Wizard WIZ-Kid Service manual

WIZ-Kid®
MANUAL DRUM OPENER
OPERATING and SERVICE MANUAL
Low Volume Drum Usage
Serial No. _________________
Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D

Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D
TABLE OF CONTENTS
GENERAL WARNINGS AND PRECAUTIONS
SECTION 1 -- GENERAL INFORMATION ..................................................................................................................... 1
PRODUCT DESCRIPTION .................................................................................................................................... 1
SECTION 2 -- HOW TO USE YOUR WIZ-KID
ä
............................................................................................................ 1
SET- UP .................................................................................................................................................................. 1
PLACING THE UNIT ON THE DRUM ..................................................................................................................... 1
CUTTING THE DRUM ............................................................................................................................................ 2
SECTION 3 -- CUTTING WHEEL POSITIONING .......................................................................................................... 2
LOCATION OF CUTTING POSITION ..................................................................................................................... 2
HEIGHT OF CUT ADJUSTMENT ........................................................................................................................... 3
SECTION 4 -- PROPER USE AND CARE ..................................................................................................................... 3
RIGHT HAND/LEFT HAND OPTION..……………………………………………………………………………………...3
SECTION 5 -- FACTORY SERVICING ........................................................................................................................... 4
SHIPPING INSTRUCTIONS ................................................................................................................................... 4
SECTION 6 -- GENERAL MAINTENANCE AND REPAIR ............................................................................................ 4
TOOLS NEEDED FOR SERVICE ........................................................................................................................... 4
FIELD SERVICING ................................................................................................................................................. 5
CUTTING WHEEL REPLACEMENT ...................................................................................................................... 5
DRIVE ROLLER REPLACEMENT .......................................................................................................................... 5
HOUSING BODY REMOVAL .................................................................................................................................. 5
DRIVE ROLLER SHAFT REPLACEMENT ............................................................................................................. 6
HOUSING BODY REASSEMBLY ........................................................................................................................... 6
SECTION 7 – TROUBLESHOOTING ............................................................................................................................. 7
SECTION 8 – LIMITED WARRANTY..............................................................................................................................7
SECTION 9 – EXPLODED VIEW DRAWING AND BILL OF MATERIALS…………………………………………………8

Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D
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. 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!
2. Keep all body parts away from the cutter wheel and roller whenever the power is on!
3. 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!
4. 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 PSE (personal safety equipment) be worn when
handling cut chimes.
5. Disconnect the power supply (electrical or air) before performing any maintenance on the
unit!
6. 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.

Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D
SECTION 1
GENERAL INFORMATION
PRODUCT DESCRIPTION
The WIZ-Kidä drum opener is a low cost, light weight,
manually operated tool designed to cut the tops and/or
bottoms off standard 55 and 30 gallon steel drums up to
16 gauge thick.
The unit requires minimal set up. The cutting mechanism
is designed to cut through most dents eliminating the
need to form the chime to its original contour. The cutting
wheel is designed to fit between the drum chime and bung
fitting so you don’t have to flatten the bung prior to cutting.
Also, there is only one simple adjustment for height,
making it easy to use for all operators.
The unit is designed for quick and easy repair using
standard tools. Maintenance is minimized by keeping the
total number of parts in the design to a minimum.
SECTION 2
HOW TO USE YOUR WIZ-Kid
ä
SET- UP
1. Although the WIZ-Kidä is designed to ride over most
dented chimes, it may be necessary to straighten
some dents with a dekinker or to hammer them into
their original contour.
2. Turn the T-bar handle counterclockwise and open the
cutting wheel assembly away from the drive assembly
to give the unit proper clearance to mount on the
drum.
CAUTION
Damage may result from the unit falling off the drum by attempting
to cut severely dented drums.
Damage to the cutting wheel’s blade edge may result from
mounting the unit on a drum without opening the unit to give proper
clearance.
PLACING THE UNIT ON THE DRUM
1. Place the unit on the drum by resting the chime rollers
on the drum chime with the cutting wheel to the inside
of the drum. The chime should be between the chime
roller shoulders. The guide rollers are adjustable and
should support the unit on the drum shell just above
the shell rib (see figure 1).
Figure 1: WIZ-Kid Set-up
2. Check the unit for the proper cutting height position.
The height is factory set, however your drums may
require adjustments to the unit. See section 3 before
continuing.
3. Turn the T-bar handle clockwise until the cutting
wheel touches the chime.
1

Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D
CAUTION
Avoid “Over-tightening” the T-Bar handle. The handle should be
adjusted as described in the following paragraph. Over-tightening
may damage the T-Bar assembly and rear housing.
CAUTION
For proper operation, the height of the cutting wheel must be
properly positioned for each drum type. Failure to adjust the cutter
wheel height properly may impair the operation and could cause
permanent damage to the unit.
CUTTING THE DRUM
The manual WIZ-Kidä is designed to cut most drums in
one lap. If the drum lid is a heavy gauge or hard steel, it
may require more laps. Also, because the unit is manually
powered, the number of laps and the time to cut a drum
will differ from person to person.
1. Turn the T-bar handle clockwise until the cutting
wheel has penetrated all the way through the first
layer of material. If the cutting wheel does not
penetrate fully, it will require another lap. If it has
penetrated too far into the second layer, it will require
additional wasted effort to drive the unit.
Figure 2: Proper Cutting Depth
2. Secure the ratchet to the drive shaft. Set the ratchet
so the unit is driven by the downward push of the
ratchet and the return motion is the upward push.
3. Begin to drive the unit by pumping the ratchet up and
down. After the first few strokes, check the inside of
the drum chime to see that the unit has fully
penetrated the first layer and hasn’t gone too deep.
Adjust accordingly.
4. As the unit moves around the drum, occasionally
check that the cutting wheel has remained level
throughout the cut. If it has moved up or down, the
cutting position may be incorrect. Refer to section 3.
5. After the drum is fully cut, retract the cutter wheel by
turning the T-bar handle counterclockwise and
tapping the end of the handle inward to dislodge the
cutting wheel. Push the unit fully open and remove
the unit from the drum.
6. Tap one end of the lid with a mallet until it either flips
or falls to the bottom of the drum.
WARNING
The cut lid is sharp. Caution should be used when attempting to
remove the lid from the drum. Leather work gloves are
recommended.
SECTION 3
CUTTING WHEEL POSITIONING
To get the best performance from your WIZ-Kidä drum
opener, accurate positioning of the cutting wheel on the
drum chime is critical. Please read section 3 carefully and
check periodically for proper cutting wheel positioning.
LOCATION OF CUTTING POSITION
Proper positioning is not an exact science. Experience will
help determine the best cutting position on your drum.
If the cutting wheel is positioned on the top radius of the
chime (too high), the cutting wheel may rise and
eventually lift the unit off the drum. If the cutting wheel is
positioned on the lower radius (too low), the wheel tends
to bury itself in the drum lid and bog down or stall the unit.
For the best results, position the cutting wheel on the flat
of the drum chime between the upper and lower radius
directly across the point of contact between the drive
roller and chime at least 1/8’’ above the drum lid (see
figure 3).
Figure 3: Proper Cutting Position

Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D
HEIGHT OF CUT ADJUSTMENT
The shaft collar controls the height of the cut. Refer to
figure 3 for proper position and figure 4 to set the height.
Set the height as follows:
1. Place the unit on the drum as described in section 2.
2. Loosen the shaft collar screw using a 5/32” Allen
wrench.
3. Push the unit towards the drum and slide the cutting
wheel up or down to position the cutting edge as
described above.
4. Let the weight of the unit hold the cutting wheel in
position, and close the unit on the drum chime by
turning the T-bar handle.
5. With the cutting wheel held in place by the clamping
force of the unit, turn the shaft collar clockwise down
the cutting wheel shaft until it is snug against the front
housing thrust washer.
6. Tighten the shaft collar screw to keep the collar from
turning on the shaft (over tightening may cause the
screw to strip).
7. Observe the unit and the cutting wheel as it moves
around the drum. The cutting wheel should not rise
up. The unit is tilted down slightly to ensure that the
cutting wheel stays down as the unit cuts the drum. If
the cutting wheel rises, it is possible that it is cutting
on a slanted or curved part of the chime which will
have a tendency to push the wheel up. Refer to
section 3 and re-adjust the cutting height.
Figure 4: Setting the Cutting Position
SECTION 4
PROPER USE AND CARE
With proper use and care, your WIZ-Kidä drum opener
will give you long and dependable service.
1. Lubricate the unit properly. The bearings should be
cleaned, checked, and repacked with food grade
grease every 500 drums (earlier, depending on the
working environment). Failure to do so may result in
a shorter life of the bearings.
2. Do not drop the drum opener. If the unit falls and the
damage is excessive or the unit fails to operate, call
the factory for assistance.
3. Occasionally check that all nuts and bolts are tight.
4. Occasionally wire brush the drive roller serrations.
5. When placing the unit on a drum, take care to protect
the blade edge of the cutting wheel from any impact
with the drum which could chip the blade.
RIGHT HAND / LEFT HAND OPTION
The unit can be set up such that the ratchet drives the
pinion shaft from the opposite side if the operator is
uncomfortable with the existing set up. To change the
position of the ratchet drive:
1. Remove the cover.
2. Remove all snap rings, and loosen the set screw on
the pinion (small) gear.
3. Slide the pinion shaft out of the housing.
For ratchet set up on the left side, looking from the front
of the unit (as shipped), and follow figure below:
1. Slide the pinion shaft part way through the housing,
with the steel washer between the head and housing.
2. Slide the oilite thrust washer over the shaft, against
the housing.
3. Slide the pinion gear over the shaft, with the key in
place.
4. Slide the snap ring over the shaft securing the
assembly against the housing.
5. Lock the pinion gear set screw.
6. Replace the cover.
Left Side Operation

Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D
For ratchet set up on the right side, looking from the front
of the unit, follow figure below:
1. Slide the pinion shaft part way through the housing,
with the steel washer between the head and housing.
2. Slide the oilite thrust washer over the shaft, against
the housing.
3. Slide the snap ring over the shaft securing the
assembly against the housing.
4. Slide the pinion gear over the shaft, with the key in
place. Move the pinion gear against the driven gear
(large) and lock in place with the set screw. The teeth
should allow free movement of both gears.
Right Side Operation
SECTION 5
FACTORY SERVICING
Send units requiring major service to the factory.
WIZARDâ will make a repair estimate, and perform the
repair only after your authorization.
SHIPPING INSTRUCTIONS
1. Get a return authorization number from the factory.
2. Clean all exterior and accessible parts.
3. Fasten an identification tag to your unit. The tag
should show your company name and shipping
address, and the serial number of the unit.
4. Ship PREPAID to:
WIZARD Drum Tool Company
400 Pilot Ct.
Waukesha, WI 53188
COD shipments are not accepted.
SECTION 6
GENERAL MAINTENANCE AND REPAIR
WIZARDâ designs its drum openers for long life,
maximum reliability and simplified maintenance.
Replacement parts are readily accessible and the number
of parts kept to a minimum for quick and easy
maintenance.
TOOLS NEEDED FOR SERVICE
(1) Snap (retaining) ring pliers
(1) 9/16” Crescent wrench
(1) 3/4” Crescent wrench
(2) 15/16” Ratchet or crescent wrench
(1) 5/32” Allen wrench (included with unit)
(1) 3/16” Long Allen wrench
(1) 1/4” Allen wrench
(1) 5/16” Allen wrench
(1) Vise
FIELD SERVICING
Light servicing and maintenance is possible with ordinary
hand tools. Replacement parts are available from factory
stock. Use and experience will determine which parts to
keep on hand for routine maintenance, such as cutting
wheels, drive rollers, and thrust bearings.
Study the exploded view drawing in section 8 and note the
relative positions of the parts before disassembly.
WARNING
For proper operation, the height of the cutting wheel must be
correctly adjusted for each unique drum type. Failure to adjust the
cutting wheel height for each drum type will impair the operation of
this unit and may cause permanent damage. Keep a 5/32” Allen
Wrench (which is included with the unit) on hand to make quick
adjustments to the cutting wheel height.

Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D
CUTTING WHEEL REPLACEMENT
1. Refer to figure 5.
2. Loosen the shaft collar screw.
3. Remove the shaft collar by unthreading it from the
cutting wheel. Remove the thrust washer.
4. Slide the cutting wheel out of the housing.
5. Clean, check, and repack the bearings with food
grade grease.
6. Slide the new cutting wheel back into the housing in
the same orientation. Replace the shaft collar and
thrust washer.
7. Adjust the height of the cutting wheel as described in
section 3.
Figure 5: Replacing the Cutting Wheel
DRIVE ROLLER REPLACEMENT
1. Refer to figure 6.
2. Using a snap ring pliers, remove the lower snap ring
located at the bottom of the drive roller shaft.
3. Slide the drive roller off the drive roller shaft.
4. Slide the new drive roller on the drive roller shaft with
its key and thrust bearing in place.
5. Hold the drive roller in place and replace the snap
ring.
Figure 6: Replacing the Drive Roller
HOUSING BODY REMOVAL
1. Refer to figure 7.
2. Use two 15/16 ratchet wrenches and remove the
nylon insert locknuts at one end of the guide shafts.
3. Slide the front housing from the guide shafts.
4. Slide the guide shafts out of the carrier housing.
5. If you need to remove the rear housing, place the
guide shafts in a vice making sure to protect them by
putting cardboard between the vice and the shaft.
Remove the locknuts and slide the shafts out.
Figure 7: Removing the Housing Body

Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D
DRIVE ROLLER SHAFT REPLACEMENT
1. Refer to figure 8.
2. Access must first be made to the top of the drive roller
shaft by removing the cover from the guide roller
bracket.
3. Using a snap ring pliers, remove the top snap ring
from the drive roller shaft and remove the bevel gear,
key, and thrust bearing.
4. Slide the drive roller shaft out of the carrier.
5. Remove the drive roller, thrust bearings, key, and
snap ring from the drive roller shaft.
6. Clean, check, and repack the bearings with food
grade grease.
7. Slide the snap ring on the lower end (the end with the
3/16” keyway) of the new drive roller shaft.
8. Slide the drive roller, with its key, over the snap ring.
9. Slide a thrust bearing over the drive roller. Insert the
shaft assembly into the carrier.
10. Hold the shaft assembly against the bottom of the
carrier with one hand and slide the other thrust
bearing over the top of the drive roller shaft and tight
against the top of the carrier.
11. Replace the other thrust bearing, bevel gear and key.
12. Hold the assembly tight against the carrier and
replace the top snap ring with snap ring pliers.
13. Replace the cover.
Figure 8: Drive Roller Replacement
HOUSING BODY REASSEMBLY
1. Refer to figure 9.
2. Slide the short shoulder ends of the guide shafts into
the rear housing body. Finger tighten a 5/8 nylon
insert locknut on each end.
3. Slide both guide shafts into the rear end (side with
guide roller bracket) of the carrier. This is important
because it will align the guide shafts with the carrier
bearings which will allow the carrier to ride smoothly
over the guide shafts.
4. Place the front housing over the long shoulder end of
the guide shafts.
5. Slide a 5/8 flat washer over each long shoulder end
of the guide shafts and against the front housing.
6. Slide three Belleville washers over each long
shoulder end of the guide shafts and against the 5/8
flat washer. Place the Belleville washers on the guide
shafts accordion style (face to face-rear to rear).
7. Slide another 5/8 flat washer on the guide shafts and
against the Belleville washers.
8. Finger tighten a 5/8 nylon insert locknut over the long
shoulder end of each guide shaft.
9. Using two 15/16 crescent or ratchet wrenches, tighten
each 5/8 nylon insert locknut at each end of the guide
shafts. Make sure the locknuts are tight and bottomed
out on the guide shafts.
10. Check the carrier for free movement over the guide
shafts.
Figure 9: Replacing the Housing Bodies
7

Wizard Drum Opener Operating and Service Manual; Version 3.0, Rev D
SECTION 7 TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
REMEDY
Unit does not turn on.
Faulty power connection.
Check / Replace line cord.
Loose power connection.
Make connection tighter.
Damaged motor.
Replace motor.
Unit stalls or does not start.
Excessive cutting force.
Back off T-bar handle.
Drive roller slips.
Clean serrations in drive roller.
Cutting too low (at lower chime radius).
Refer to section 3. Cut higher, on flat portion of
the chime.
Cutting wheel rides up.
Cutting too high (at upper chime radius).
Refer to section 3. Cut lower, on flat portion of
the chime.
Does not cut drums.
Cutting wheel dull or chipped.
Replace cutting wheel.
Not enough passes around drum.
Allow more passes.
Not enough cutting force.
Tighten T-bar handle
Unstable- wobbles going around drum.
Drum chime kinked.
Straighten using dekinker.
Drum shell dented.
Guide unit past dented area. USE CAUTION.
Drum head can’t be removed.
Outer chime layer not cut completely through.
Tighten T-bar handle. Allow more passes.
Cutting wheel not penetrating metal.
Replace dull or chipped cutting wheel.
Does not run or cut.
Defective motor.
Replace motor.
Key missing from drive wheel or motor.
Inspect parts. Replace key.
Clean serrations.
Drive roller slips.
Possibly cutting too low (at lower chime radius).
Cut higher on chime
NOTE: Contact Factory for Repair Authorization before Returning Unit.
Figure 10: Name Plate