Wizard FS Service manual

TABLE OF CONTENTS
i
WIZARD DRUM TOOL CO.
Wizard®
DRUM DEHEADER
OPERATING and SERVICE MANUAL
Electric, Air and Automatic Air
Models F, G & J
Serial No. _________________
Wizard Drum Opener Operating and Service Manual; Version 2.0, Rev D

TABLE OF CONTENTS
ii
MODEL DESIGNATION AND FEATURES ................................................................................................................................................. 1
GENERAL WARNINGS AND PRECAUTIONS ........................................................................................................................................... 3
SECTION 1 - GENERAL INFORMATION ................................................................................................................................................... 4
DESCRIPTION ....................................................................................................................................................................................... 4
MODEL DESCRIPTIONS (See Illustrations on Page 1) ........................................................................................................................ 4
STANDARD POWER SOURCE ............................................................................................................................................................. 4
Electric .............................................................................................................................................................................................. 4
Air ..................................................................................................................................................................................................... 4
SUPPORT TOWER ................................................................................................................................................................................ 5
WIZARD COVER LIFTER (Model F Only) ............................................................................................................................................. 5
WIZARD DEKINKER .............................................................................................................................................................................. 5
BUNG WRENCH .................................................................................................................................................................................... 5
SECTION 2 - HOW TO USE YOUR WIZARD ............................................................................................................................................. 6
BEFORE PLACING THE WIZARD ON A DRUM ................................................................................................................................... 6
PLACING THE WIZARD ON A DRUM ................................................................................................................................................... 6
STARTING THE UNIT ............................................................................................................................................................................ 6
CUTTING THE DRUM ............................................................................................................................................................................ 7
Non-Automatic Units ......................................................................................................................................................................... 7
Automatic Units ................................................................................................................................................................................. 7
SECTION 3 - REMOVING DRUM LIDS ....................................................................................................................................................... 8
CUTTING TECHNIQUE (Models F and G Only) .................................................................................................................................... 8
SECTION 4 - CUTTER WHEEL POSITIONING .......................................................................................................................................... 9
LOCATION OF CUTTING POSITION .................................................................................................................................................... 9
HEIGHT OF CUT ADJUSTMENT .......................................................................................................................................................... 9
DEPTH OF CUT ADJUSTMENT ............................................................................................................................................................ 9
Non-Automatic Units ......................................................................................................................................................................... 9
Automatic Units ................................................................................................................................................................................. 9
SECTION 5 - PROPER USE AND CARE .................................................................................................................................................. 10
SECTION 6 -- FACTORY SERVICING ...................................................................................................................................................... 10
SHIPPING INSTRUCTIONS ................................................................................................................................................................ 10
SECTION 7 -- GENERAL MAINTENANCE AND REPAIR ....................................................................................................................... 11
MAINTENANCE FOR INDUSTRIAL UNITS ......................................................................................................................................... 11
FIELD SERVICING ............................................................................................................................................................................... 11
RETAINING RINGS .............................................................................................................................................................................. 11
SWIVEL CONNECTOR REMOVAL ..................................................................................................................................................... 11
DRIVE CHAIN REMOVAL .................................................................................................................................................................... 11
HEAD REMOVAL AND REPLACEMENT ............................................................................................................................................ 12
LUBRICATION ..................................................................................................................................................................................... 12
Electric Motors ................................................................................................................................................................................ 12
Gear Reducers ............................................................................................................................................................................... 12
SECTION 8 -- CUTTER WHEEL AND DRIVE ROLLER ADJUSTMENT AND MAINTENANCE ............................................................. 12
CUTTER WHEEL OR DRIVE ROLLER REMOVAL AND REPLACEMENT FROM FRONT SHAFT .................................................. 12
CUTTER WHEEL OR DRIVE ROLLER REMOVAL AND REPLACEMENT FROM REAR SHAFT. .................................................... 12
SECTION 9 -- SHAFT ASSEMBLIES ........................................................................................................................................................ 13
FRONT SHAFT REMOVAL AND REPLACEMENT ............................................................................................................................. 13
REAR SHAFT REMOVAL AND REPLACEMENT ................................................................................................................................ 13
SECTION 10 -- TROUBLESHOOTING PROCEDURES ........................................................................................................................... 15
ELECTRIC MODELS ............................................................................................................................................................................ 15
Unit does not run (may also give off sparks) .................................................................................................................................. 15
Unit stalls or does not start ............................................................................................................................................................. 15
Unit does not cut drums .................................................................................................................................................................. 15
Unit is unstable – wobbles while traveling around drum ................................................................................................................. 15

TABLE OF CONTENTS
iii
Top drum head cannot be removed (Model F) ............................................................................................................................... 15
Unit does not run or cut .................................................................................................................................................................. 15
AIR MODELS ....................................................................................................................................................................................... 16
Unit does not run ............................................................................................................................................................................ 16
Unit runs too slow ........................................................................................................................................................................... 16
Unit does not cut drums (Manual models) ...................................................................................................................................... 16
Unit does not cut drums (Automatic models) .................................................................................................................................. 16
Top drum head cannot be removed (Model F) ............................................................................................................................... 16
Unit does not run or cut .................................................................................................................................................................. 16
SECTION 11 – PARTS LISTS ................................................................................................................................................................... 17
ALL THREE UNITS .............................................................................................................................................................................. 17
SECTION 12 -- GLOSSARY ...................................................................................................................................................................... 21

Wizard Drum Opener Operating and Service Manual; Version 2.0, Rev D
1
Model Designation and Features
Standard Duty WIZARD Drum Openers come in three basic models (F, G and J). Each model opens a drum in one of three ways:
1) (OC) cutting around the outside diameter of the chime (the flat or round rim that fastens the lid to the drum).
2) (IC) cutting around the inside diameter of the chime.
3) (OS) cutting around the drum shell below the chime.
All models operate on either air or electricity. Air driven models F, G and J are also available with an air driven regulator to
automatically maintain cutter wheel force through an integral air cylinder. The following table shows the eleven currently available
variations of the four standard duty basic model groups:
Model
Power Source
Auto.
Type
Color
Comments
No.
Air
Elec.
Air
Of Cut
FS
X
NO
OC
White
USDA approved for Food industry applications.
FA
X
NO
OC
White
Same as FS. Recommended for washdown areas
RFA
X
YES
OC
White
Same as FS but with cutting pressure automatically
maintained.
GS
X
NO
IC
Yellow
For general purpose use. Reuse or scrap drum.
GA
X
NO
IC
Yellow
Same as GS.
RGA
X
YES
IC
Yellow
Same as GS but with cutting pressure automatically
maintained.
JS
X
NO
OS
Blue
Scrap drum.
JA
X
NO
OS
Blue
Same as JS.
RJA
X
YES
OS
Blue
Same as JS but with cutting pressure automatically
maintained.
Model FA
Model RGA
Model JA
Model GS

Wizard Drum Opener Operating and Service Manual; Version 2.0, Rev D
2
SERIAL NUMBERS: Always specify model and serial number (located on housing nameplate) in correspondence and parts requests. This identification
is the key to many engineering details applying to your deheader.

Wizard Drum Opener Operating and Service Manual; Version 2.0, Rev D
3
GENERAL WARNINGS AND PRECAUTIONS
ATTENTION
This section must be read thoroughly before operating any equipment
supplied by WIZARD Drum Tool Co. Failure to do so may result in damage
to equipment and/or severe injury to personnel.
• When using the unit, make sure you are wearing all personal safety equipment such as gloves, safety glasses, and
steel toe boots.
1. To avoid serious injury or death from electrical shock, make certain the unit is properly
grounded.
2. Do not operate any of the electrical units in wet areas.
3. Always use the correct voltage supply as indicated on the unit motor nameplate.
4. Do not use power cord if damaged or frayed.
1. Flip switch to “OFF” position.
2. In the event of a temporary power loss, there is the potential that the unit may be
restarted automatically if the power switch is left in the “ON” position!
3. Keep all body parts away from the cutter wheel and roller whenever the power is on!
4. If the unit stalls due to blockage between the cutter wheel and the roller, always turn the
unit off before attempting to dislodge any debris!
5. The chime of a cut drum may be sharp! Caution should be used when attempting to
remove the lid from the drum. It is recommended that leather work gloves be worn when
handling cut chimes.
6. Disconnect the power supply (electrical or air) before performing any maintenance on the
unit!
7. Do not operate unit on flooring that is not level. The drum may tip over during operation.
The following applies to units purchased for use in non-explosive environments:
1. Do not use any of the units to remove the lids off drums which may contain explosive
materials.
2. THE UNITS ARE NOT TO BE OPERATED IN EXPLOSIVE ENVIRONMENTS!
3. Extreme care must be taken so that the unit is not operated in any manner to potentially
ignite the drum contents and/or any explosive material.
ELECTRICAL
HAZARD
MECHANICAL
HAZARD
EXPLOSIVE
HAZARD

Wizard Drum Opener Operating and Service Manual; Version 2.0, Rev D
4
SECTION 1 - GENERAL INFORMATION
DESCRIPTION
The WIZARD drum openers are portable, self-propelled and
designed to cut the tops and/or bottoms of standard, 30-55
gallon (208 liters) steel drums up to 16 gauge.
All models are available with either an electric or air motor.
Models F, G and J are available with an automatic air powered
cutting feature.
WIZARD designs all its drum deheaders for long life, maximum
reliability and simplified maintenance. Modular construction
permits easy disassembly and adjustment, making parts
accessible for repair or replacement with a spare.
MODEL DESCRIPTIONS (See Illustrations on Page 1)
Model F opener (white) includes USDA-compliant parts and an
USDA-approved cutting method that cuts on the OUTSIDE of
the drum chime. Designed specifically for food industry aseptic
drums, no part of the Model F touches the drum contents. The
outside cut also prevents dirt, paint chips or other debris from
falling into the drum and contaminating its contents when
opening the drum. The drum deheader’s patented, continuous
cutting operation and round cutter wheel leave a completely
smooth edge, free of slivers or burrs. The drum lid remains
secure to protect the drum contents until it is removed with a
cover lifter.
The Model G opener (yellow) cuts on the INSIDE of the drum
chime and leaves a smooth burr-free edge for safe handling.
This versatile model is considered a general purpose opener
because opened drums can either be used for utility containers
or sold for scrap. This model has a small, 1-1/2" diameter
cutter wheel that travels between the chime and bung fittings
as it cuts. It is designed to open standard, 30-55 gallon
industrial drums of up to 16-gauge steel with either flat or
round chimes.
CAUTION
(For model J) Since the lid becomes completely separated from the
drum when cut, the unit has the potential to fall off the drum. Use
caution!
Model J opener (blue) cuts the drum shell BELOW the chime.
This model was designed for drum disposal because it
removes the entire drum head. Removing both top and bottom
heads of a drum makes it easy to flatten or crush the drum,
store it and later sell it for scrap.
STANDARD POWER SOURCE
WARNING
To avoid serious injury or death from electric shock, make sure the
unit is properly grounded and do not use the electric model in wet
areas.
Electric
Totally enclosed, fan cooled, permanently lubricated helical
gear/needle bearing gear motor. Furnished standard with 1/3
HP, 110 volt single phase, 60 Hz, electric drive and swivel
connectors matching standard single grounding plugs.
Deheaders are also available in 220VAC 50/60Hz
configurations. Satisfactory operation requires a 14ga or larger
3 prong plug properly grounded to earth ground.
Air
Variable speed, vane-type air motor and speed reducer.
Develops approximately 1/2 HP at 40 psig (275 kPa) (with 25
cfm (0.71 m3/min) free air. Best performance is generally
achieved with 80-100 PSIG air. Furnished with quick-
disconnect coupling for 1/4 inch MINIMUM diameter air line.
For long air hose runs we recommend larger 3/8 or 1/2 inch
diameter hoses.
Also, for proper operation and maximum service life you MUST
place pneumatic oil in the air line feeding into the motor.

Wizard Drum Opener Operating and Service Manual; Version 2.0, Rev D
5
SUPPORT TOWER
We recommend using a
WIZARD Tower to suspend
your WIZARD Drum Opener.
The tower keeps the opener
at working height and also
prevents the opener from
being dropped or from falling
off a wobbly drum.
WIZARD COVER LIFTER (Model F Only)
After the WIZARD cuts the chime the lid is ready to be lifted
vertically off the drum
with a WIZARD Cover
Lifter. The cover lifter
will remove a properly
cut lid quickly and
easily. Drum lids may
be reused to cover
drum.
WIZARD DEKINKER
Easily straightens bent or dented
chimes so your WIZARD Drum
Openers can operate with
maximum efficiency. Reseals
leaking drums caused by bent
chimes.
BUNG WRENCH
All-plug universal wrench
easily, safely opens all known
styles of American and foreign-
made bungs and fittings.
Ductile iron and non-ferrous
style are available.

Wizard Drum Opener Operating and Service Manual; Version 2.0, Rev D
6
SECTION 2 - HOW TO USE
YOUR WIZARD
BEFORE PLACING THE WIZARD
ON A DRUM
1. See Figure 1. Remove the plugs
from the bung fittings with a WIZARD
WRENCH (1 and 2).
2. Hammer down the bungs so they
do not block or interfere with either the drive roller or cutter
wheel. Note: For Model G with 1-1/2" diameter cutter wheel,
only hammer bungs less than 1-1/2" from the drum chime.
3. Straighten any bent chime using a WIZARD Dekinker or
hammer them into original contour (3).
4. Make sure the cutter wheel is in the retracted position, away
from the drive roller to allow chime clearance.
Non-Automatic Units: Turn the adjusting screw handle about
six turns counterclockwise.
Automatic Units: Turn on supply air to the drum opener and
push/pull the plunger button of the air valve.
PLACING THE WIZARD
ON A DRUM
1. See Figure 2. Place the
WIZARD on the drum so the
chime rollers ride on the top
of the chime. If using an
automatic air unit, push/pull
the plunger button of the air
valve to engage the cutter
wheel and skip step 3 below.
Dropping the Wizard on the
chime may damage the cutter
wheel.
2. Check the unit for proper
cutter height position.
The cutter height
position is factory set;
however, you may need
to make some minor
adjustments. Please
refer to section (4)
before continuing.
3. Refer to Figure 1. Turn
the adjusting screw handle (4) clockwise until the cutter
wheel just touches the chime (3). The cutter wheel must
not bite into metal at this point. Excess pressure prevents
the electric or air motor (5) from reaching operating speed
which may overload motor. The Warranty does not cover
motor damage caused by overload.
STARTING THE UNIT
Many operators place the electric cord or air line over their left
shoulder to keep it clear of the WIZARD. This also prevents the
cord or line from wrapping itself around the drum as the opener
rotates around the drum. Both the electric socket and the air
line connector swivel 360o to prevent the line/cord from
twisting during rotation.
Electric models have a toggle switch on the side of the handle.
Air driven models have a ball valve located on the air line and
an air regulator to adjust the rate of travel.
WARNING
DO NOT FOLLOW THE WIZARD AROUND THE DRUM.
Stand in one place and keep the cord or line out of the
WIZARD's path. Let the WIZARD make one complete
revolution and check for interference from bungs or chime.
Figure 1
Figure 2
Handle Assy.
Drive Unit
(Electric
or Air)
Motor
Bracket
Guide Rollers
Housing
Body
Front Shaft
Adj.
Screw
Assy.
Rear Shaft
CAUTION

Wizard Drum Opener Operating and Service Manual; Version 2.0, Rev D
7
CUTTING THE DRUM
Non-Automatic Units
1. Without stopping the drive unit, use HAND ACTION ONLY
to turn the adjusting screw handle about 1/4 turn clockwise.
DO NOT USE pipe, rod, or any other leveraging device to raise
cutting force. Excessive cutting force may damage the housing
body.
2. If you stop the unit for any reason, turn the adjusting screw
handle 1/4 turn counterclockwise before you restart. This
prevents overloading the drive unit.
3. After each revolution of the WIZARD around the drum, turn
the adjusting screw handle another 1/4 turn clockwise. This
gradually raises pressure on the cutter wheel so it can cut
through the drum or outer chime layer of metal. As the metal
splits, it makes a popping or cracking sound. Usually only 2 to
5 revolutions are enough to cut through the metal.
4. After you finish cutting the drum or its chime, turn the
adjusting screw handle six turns counterclockwise to retract the
cutter wheel. Tilt the WIZARD toward the center of the drum lid
and lift the WIZARD off the drum.
Automatic Units
1. Apply air to the opener and push/pull the plunger button of
the air valve. With the cutter wheel engaged, the cutting action
is automatic as the WIZARD travels around the drum. As the
metal splits, it makes a popping or cracking sound. Usually
only 2 to 5 revolutions are enough to cut through the metal.
2. After you finish cutting the drum or its chime, push/pull the
plunger button of the air valve to disengage the cutter wheel.
Tilt the WIZARD toward the center of the drum lid and lift the
WIZARD off the drum.