Bettcher AirMax Mach 3 Installation guide

AirMax Mach 3 Maintenance Overview
A I R M A X
™
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Large Hex
Wrench
#184128
Spanner
Wrench
#184134
Top Plate
Removal Clamp
(2 Required)
#184255
Cup
Assembly
#184246
Rotor Removal
#
Punch 184254
Gear Teeth
#
Cap 185977
Bearing Tool
#185978
#
Air Motor Maintenance Kit 185975 Additional Maintenance Kit Tools
The Proper Tools
To perform maintenance on the AirMax power unit it is essential to have
the proper Bettcher maintenance tools and lubricants. Proper
maintenance and lubrication will improve tool performance and parts life.
Base Assembly
#185976
T a b l e o f C o n t e n t s
Tools for Power Unit . . . . 1
Proper Lubrication . . . . . . 2
Power Unit Maintenance . . . 3
Power Unit Reassembly . . . 4
Handle Assembly . . . . . . . 5
Head Attachment . . . . . . 6
Pa r t s L i s t . . . . . . . . 7
Lubricants for Air Tools . . . 8
Note: This is an interactive
PDF. Click on the blue
hyperlinks and Video icons
to see additional content.
INTERACTIVE
PDF
Please review Operating Instructions for complete instructions & safety information.

Air motors after 80 hours
of operation without
proper lubrication.
Add Whizard Oil
to exhaust ports
™
AirMax Mach 3 Lubrication
Proper lubrication improves both performance and parts life.
Lubrication
Proper lubrication of the AirMax™ power unit is an
important part of daily operation. It is essential to maintain a
proper amount of lubrication inside the power unit while the
tool is running. The absence of proper lubricant will destroy
the vanes and cause premature wear on cylinder parts. In
addition, be sure the air pressure and volume are optimal and
the air supply is clean and dry.
Daily Checklist
1. Constant air pressure of 90 psi (6,2 bars).
Do not exceed 100 psi.
2. Air volume is 14 cfm (396 lpm).
3. The filter bowl (on FRL) should be drained and the
lubricator refilled with ®
Bettcher Whizard Food Grade
Multipurpose Oil Whizard Oil ( - Part #103603).
4. Lubrication on FRL is set at three drops per minute.
After Every 80 Hours
1. Completely disassembly the power unit. Disassembly
information on this can be found on the following pages.
2. Lubricate the gear head by injecting ™ high Max-Z-Lube
performance grease into Gear Head Assembly. See Figure 2
on this page. Max-Z-Lube Part #184282.
®
3. Lubricate air motor with Whizard Oil through the exhaust
ports. See Image Directly Below.
Inspect the seal plate for nicks, dents
or wear. Inspect the O-Ring seal for
cracks or cuts. Replace if damaged.
Re-grease gear head using Max-Z-Lube
grease every 80 hours. The new grease
will push out the old, dirty grease.
Part #184282
2
1
Max-Z-Lube Lubricant
is a high performance
lubricant that provides
valuable protection for
moving parts. This super
slick formula provides
optimum protection from
friction, oxidation and
high temperatures. This is
the best lubricant for your
®
AirMax motor.
Order Part #184282.

The AirMax™ Mach 3 motor delivers
high levels of torque over a wide range
of speeds. To keep the motor operating at peak
efficiency, it should be cleaned and inspected after every
80 hours of usage.
As long as there is no performance loss, most of the
inspection of the air motor can be done without disas-
sembly. However, if the operator mentions a loss in
power, use the following procedure. For complete instruc-
tions refer to the AirMax™ Mach 3 Operating Instructions.
Air Motor Disassembly
1. Tool and Maintenance Kit #185975 is required to
dissemble a Mach 3 trimmer.
2. Unscrew retainer using the spanner wrench. Note:
This is a left-hand thread and must be turned right
(clockwise) to unscrew. Slide components out of
handle. If parts don't slide out easily, tap the handle
lightly against a plastic block to dislodge.
3. Separate the motor from the gear head and adapter.
4. Place the upper bearing plate removal clamps around
the upper bearing as shown in Figure 3.
5. Using a hammer and plastic sleeve, tap the gear teeth
cap until the rotor is free from the upper bearing
plate. Figure 4. Remove the upper bearing and
cylinder.
6. Remove vanes from the rotor and inspect for
chipped or broken tips, grooves and vane height.
Replace vanes with grooves more that .010" (.25
mm) deep or with a height less than .195" (.5 mm).
Next, inspect the rotor for cracked, broken teeth, or
excessive wear.
Inspect
¨Clean buildup out of inlet and exhaust ports
¨Check gear teeth for cracks or damage. Worn teeth
are indicated by rounded or pointed tops
¨Inspect guide pin to verify it is not bent
¨Check the cylinder interior for grooves
¨Replace any parts that are damaged or worn
¨Check vanes as shown in Figure 5
¨Verify the O-Ring is inplace inside handle Figure 6
Place air motor in bearing plate assembly tool and
tap to remove.
™
AirMax Mach 3 Power Unit Maintenance
Maintenance tips that improve both performance and tool life
Gear Head Mach 3 Air Motor Adapter, Muffler
Retainer
2
34
New Worn Broken Make sure O-Ring
is seated.
56
Note:
Left-hand thread
1
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Reassembly
Oil is the lifeblood of any motor. Not only does it lubricate
moving parts, it dissipates heat and prevents corrosion.
The quality of oil is equally important … too little, too thin
or too thick will either reduce performance or motor life.
Use only ® Whizard Food Grade Multipurpose Lubricating
Oil ®
Part #103603 (Whizard Oil ) as a high quality, long-
lasting lubricant that will protect your trimmer investment.
Lubricate and Reassemble Air Motor
1. Saturate vanes with before assembly.
®
Whizard Oil
2. Insert the vanes with the curved side toward the
rotor center.
3. Slide the cylinder over the rotor and add a small amount
of around the top of the rotor assembly.
®
Whizard Oil
Note: The alignment pin in the bearing plate inserts
into the alignment hole in the cylinder. Make sure the
exhaust notches line up.
4. The upper bearing plate is installed by first inserting the
alignment pin of the lower bearing plate into the
alignment hole in the base of the assembly tool fixture.
5. Place the upper bearing plate onto the cylinder and then
the bearing. Using a hammer and the bearing tool, tap
the bearing tool until the bearing plate is fully seated on
the cylinder.
6. The air motor is now assembled and the shaft should
rotate freely.
®
Add a small amount of Whizard Oil and then place in
the maintenance tool block.
Saturate vanes and insert in rotor, curved side
towards rotor.
Mach 3 Air Motor — Reassembly
3
1
4
5
2
Using the bearing tool and hammer, tap bearing onto
cylinder. Make sure notches are aligned (note circle).
Assembled
Motor
• Use one FRL for each trimmer.
• Constant 90 psi (6,2 bars) at a
volume of 14 cfm (396 lpm).
• Filter bowls should be drained
and lubricator refilled daily.
• Oil should be set for three drops
®
per minute of Whizard Oil for
proper lubrication and protection.
Performance Tip
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Assembly of the Power Unit
Holding the handle ‘up’ and all the power unit components
together, slide them up into the handle. With all the components
together and the handle in the ‘up’ position, components are less
likely to get misaligned.
Spin and Tighten
To insure power unit components stay aligned when installed into
the handle, use the following procedure:
1. Using the spanner wrench, snug the retainer (Figure 2).
This is a left-hand thread. Counter-clockwise tightens.
2. Place the driver adapter into position and rotate the air
motor back and forth a few times (Figure 3).
3. Snug the retainer again, using the spanner wrench
(Figure 2), then rotate the driver and air motor back and
forth (Figure 3) with the driver adapter.
4. Repeat the process one last time.
5. The drive adapter should turn freely in the power unit.
6. Using the spanner wrench, make sure the retainer is tight after
each days use, as the retainer may loosen with time or usage.
7. When the motor is properly installed one or two threads will
be visible (Figure 4). If there are more threads the O-Ring
may be missing. No threads visible – either Step 1 or 3 was
not done correctly.
Power Unit Alignment & Installation
Align the power components and push up
inside the AirMax™ handle.
Snug the retainer using the spanner wrench.
Using the driver adapter, rotate the air motor
back and forth.
When the air motor is properly installed there
will be one or two threads visible — too many
or no threads means miss installation.
1
3
2
Note:
Left-hand thread
What happens with an
improperly seated power unit ...
An improperly tightened power unit will spin
inside the handle, causing a total loss of power and
damage to the handle. The procedures on this
page will prevent this.
Performance Tip
Cut-a-way
of AirMax™ Handle
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4

Attachment and Adjustment
To ensure a proper, comfortable fit, several options
are available for the AirMax™. Select from left- or
right-handed frame configurations, and the thumb
support or spacer ring. The frames are designed with
several notches to allow the most comfortable
position of the handle and thumb support for the
operator.
AirMax™ Mach 3 handles are available in either
yellow or dark blue. The dark blue handle is typically
used with the TrimVac™ for processing cattle over
the age of 30 months.
Step 1
Select the spacer ring or optional thumb supports. If
a spacer ring is used, slide the spacer ring onto the
frame, small end first.
If the thumb support is used, it should be positioned on
the side opposite the grease cup. Align the thumb
support tab with a notch on the frame and slide the
thumb support onto the frame.
Step 2
While holding the AirMax™ frame, align the pin in
the handle with one of the notches on the frame. For
the initial adjustment the short groove on the handle
should be facing up.
Next, let the operator test the assembly. Make
adjustments for the most comfortable fit.
Step 3
Insert the attachment screw in the frame and tighten
firmly using the supplied hex wrench.
Note: Recommended torque:
115-140 lb-in ( 13-16 N-m ).
Thumb Support
Short
Groove
Spacer
Ring
™
AirMax Mach 3 Head Attachment
The operator can choose whether to use the
thumb support or not.
Align the short groove with the notch in the frame.
Secure the Hex Wrench in a vice and turn the trimmer
to the recommended 115 - 140 lb-in of torque.
1
3
2
Never put the AirMax™ handle into a vice,
this will crush the hollow handle.
X

Mach 3 Power Unit and Motor Parts List
#
Cap 184286
Seal Block
#184062
Seal Kit
#184427
Gear Head
Assembly
#185935
Air Motor
Assembly
#185942
Adapter Plate
Assembly
#184047
Muffler
#184388
Retainer
#184049
Upper
Bearing
#185950
Upper
Bearing
Plate Assy
#185948
Cylinder
#185947
Rotor
#185944
Vane Kit
(5 Vanes)
#185790
O-Ring
#122316
O-Ring
#122316
Lower
Bearing
#184046
Lower Bearing
Plate Assy
#184042
(Spacer)
#184043
Complete Air Motor
#185942
#
Complete Power Unit Assembly 185923
#
Handle with O-Ring 185927
AirMax™ Mach 3 – Handle Color Options
Dark blue handle for cattle over 30 months.
#
Complete Power Unit Assembly 185924
#
Handle with O-Ring 185928

www.bettcher.com
Headquarters: 6801 State Route 60 • Birmingham, OH 44816
Tel: [phone] • [phone] • Fax: [phone] • E-mail: [e-mail]
AirMax Lubrication
Proper lubrication improves both performance and parts
Whizard Oil
Specially formulated oil for air tools.
Essential for adding protective
lubrication to the AirMax motor,
®
AirShirz and all FRL (Filter,
Regulator, Lubricator)
Whizard Multipurpose
Lubricating Oil
#
16 Fluid oz 103603
Whizard Multipurpose
#
Lubricating Oil 103603
Performance lubricant that delivers
superior protection for high RPM
gear-head. Super-slick formula
provides premium protection from
friction, oxidation and high tempera-
tures. This is the best lubricant for
®
your AirMax gear head assembly.
4 oz. Tube
#184282
Premium, high-speed, long-lasting
synthetic lubricant tailored to exceed
the demanding conditions of USDA
inspected meat, poultry and food
processing facilities. Formulated for
all Whizard Trimmer grease cups for
better performance and protection.
13.5 oz. Cartridge
#102609
®
HIGH PERFORMANCE GREASE
MA X L U B E
HI G H P E R F O R M A N C E L U B R I C A N T Formulated for extended high
RPM performance and superior
#
gear head protection 184282
Performance and protection for
#
all trimmer models 102609
TS102 3.7.2018