slight tension on the left cover screw will allow the blade housing to stay open.

 Holding the tool blade side up, pry

open the blade housing with a
screwdriver.

 Carefully remove the old blade.
 Insert a new blade in the housing.

Instructions for Operation

4-20

Instructions for Operation
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Left Cover
Retaining
Screw

Screwdriver

Left Cover
Retaining
Screw

Pivot Support

Point

Housing

Slot

Screwdriver

Blade Changing (Continued)

 Loosen the left cover retaining screw to allow the housing to close.
 Tighten the right cover retaining screw.
 With left cover retaining screw ½ turn loose, adjust housing for proper fit.
 Gently pry the housing open until the blade rotates freely and has enough clearance to

allow the blade to move forward and backward in the housing. Only a slight amount of
movement is necessary.

 Tighten the cover retaining screws to the recommended torque.

NOTE: Recommended torque of 30-40 lb-in (3.4-4.5 N-m).
IMPORTANT: Be sure that the blade is free to move in the housing. If the blade does

not move freely, it may cause the trimmer to overheat.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-1

Section 5

Maintenance

Maintenance Schedule ........................................................................................................... 5-3

General Maintenance ............................................................................................................. 5-3

Handpiece Maintenance ......................................................................................................... 5-3

Required Tools for Handpiece Maintenance ...................................................................... 5-3

Disassembly of Handpiece ................................................................................................. 5-4

Inspection and Maintenance of Handpiece ...................................................................... 5-10

Blade Sharpening ............................................................................................................. 5-13

Assembly of Handpiece .................................................................................................... 5-15

TRIMVAC® AMX Handpiece Maintenance ............................................................................5-21

Required Tools for Handpiece Maintenance .................................................................... 5-21

CONTENTS OF THIS SECTION

Disassembly of TRIMVAC® AMX Handpiece ................................................................... 5-22

Inspection and Maintenance of TRIMVAC® AMX Handpiece ........................................... 5-29

Blade Sharpening of TRIMVAC® AMX Handpiece ........................................................... 5-31

Assembly of TRIMVAC® AMX Handpiece ........................................................................ 5-33

Power Unit Maintenance .......................................................................................................5-44

Required Tools for Power Unit Maintenance .................................................................... 5-44

Disassembly of Power Unit .............................................................................................. 5-44

Inspection and Maintenance of Power Unit ...................................................................... 5-47

Assembly of Power Unit ................................................................................................... 5-51

Seal Plate Maintenance .........................................................................................................5-55

Required Tools for Seal Plate Maintenance ..................................................................... 5-55

Replace Seal .................................................................................................................... 5-55

Maintenance

5-2

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Contents of this section (Continued)

Air Motor Maintenance .......................................................................................................... 5-56

Required Tools for Air Motor Maintenance ....................................................................... 5-56

Disassembly of Air Motor .................................................................................................. 5-57

Inspection and Maintenance of Air Motor ......................................................................... 5-60

Assembly of Air Motor ...................................................................................................... 5-62

Valve and Hose Assembly Maintenance .............................................................................. 5-65

Required Tools for Valve and Hose Assembly Maintenance ............................................ 5-65

Inspection of Valve and Hose Assembly .......................................................................... 5-65

Disassembly of Valve and Hose ....................................................................................... 5-66

Assembly of Valve and Hose ............................................................................................ 5-67

Quick Start Valve and Hose Assembly Maintenance ............................................................ 5-68

Required Tools for Quick Start Valve and Hose Assembly Maintenance ......................... 5-68

Inspection of Valve and Hose Assembly .......................................................................... 5-68

Disassembly of Quick Start Valve and Hose .................................................................... 5-69

Assembly of Quick Start Valve and Hose ......................................................................... 5-70

Fault Detection and Correction ............................................................................................. 5-71

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-3

Description

Maintenance Schedule

Handpiece

Daily

Power Unit

After Every 80 Hours of Use

Hose Assembly

As Required

W A R N I N G

SHARP BLADES MAY CAUSE INJURY!

FOR PROPER PROTECTION OF HANDS, A PROTECTIVE

GLOVE SHOULD BE USED WHEN OPERATING THIS

EQUIPMENT AND DURING THE HANDLING OF BLADES.

ALWAYS DISCONNECT AIR SUPPLY AND REMOVE TOOL

FROM HOSE ASSEMBLY PRIOR TO SERVICING.

Maintenance Schedule

General Maintenance

 Drain filter bowls daily.
 Inspect filter for damage and dirt build-up. Replace when necessary.
 Fill lubricator (oiler) daily or more often if needed.
 Verify oiler is set to deliver 3 drops of oil per minute.
 Verify air pressure is set at 90-100 psi. Do not exceed 100 psi!

Handpiece Maintenance

The Whizard® AirMax MACH 3 Trimmer was designed to allow quick and easy removal of the
handpiece from the hose assembly. This allows the trimmer to be removed from the hose
assembly while still on the production line. The hose assembly can be left hanging on the
production line and the handpiece can be returned to the knife room for service. It is
recommended that this procedure be followed. The removal of the 10 feet (3.05 m) of hose will
allow easier service, storage, and handling by knife room personnel.

Required Tools for Handpiece Maintenance

1 – Flat head screwdriver
1 – Hex Wrench (supplied with the Whizard

®

AirMax MACH 3 Trimmer)

Maintenance

5-4

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Lever

Grease Cup

Knob
Assembly

Handpiece

Cap

Handpiece

Disassembly of Handpiece

Step 1: Remove Handpiece from Hose Assembly:

 While holding the handpiece, grip the knob assembly with the opposite hand.
 Rotate the knob assembly 90° and pull the hose assembly from the handpiece.

NOTE: The lever will rotate toward the grease cup for right-handed models,

and away from the grease cup for left-handed models.

 Place the cap over the end of the handpiece to protect the handle and protect the motor

from water damage.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-5

Depth Gauge

Attachment Screws

Depth Gauge

Disassembly of Handpiece (Continued)

Step 2: Removal/Disassembly of the Depth Gauge from the Cover:

 Loosen, but do not remove, the depth gauge attachment screw(s) located inside the depth

gauge.

 Slide the depth gauge upward until the depth gauge clamp(s) slide out of the cover plate

grooves.

Maintenance

5-6

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Left Cover
Retaining
Screw

Screwdriver

Left Cover
Retaining
Screw

Pivot Support

Point

Housing

Slot

Screwdriver

Disassembly of Handpiece (Continued)

Step 3: Remove Blade:

 Hold the tool with

the blade side up.

 Loosen only the left

cover retaining screw.

NOTE: A slight tension on the left

cover screw will allow the blade
housing to stay open on its own.

 Insert a screwdriver into the housing

slot.

 Using the frame as the support point,

spread
open the housing, just far enough to
remove the blade.

 Carefully remove the blade.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-7

Cover

Pinion

Frame

Cover Retaining
Screws (2)

Blade Housing

Disassembly of Handpiece (Continued)

Step 4: Remove Cover and Blade Housing:

 Loosen the cover retaining screws until the cover can be removed.
 Remove the blade housing and cover.

Step 5: Remove Pinion:

 Pull the pinion out of the frame.

Maintenance

5-8

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Drive
Adapter

Frame

Bearing

Frame

Disassembly of Handpiece (Continued)

Step 6: Remove Bearing:

 Pull the bearing out of the frame.

Step 7: Remove Drive Adapter:

 Pull the drive adapter out of the frame.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-9

Power Unit

Frame

Hex Wrench

Attachment
Screw

Disassembly of Handpiece (Continued)

Step 8: Remove Frame from Power Unit:

 Remove attachment screw from inside the frame using the supplied hex wrench.
 Remove the frame from the power unit.

Maintenance

5-10

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

W A R N I N G

SHARP BLADES MAY CAUSE CUT INJURY!

ALWAYS DISCONNECT THE AIR SUPPLY PRIOR TO

SERVICING.

FOR PROPER PROTECTION OF HANDS, A PROTECTIVE

GLOVE SHOULD BE USED WHEN OPERATING THIS

EQUIPMENT AND DURING THE HANDLING OF BLADES.

Gap –

Housing is Acceptable

No Gap –

Replace Housing

Inspection and Maintenance of Handpiece

Blade

 Inspect the cutting edge height with a Whizard

®

blade gauge.

 Check for worn or chipped teeth.
 Check for damage to the cutting edge.

Blade Housing

 Inspect 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.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-11

Inspection and Maintenance of Handpiece (Continued)

Pinion Gear

 Check for worn or chipped teeth. Worn out teeth are indicated by rounded off or pointed

tops on the teeth.

Bearing

 Install a new pinion and move the pinion side to side.
 If the pinion feels loose in the bearing, the bearing should be replaced.
 The bearing should be replaced after 500 hours of use.

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.

 Look for signs of wear on the pinion cover surface. If excessive wear signs are present,

check the seal on the power unit for leakage.

Frame

 Inspect the frame surface where the housing is attached.
 Look for corrosion and any nicks or burrs that may prevent proper housing seating.
 Inspect the housing locating key for damage.
 Inspect the cover retaining screws and replace if bent or damaged.

Steeling Device

 Inspect the surface condition of the carbide steel. If chipped or cracked, it should be

replaced.

 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.
 If the depth gauge clamps are bent, replace the depth gauge.

Maintenance

5-12

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Inspection and Maintenance of Handpiece (Continued)

Drive Adapter Assembly

 Inspect the drive adapter assembly for the following. Replace the drive adapter assembly

if damaged.

 Inspect the square end of the driver for rounded corners.
 Inspect the retaining ring for damage.

 If retaining ring has moved out of the groove or is missing, replace drive adapter

assembly.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-13

W A R N I N G

SHARP BLADES MAY CAUSE INJURY!

FOR PROPER PROTECTION OF HANDS, A PROTECTIVE

GLOVE SHOULD BE USED WHEN OPERATING THIS

EQUIPMENT AND DURING THE HANDLING OF BLADES.

W A R N I N G

AFTER SHARPENING, ALL ABRASIVE DUST MUST BE

COMPLETELY REMOVED FROM THE HANDPIECE.

DISASSEMBLE THE UNIT AND CAREFULLY WASH EACH

PIECE WITH HOT, SOAPY WATER AND A SMALL BRUSH.

Blade Sharpening

 The blade should be sharpened daily with the use of a Whizard

Blade Sharpener, a Whizard Model 214 Blade Sharpener, a Bettcher® AutoEdge, or by
hand stoning.

 Clean all grease and meat particles from the blade before sharpening. Sharpening blades

that have not been cleaned will coat the stone or grinding wheel and greatly reduce its
effectiveness.

 If the stone or grinding wheel becomes coated, gently scrub them clean using hot,

soapy water.

®

Model 210 Universal

Maintenance

5-14

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

W A R N I N G

SHARP BLADES MAY CAUSE INJURY!

FOR PROPER PROTECTION OF HANDS, A PROTECTIVE

GLOVE SHOULD BE USED.

Stone

Blade Sharpening (Continued)

Hand Stoning

 With the motor running, apply the flat side of the stone to the flat part of the blade.

 Move the stone, using a “back and forth” motion.
 Use the Special Whizard

®

Steel to finish sharpening. (See Blade Steeling in Section 4)

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-15

Thumb
Support

Tab

Frame

Notches

Spacer Ring

Small End

Frame

Assembly of Handpiece

Prior to assembly, be sure all parts are clean and have been inspected for wear per Section 5.

Step 1: Attach Head to Power Unit

 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.

Maintenance

5-16

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Pin

Short
Groove

Notches
Frame

Power
Unit

Hex Wrench

Frame

Attachment

Screw

Assembly of Handpiece (Continued)

 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.

 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)

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-17

Drive Adapter

Retaining Ring

Bearing

Bearing Flat

Frame Flat

Frame

Assembly of Handpiece (Continued)

Step 2: Install Drive Adapter

 Insert drive adapter and align the square

end with the square hole in the power
unit.

 Drive adapter should drop in with no

pressing force required.

 The retaining ring will sit flush against

the attachment screw when properly
aligned.

Step 3: Install Bearing

 Push handpiece bearing into the

frame bore and align the bearing flat
with the frame flat.

 The bearing should go in with

minimal effort and not require
pressing.

 Do not force the bearing in. If the

bearing does not go in easily, check
frame and bearing for damage or
build-up.

Maintenance

5-18

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Pinion

Bearing

Cover

Plate

Cover
Retaining
Screw (2)

Frame

Blade Housing

Assembly of Handpiece (Continued)

Step 4: Install Pinion

 Insert the pinion into the bearing bore.
 The pinion should go in with minimal

effort and not require pressing.

 Do not force the pinion into the

bearing. If the pinion does not go in
easily, check bearing and pinion for
damage or build-up.

 The pinion should sit flush against the

bearing. If it does not, rotate the
pinion to seat it flush with the bearing.

Step 5: Install Cover and Blade Housing

 Set the blade housing on the frame

and place the cover plate over the
blade housing.

 While holding the cover plate firmly

against the housing and frame, start
the two cover mounting screws.

 Thread the cover retaining screws in,

leaving a slight tension to allow for
blade adjustment.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-19

Left Cover
Retaining
Screw

Screwdriver

Left Cover
Retaining
Screw

Pivot Support

Point

Housing

Slot

Screwdriver

Assembly of Handpiece (Continued)

Step 6: Install Blade

 Holding the tool blade side up, pry

open the blade housing with a
screwdriver.

 Insert a new blade into the housing.
 Loosen the left cover retaining screw to

allow the housing to close.

 Tighten the right cover retaining screw.
 With left cover retaining screw ½ turn

loose, adjust housing for proper fit.

 Gently pry the housing open until the

blade rotates freely and has enough
clearance to allow the blade to move
forward and backward in the housing.
Only a slight amount of movement is
necessary.

NOTE: Recommended torque of 30-40 lb­in (3.4-4.5 N-m).

IMPORTANT: Be sure that the blade is
free to move in the housing. If the blade
does not move freely, it may cause the
trimmer to overheat.

 Tighten the cover retaining screws to

the recommended torque.

Maintenance

5-20

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Model Shown is

880-B

Depth Gauge Assembly

Depth Gauge
Mounting
Screws

Cover

Assembly of Handpiece (Continued)

Step 7: Install Depth Gauge (Optional)

 Loosen depth gauge mounting screw(s).
 Slide depth gauge onto the cover.
 Adjust the depth gauge to the desired height.
 (See Depth Gauge Adjustment for more information)
 Tighten the depth gauge mounting screw(s).

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-21

W A R N I N G

SHARP BLADES MAY CAUSE INJURY!

FOR PROPER PROTECTION OF HANDS, A PROTECTIVE

GLOVE SHOULD BE USED WHEN OPERATING THIS

EQUIPMENT AND DURING THE HANDLING OF BLADES.

ALWAYS DISCONNECT AIR SUPPLY AND REMOVE TOOL

FROM HOSE ASSEMBLY PRIOR TO SERVICING.

TRIMVAC® AMX Handpiece Maintenance

Required Tools for Handpiece Maintenance

1 – Flat head screwdriver
1 – 3/32” hex wrench (supplied with the TRIMVAC® AMX Trimmer)
1 – 9/64” hex wrench (supplied with the TRIMVAC® AMX Trimmer)
1 – 3/8” hex wrench (supplied with the TRIMVAC® AMX Trimmer)

Maintenance

5-22

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Disassembly of TRIMVAC® AMX Handpiece

Step 1: Remove Blade from Handpiece:

TRIMVAC® 18AMX:

 Hold the tool with the blade side up.
 Loosen only the left cover retaining screw, using the

supplied 3/32” hex wrench.

 Insert a screwdriver into the housing slot.
 Using the frame support point, spread open the

housing, just far enough to remove the blade.

 Carefully remove the blade.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-23

Disassembly of TRIMVAC® AMX Handpiece (Continued)

TRIMVAC® 45AMX:

 Hold the tool with the blade side up.
 Loosen only the left cover retaining screw.

 Insert a screwdriver into the housing slot.
 Using the frame support point, spread open the

housing, just far enough to remove the blade.

 Carefully remove the blade.

Maintenance

5-24

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Disassembly of TRIMVAC® AMX Handpiece (Continued)

Step 2: Remove Vacuum Hose:

 Slide the Whizard

®

AirMax MACH 3 hose out of the

clips on the vacuum hose.

 Repeat for each clip.

 Loosen the screw on the hose clamp.

 Slide the vacuum hose off of the hose adapter.

 Slide the hose out of the vacuum hose bracket.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-25

Disassembly of TRIMVAC® AMX Handpiece (Continued)

Step 3: Remove Handpiece from Hose Assembly:

 While holding the handpiece grip the knob

assembly with the other hand.

 Rotate the knob assembly 90º and pull the hose

assembly from the handpiece.

Step 4: Remove Hose Adapter, Cover, and Blade Housing:

TRIMVAC® 18AMX:

 Loosen the cover retaining screws until the hose

adapter, cover, and blade housing can be removed.

 Remover the hose adapter, cover and blade housing

Maintenance

5-26

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Disassembly of TRIMVAC® AMX Handpiece (Continued)

Step 4: Remove Hose Adapter, Cover, and Blade Housing (Continued):

 Separate the parts.

TRIMVAC® 45AMX:

 Loosen the cover retaining screws until the hose

adapter, cover and blade housing can be removed.

 Remove the hose adapter, cover and blade housing

 Separate the parts.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-27

Disassembly of TRIMVAC® AMX Handpiece (Continued)

Step 5: Remove Pinion:

 Pull the pinion out of the bearing.

Step 6: Remove Bearing:

 Pull the bearing out of the frame.

Step 7: Remove Drive Adapter:

 Pull the drive adapter out of the frame.

Maintenance

5-28

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Disassembly of TRIMVAC® AMX Handpiece (Continued)

Step 8: Remove Vacuum Hose Bracket:

 Loosen the hose bracket screws.

 Slide the hose bracket off of the power unit.

Step 9: Remove Frame from Power Unit:

 Remove the attachment screws from inside the frame using the supplied hex wrench.
 Remove the frame from the power unit.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-29

W A R N I N G

SHARP BLADES MAY CAUSE CUT INJURY!

ALWAYS DISCONNECT THE AIR SUPPLY PRIOR TO

SERVICING.

FOR PROPER PROTECTION OF HANDS, A PROTECTIVE

GLOVE SHOULD BE USED WHEN OPERATING THIS

EQUIPMENT AND DURING THE HANDLING OF BLADES.

Gap –

Housing is Acceptable

No Gap –

Replace Housing

Inspection and Maintenance of TRIMVAC® AMX Handpiece

Blade

 Inspect the cutting edge height with a Bettcher blade gauge.
 Check for worn or chipped teeth.
 Check for damage to the cutting edge.

Blade Housing

 Inspect 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.

Maintenance

5-30

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Inspection and Maintenance of TRIMVAC® AMX Handpiece

(Continued)

Pinion Gear

 Check for worn or chipped teeth. Worn out teeth are indicated by rounded off or pointed

tops on the teeth.

Bearing

 Install a new pinion and move the pinion side to side.
 If the pinion feels loose in the bearing, the bearing should be replaced.
 The bearing should be replaced after 500 hours of use, or if it is worn, whichever comes

first.

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.

 Look for signs of wear on the pinion cover surface. If excessive wear signs are present,

check the seal on the power unit for leakage.

Hose Adapter

 Inspect the hose adapter for chips or cracks and replace if damaged.

Frame

 Inspect the frame surface where the housing is attached.
 Look for corrosion and any nicks or burrs that may prevent proper seating of the housing.
 Inspect the housing locating key for damage.
 Inspect the cover retaining screws and replace if bent or damaged.

Drive Adapter Assembly

 Inspect the drive adapter assembly for the following. Replace the drive adapter assembly

if damaged.

 Inspect the square end of the driver for rounded corners.
 Inspect the retaining ring for damage.

 Press the retaining ring back into the groove if the retaining ring has moved.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-31

W A R N I N G

SHARP BLADES MAY CAUSE INJURY!

FOR PROPER PROTECTION OF HANDS, A PROTECTIVE

GLOVE SHOULD BE USED WHEN OPERATING THIS

EQUIPMENT AND DURING THE HANDLING OF BLADES.

W A R N I N G

AFTER SHARPENING, ALL ABRASIVE DUST MUST BE

COMPLETELY REMOVED FROM THE HANDPIECE.

DISASSEMBLE THE UNIT AND CAREFULLY WASH EACH

PIECE WITH HOT, SOAPY WATER AND A SMALL BRUSH.

Blade Sharpening of TRIMVAC® AMX Handpiece

 The blade should be sharpened daily with the use of a Whizard

Blade Sharpener, a Whizard® Model 214 Blade Sharpener, Bettcher® AutoEdge, or by
hand stoning.

 Clean all grease and meat particles from the blade before sharpening. Sharpening blades

that have not been cleaned will contaminate the stone or grinding wheel and greatly
reduce its effectiveness.

 If the stone or grinding wheel becomes contaminated, gently scrub them clean

using hot, soapy water.

®

Model 210 Universal

Maintenance

5-32

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Blade Sharpening of TRIMVAC® AMX Handpiece (Continued)

TRIMVAC® Sharpening

 With the trimmer running, insert the blade into the TRIMVAC

®

Sharpener. The plastic

cap on the top of the sharpener will guide the handpiece into the sharpener.

 Press the blade lightly onto the sharpening and steeling rods for a few seconds.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-33

Assembly of TRIMVAC® AMX Handpiece

Prior to assembly, be certain all parts are clean and have been inspected for wear per Section 5.

Step 1: Attach Frame to Power Unit:

 Slide the spacer ring onto the frame, small end

first.

 While holding the Whizard

frame, align the pin in the power unit with one of
the notches on the frame.

®

AirMax MACH 3

 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.

 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).

Step 2: 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 pressing

force required.

 The retaining ring will sit flush against the

attachment screws when properly inserted.

Maintenance

5-34

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Align Flats

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 3: Install Bearing:

 Push the handpiece bearing into the frame bore and align the bearing flat with the frame

flat.

 The bearing should go in with minimal effort and not require pressing.
 Do not force the bearing in. If the bearing does not go in easily, check frame and bearing

for damage or build-up.

Step 4: Install Pinion:

 Insert the pinion into the bearing bore.
 The pinion should go in with minimal effort and

not require pressing.

 Do not force the pinion into the bearing. If the

pinion does not go in easily, check the bearing
and pinion for damage or build-up.

 The pinion should sit flush against the bearing.

If it does not, rotate the pinion to seat it flush
with the bearing.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-35

TRIMVAC® 18AMX

TRIMVAC® 45AMX

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 5: Install Hose Adapter onto Housing:

 Slide the hose adapter into the housing.

Maintenance

5-36

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 6: Attach Housing to Frame:

TRIMVAC® 18AMX:

 Set the blade housing with the hose adapter installed on the frame.

 Insert the cover plate into the housing. Align the holes in the cover plate with the holes

in the frame.

 Insert the cover retaining screws. Thread the cover retaining screws in, leaving a slight

tension to allow for blade adjustment.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-37

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 6: Attach Housing to Frame (Continued):

TRIMVAC® 45AMX:

 Insert the cover into the hose adapter and blade housing assembly.

 Set the blade housing on the frame. Make sure both the housing and cover are seated

properly.

 While holding the cover plate firmly against the housing and frame, start the two cover

retaining screws.

 Thread the cover retaining screws in, leaving a slight tension to allow for blade

adjustment.

Maintenance

5-38

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 7: Install Blade:

TRIMVAC® 18AMX:

 Hold the tool with the blade side up.
 Loosen only the left cover retaining screw using the supplied 3/32” hex wrench.

NOTE: Leave a slight tension on the left cover retaining screw so the blade housing will stay open.

 Insert a screwdriver into the housing slot.
 Using the frame support point, spread open the housing, just far enough to install the

blade.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-39

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 7: Install Blade (Continued):

TRIMVAC® 18AMX:

 Carefully insert the blade.

 Loosen the left cover retaining screw so the housing will close.

NOTE: Be certain that the blade is free to move in the housing. If the blade does not move freely, it
may cause the trimmer to overheat.

 Adjust the housing for proper running clearance.
 When the housing is properly adjusted there will

be a slight “left to right” movement, plus a light

“up and down” movement.

 If the blade does not move “left to right” and “up

and down”, pry the housing open slightly.

 Retighten the cover retaining screws.

NOTE: Recommended torque of 30-40 lb-in (3.4-4.5 N-m)

Maintenance

5-40

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 7: Install Blade (Continued):

TRIMVAC® 45AMX:

 Hold the tool with the blade side up.
 Loosen only the left cover retaining screw.

NOTE: Leave a slight tension on the left cover retaining screw so the blade housing will stay open.

TRIMVAC® 45AMX:

 Insert a screwdriver into the housing slot.
 Using the frame support point, spread open the housing, just far enough to install the

blade.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-41

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 7: Install Blade (Continued):

 Carefully insert the blade.

 Loosen the left cover retaining screw so the housing will close.

NOTE: Be certain that the blade is free to move in the housing. If the blade does not move freely, it
may cause the trimmer to overheat.

TRIMVAC® 45AMX:

 Adjust the housing for proper running clearance.
 If the blade is tight in the housing, adjustments can

be made by loosening the left cover retaining screw
and slightly spreading open the housing. Check for
free movement.

 Retighten the cover retaining screws.

NOTE: Recommended torque of 30-40 lb-in (3.4-4.5 N-m)

Maintenance

5-42

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 8: Install Vacuum Hose Bracket:

 Slide the hose bracket onto the power unit.
 Align the flat on the vacuum hose bracket with the lever relief groove on the power unit.
 Tighten the hose bracket screws.

Step 9: Attach Whizard® AirMax MACH 3 Hose to Power Unit:

 Align the pins in the hose assembly with the

grooves on the power unit.

 Slide the power unit into the hose assembly.
 Rotate the power unit 90º.
 The lever will rotate toward the bottom of the

tool.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-43

Assembly of TRIMVAC® AMX Handpiece (Continued)

Step 10: Attach Vacuum Hose:

 Slide the vacuum hose through the vacuum hose

bracket.

 Slide the vacuum hose onto the hose adapter.

 Tighten the hose clamp screw.

 Slide the Whizard

clips on the vacuum hose.

®

AirMax MACH 3 hose into the

 Repeat step for each clip.

Maintenance

5-44

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Power Unit

Spanner Wrench

Retainer

Spanner Wrench

Power Unit

Cap

Power Unit Maintenance
Required Tools for Power Unit Maintenance

1 – Spanner Wrench (Supplied with your Whizard® AirMax MACH 3 Trimmer)

Disassembly of Power Unit

Step 1: Remove Cap

 Remove the cap.

NOTE: Do not discard the cap.

Step 2: Unscrew Retainer

 Unscrew the retainer using the supplied spanner wrench. The retainer is a left-handed

thread and must be turned to the right (clockwise) to unscrew.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-45

Handle

Seal Plate

Gear Head

Disassembly of Power Unit (Continued)

STEP 3: Slide Components Out Of Handle

 Slide the seal plate, gear head,

air motor, adapter plate,
muffler, and retainer out of the
handle.

 The parts should slide out

easily. If the parts do not slide
out, tap the handle lightly
against a plastic block to
dislodge the parts.

STEP 4: Separate Seal Plate And Gear Head Assembly

 Separate the seal plate and gear head assembly

from the air motor, adapter plate, muffler, and
retainer.

Maintenance

5-46

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Air Motor

Retainer

Muffler

Adapter

Plate

Seal Plate

Gear Head

Screwdriver

Disassembly of Power Unit (Continued)

Step 5: Remove Seal Plate

 Remove the seal plate from the top of the gear head.
 Insert a screwdriver between the seal plate and ring gear and twist to remove the seal

plate.

Step 6: Separate Remaining Components

 Separate air motor, adapter plate, muffler, and retainer.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-47

Grip

Groove (2)

Inspection and Maintenance of Power Unit

Inspection and maintenance should be performed after every 80 hours of use.

Handle

 Clean the handle with warm soapy water and a soft brush. Remove any build up from the

grooves. Rinse the handle and dry thoroughly.

 Inspect the handle for the following and replace if damage is detected.

 Inspect the handle grip for tears, cuts, or wear.
 Inspect the handle grooves for nicks or wear.
 Inspect the handle I.D. for dents.

Maintenance

5-48

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Seal Plate

Seal

Shaft

Grease Holes
(on both sides)

Inspection and Maintenance of Power Unit (Continued)

Seal Plate

 Inspect the seal plate I.D. and O.D. for nicks, dents or wear. Replace the seal plate if damaged.

(See Seal Plate Maintenance).

 Inspect the seal I.D. for nicks, cuts or cracks. Replace the seal if damaged. (See Seal Plate

Maintenance).

Gear Head

 Inspect the gear head, by rotating the shaft.

 If the shaft does not rotate, replace the gear head.
 If you feel a rough or gritty resistance while rotating the shaft, replace the gear head.

 Re-grease gear head with Max-Z-Lube grease every 80 hours of use.

 Squeeze grease in through the rotor shaft hole in the bottom of the gear head.
 Continue to supply grease until clean grease comes out of the grease holes in the ring

gear.

 This method will thoroughly re-grease gear head and clean out debris trapped in the gear

NOTE: Use only Max-Z-Lube high performance lubricant.

head.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-49

Exhaust

Ports

Shaft

Guide
Pin

Vane (5)

Inlet

Port

Gear Teeth

Upper Bearing

Plate

Inspection and Maintenance of Power Unit (Continued)

Air Motor

 Clean all build-up out of the inlet and exhaust ports.
 Inspect the air motor for the following and replace or repair the air motor if damage is detected.

(See Air Motor Maintenance Section to repair the air motor).

 Check for worn or chipped teeth. Worn out teeth are indicated by rounded off or pointed

tops on the teeth.

 Look for cracked or broken gear teeth.
 Inspect the upper bearing plate I.D. and O.D. for nicks, dents, or wear.
 Inspect the vanes for chipped or broken tips by looking through the exhaust ports and

rotating the shaft to see all five vanes.

 Inspect the guide pin to verify it is not bent.
 The shaft should rotate freely.

 Lubricate the air motor with mineral oil through the exhaust ports.

Maintenance

5-50

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Adapter

Plate

O-Ring

Note:

Do not clean the muffler
while it is installed in the
power unit.

Inspection and Maintenance of Power Unit (Continued)

Adapter Plate

 Inspect the adapter plate for cracks or chips. Replace the adapter plate if damaged.
 Inspect o-ring for nicks, cuts or tears. Replace the o-ring if damaged.

Muffler

 Inspect the muffler for broken or protruding wires. Replace the muffler if damaged.
 Muffler may be cleaned with parts cleaner to remove build-up. Replace muffler if

excessive build up prevents proper cleaning.

Retainer

 Inspect the retainer for cracks or chips. Replace the retainer if damaged.
 Inspect the retainer threads for damage. Replace the retainer if damaged.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-51

Gear Head

Air
Motor

Align
NotchesUpper Bearing Plate

Shaft

Lubricate

Seal I.D.

Gear Head

Assembly of Power Unit

Step 1: Install Seal Plate

 Apply a small amount of

Max-Z-Lube to the seal I.D.

NOTE: Use only Max-Z-Lube
high performance lubricant.

 Slide the seal plate over the

gear head shaft and onto the
gear head bearing.

Step 2: Align Gear Head And Air Motor

 Slide the gear head over the rotor shaft.
 Align the top notches on the gear head and upper bearing plate.
 Seat gear head in top plate.

Maintenance

5-52

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Air
Motor

Adpater
Plate

Pin

Exhaust Notches

Components

Handle

Assembly of Power Unit (Continued)

Step 3: Align Adapter Plate

 Slide the adapter plate over the pin in the

air motor.

 Align the exhaust notches on the adapter

plate and the air motor.

Step 4: Slide Components Into Handle

 Slide components up into the handle.
 Be careful not to let the components

separate and become misaligned.

 While holding the components in place,

turn the handle over.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-53

Muffler

Muffler

Installed

Retainer

Spanner

Wrench

Assembly of Power Unit (Continued)

Step 5: Install Muffler

Slide the muffler into the power unit.

Step 6: Install Retainer

 Screw the retainer firmly into the power unit, using the supplied spanner wrench. The

retainer is a left-hand thread, and must be turned to the left (counter clockwise), to
tighten.

NOTE: Recommended torque of 25-30 lb-in (2.8-3.4 N-m)
IMPORTANT: Be careful not to cross thread the retainer.

This will cause poor motor performance.

Maintenance

5-54

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Grease Inside of Handle

Grease Inside ofAdapter Plate

Cap

Assembly of Power Unit (Continued)

Step 7: Grease Power Unit

 Grease the inside of the handle and the inside of the adapter plate with Max-Z-Lube.

Step 8: Install Cap

 Slide the cap over the end of the power unit.

Maintenance

Manual No. 188000
September 1, 2009

Maintenance
Whizard® AirMax MACH 3 Operating Instructions and Parts
List

5-55

Seal Plate

Seal

Screwdriver

Lip

Seal

Lubricate I.D.

Seal

Seal

Seal Plate

Seal Plate Maintenance
Required Tools for Seal Plate Maintenance

1 – Small flat head screwdriver

Replace Seal

Step 1: Remove Seal

 Use a small flat head screwdriver to pry the seal out of the seal plate.

Step 2: Install Seal

 Apply a small amount of Max-Z-Lube to ID of the seal plate.

NOTE: Use only Max-Z-Lube high performance lubricant.

 Press the seal into the seal plate. The lip of the seal should curl into the seal plate.

Maintenance

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Maintenance
Whizard® AirMax MACH 3 Operating Instructions and
Parts List

Manual No. 188000
September 1, 2009

Cup Assembly

Air Motor Assembly Tool

Rotor
Removal
Punch

Gear Teeth
Cap

Bearing Tool

Upper Bearing

Plate Removal
Clamps

Air Motor Maintenance
Required Tools for Air Motor Maintenance

1 – Hammer
1 – Whizard® AirMax MACH 3 Maintenance Kit