Crafco 30 Pavement Router, 30 Self Propelled Pavement Router, 30 Dust Control Router, 30 Saw Cut Router Parts Manual

Model 30 Pavement Router

Revision F

Model 30 Pavement Router Non-Clutch

Self-Propelled Router

Dust Control Router

Saw Cut Router

Parts Manual - 21320

Fill in appropriate fields that apply to this machine Machine S/N: _ _______________________________

st

Hose S/N: _______________________________

1

nd

2

Hose S/N: _______________________________

st

1

Pump S/N: _______________________________

nd

Pump S/N: ______________________________

2 Engine S/N: ________________________________ Compressor S/N: _____________________________ Gear Box S/N (Patcher): ______________________ Blower S/N (Magnum): ________________________

Model 30 Pavement Router Manual

Revision

Date

Revisions

“F” Updated to new format. Updated engine model to PA-CH752-3125,

Updated specifications to have ship weight for different machines. Updated Chapter 9 with new illustrations and wiring diagrams. Updated troubleshooting with references to Engine Owner’s Manual and checking voltages. Added section 6.12. Added saw cut attachment to Chapter 5 and

9. Table 9-5 changed Item 9 to 20860

11/2018

MODEL 30 SELF PROPELLED PAVEMENT ROUTER

PN 21340

MODEL 30 PAVEMENT ROUTER

PN 21300

MODEL 30 DUST CONTROL ROUTER

PN 21350

Model 30 Pavement Router Manual

Table of Contents

1.0 About This Manual .................................................................................................................. 1-1

1.1 How to use this manual: ...................................................................................................... 1-1

2.0 Safety Precautions .................................................................................................................. 2-1

2.1 General Safety..................................................................................................................... 2-1

2.2 Personal Safety ................................................................................................................... 2-1

2.3 Equipment or Operational Safety for All Routers .................................................................. 2-2

Operational Safety for Dust Control Router .............................................................. 2-2 2.3.1

2.4 California Proposition 65 ...................................................................................................... 2-2

All Crafco, Inc. Equipment ........................................................................................ 2-2 2.4.1

All Crafco, Inc. Equipment using a gasoline engine.................................................. 2-2 2.4.2

2.5 Safety Symbols and Notices ................................................................................................ 2-3

3.0 Limited Warranty ..................................................................................................................... 3-1

3.1 Warranty Claim Instructions ................................................................................................. 3-2

4.0 Machine Specifications ........................................................................................................... 4-1

5.0 Operating Instructions ............................................................................................................. 5-1

5.1 Preparing the Machine for Start Up ...................................................................................... 5-2

5.2 Starting ................................................................................................................................ 5-3

5.3 Cold Weather Starting ......................................................................................................... 5-4

5.4 Battery ................................................................................................................................. 5-4

5.5 Stopping the Engine ............................................................................................................ 5-4

5.6 Operation Guidelines ........................................................................................................... 5-4

Angle of Operation ................................................................................................... 5-4 5.6.1

Cooling .................................................................................................................... 5-5 5.6.2

Engine Speed .......................................................................................................... 5-5 5.6.3

5.7 Attaching Cutter Head Dust Shroud ..................................................................................... 5-6

5.8 Cleaning Joints and Cracks ................................................................................................. 5-8

Routing with Dust Control ...................................................................................... 5-11

Moving the Self Propelled Router........................................................................... 5-12 5.8.2

5.9 Saw Cut Attachment .......................................................................................................... 5-13

5.8.1

5.10 Storing the Machine ......................................................................................................... 5-17

CRAFCO Model 30 Dust Control Router ................................................................ 5-17 5.10.1

CRAFCO Model 30 Pavement Router and Self-Propelled Router (without dust control)5.10.2

5-17

6.0 Maintenance Instructions ........................................................................................................ 6-1

Model 30 Pavement Router Manual

Table of Contents

6.1 Oil Recommendations ......................................................................................................... 6-1

Oil type .................................................................................................................... 6-1 6.1.1

6.2 Fuel Recommendations ....................................................................................................... 6-2

General Recommendations ..................................................................................... 6-2 6.2.1

Fuel Type ................................................................................................................ 6-2 6.2.2

Gasoline/Alcohol Blends .......................................................................................... 6-2 6.2.3

Gasoline/Ether Blends ............................................................................................. 6-2 6.2.4

6.3 Battery ................................................................................................................................. 6-3

Battery Recharging .................................................................................................. 6-3 6.3.1

6.4 Periodic Maintenance .......................................................................................................... 6-3

6.5 Maintenance Schedule ........................................................................................................ 6-4

6.6 Air Cleaners ........................................................................................................................ 6-5

6.7 Changing Cutters ................................................................................................................ 6-6

6.8 Changing Cutter Heads ....................................................................................................... 6-9

6.9 V-Belts .............................................................................................................................. 6-12

6.10 Electric Clutch ................................................................................................................. 6-13

6.11 Dust Control Router Specific Maintenance ...................................................................... 6-13

Dust Collection Bag Maintenance .......................................................................... 6-13 6.11.1

Cutter Head Dust Shroud ...................................................................................... 6-14 6.11.2

Replacing Seal Brushes ........................................................................................ 6-14 6.11.3

6.12 Common Maintenance Parts and Kits ............................................................................. 6-15

7.0 How to Use a Multimeter ......................................................................................................... 7-1

7.1 Checking DC Voltage with a Multimeter .............................................................................. 7-1

7.2 Checking Resistance (Ohms) .............................................................................................. 7-1

7.3 Checking Wire Continuity .................................................................................................... 7-1

8.0 Model 30 Pavement Router Troubleshooting .......................................................................... 8-1

9.0 About the Illustrated Parts List ................................................................................................ 9-1

9.1 Ordering Crafco Parts ......................................................................................................... 9-1

9.2 Model 30 Pavement Router ................................................................................................. 9-2

9.3 Electrical Schematic Model 30 Pavement Router with Clutch .............................................. 9-8

9.4 Electrical Diagram Model 30 Pavement Router Non-Clutch ............................................... 9-10

9.5 Model 30 Self Propelled Router ......................................................................................... 9-11

9.6 Electrical Diagram Model 30 Self Propelled Router ........................................................... 9-17

9.7 Model 30 Pavement Router with Dust Control ................................................................... 9-19

Model 30 Pavement Router Manual

Table of Contents

9.8 Cutter Head and Drive Components .................................................................................. 9-25

9.9 Pavement Cutter Selection ................................................................................................ 9-27

9.10 Cutter Positioning ............................................................................................................ 9-28

9.11 Cutter Positioning ............................................................................................................ 9-29

Cutter Positioning for Cutter Part Numbers 31134, 31136, 31137, 31149 .............. 9-29 9.11.1

Cutter Position for Cutter Part Number 31135 Shaved Cutter ................................ 9-29 9.11.2

Cutter Positioning for Part Number 31145 (Patent Pending) .................................. 9-30 9.11.3

Cutter Positioning for Part Number 31138, 6 1/2” Cutter ........................................ 9-30 9.11.4

9.12 Crack Saw Attachment .................................................................................................... 9-31

Model 30 Pavement Router Manual

List of Figures

Figure 5.1 Model 30 Router Raised for Dust Shroud Installation ................................................... 5-7

Figure 5.2 Using the Brush Manipulation Tool .............................................................................. 5-7

Figure 5.3 Depth Indicator ............................................................................................................ 5-9

Figure 5.4 Model 30 Router Handle .............................................................................................. 5-9

Figure 5.5 Stabilizer Mechanism ................................................................................................. 5-10

Figure 5.6 Model 30 with Saw Cut Attachment ........................................................................... 5-13

Figure 6.1 Recommended Engine Oil Viscosity ............................................................................ 6-1

Figure 6.2 Router on Front Stand ................................................................................................. 6-7

Figure 6.3 Raised Rear Support Strip ........................................................................................... 6-7

Figure 6.4 Wrench in Cutter Window ............................................................................................ 6-8

Figure 6.5 Pin Removal Tool ......................................................................................................... 6-8

Figure 6.6 Belt Tensioner .............................................................................................................. 6-9

Figure 6.7 Belt Guard.................................................................................................................. 6-10

Figure 6.8 Electric Clutch ............................................................................................................ 6-13

Figure 7.1 Standard Multimeter ..................................................................................................... 7-2

Figure 7.2 Clamp – On Amp Meter/Multimeter .............................................................................. 7-3

Figure 9.1 Model 30 Pavement Router: PN 21300, 21330 Non-Clutch ......................................... 9-2

Figure 9.2 Model 30 Pavement Router: PN 21300 ........................................................................ 9-4

Figure 9.3 Model 30 Pavement Router Back Side: PN 21300 ....................................................... 9-6

Figure 9.4 Electrical Diagram Model 30 Router with Electric Clutch .............................................. 9-8

Figure 9.5 Electrical Diagram Model 30 Router Non Clutch ........................................................ 9-10

Figure 9.6 Model 30 Self-Propelled Router PN 21340 ................................................................ 9-11

Figure 9.7 Self-Propelled Router Mechanisms ............................................................................ 9-12

Figure 9.8 Self-Propelled Router Wheel Spacer.......................................................................... 9-14

Figure 9.9 Model 30 Self-Propelled Router Drive Wheel Clutch Assembly .................................. 9-15

Figure 9.10 Model 30 Self-Propelled Router Drive System ......................................................... 9-16

Figure 9.11 Electrical Diagram Self-Propelled Router ................................................................. 9-17

Figure 9.12 Model 30 Router with Dust Control, PN 21350, 21360 (Self-Propelled with Dust Control)

................................................................................................................................................... 9-19

Figure 9.13 Dust Shroud Assembly............................................................................................. 9-20

Figure 9.14 Dust Control Router ................................................................................................. 9-22

Model 30 Pavement Router Manual

List of Figures

Figure 9.15 Dust Control Router Parts ........................................................................................ 9-22

Figure 9.16 Cutter Head and Drive Assembly ............................................................................. 9-25

Figure 9.17 Cutter Positioning for 31134, 31136, 31137, 31149 .................................................. 9-29

Figure 9.18 Cutter Positioning for 31135 ..................................................................................... 9-29

Figure 9.19 Cutter Positioning for 31145 (Patent Pending) ......................................................... 9-30

Figure 9.20 Cutter Positioning for 31138 ..................................................................................... 9-30

Figure 9.21 Model 30 Router with Crack Saw Attachment .......................................................... 9-31

Figure 9.22 Crack Saw Attachment Parts .................................................................................... 9-32

Model 30 Pavement Router Manual

List of Tables

Table 2-1 Safety Symbols and Notices ......................................................................................... 2-3

Table 2-2 Safety Symbols and Notices (continued) ....................................................................... 2-4

Table 4-1 Machine Specifications ................................................................................................. 4-1

Table 5-1 Preparing the Machine for Start Up ............................................................................... 5-2

Table 5-2 Engine Starting Instructions .......................................................................................... 5-3

Table 5-3 Cold Weather Starting Hints .......................................................................................... 5-4

Table 5-4 Stopping the Engine ...................................................................................................... 5-4

Table 5-5 Attaching Cutter Head and Dust Shroud ....................................................................... 5-6

Table 5-6 Cleaning Joints and Cracks ......................................................................................... 5-8

Table 5-7 Routing with Dust Control Router ................................................................................ 5-11

Table 5-8 Routing with Dust Control Router (continued) ............................................................. 5-12

Table 5-9 Moving the Self Propelled Router ................................................................................ 5-12

Table 5-10 Removing Cutter H ead.............................................................................................. 5-14

Table 5-11 Saw Cut Attachment Installation ............................................................................... 5-15

Table 5-12 Saw Cut Attachment Installation (continued) ............................................................. 5-16

Table 6-1 Maintenance Chart ........................................................................................................ 6-4

Table 6-2 Changing Primary Air Cleaner Element ......................................................................... 6-5

Table 6-3 Changing Secondary (safety) Air Cleaner Element ....................................................... 6-5

Table 6-4 Cutter Changing ............................................................................................................ 6-6

Table 6-5 Removing Old Cutter Head and Main Shaft .................................................................. 6-9

Table 6-6 Installing New Cutter Head and Main Shaft ................................................................. 6-11

Table 6-7 Changing V-Belts ........................................................................................................ 6-12

Table 6-8 Changing Seal Brushes .............................................................................................. 6-14

Table 6-9 Common Add On, Optional, and Maintenance Parts ................................................... 6-15

Table 8-1 Trouble Shooting Guide Model 30 Pavement Router .................................................... 8-1

Table 8-2 Trouble Shooting Guide Model 30 Pavement Router (Continued) ................................. 8-2

Table 9-1 Model 30 Pavement Router: PN 21300 ........................................................................ 9-3

Table 9-2 Model 30 Pavement Router: PN 21300 ......................................................................... 9-5

Table 9-3 Model 30 Pavement Router: PN 21300 ......................................................................... 9-7

Table 9-4 Electrical Diagram Model 30 Router with Clutch ........................................................... 9-9

Table 9-5 Self-Propelled Router Mechanisms ............................................................................. 9-13

Model 30 Pavement Router Manual

List of Tables

Table 9-6 Self-Propelled Router Mechanisms ............................................................................. 9-14

Table 9-7 Electrical Diagram Self-Propelled Router .................................................................... 9-18

Table 9-8 Dust Shroud Assembly ................................................................................................ 9-21

Table 9-9 Dust Control Router Parts ........................................................................................... 9-23

Table 9-10 Dust Control Router Hardware (Not Shown) .............................................................. 9-24

Table 9-11 Electrical Diagram Model 30 Router with Clutch ........................................................ 9-26

Table 9-12 Cutter Options and Selection Guide .......................................................................... 9-27

Table 9-13 Parts List for Crack Saw Attachment ......................................................................... 9-33

Table 9-14 Parts List for Crack Saw Attachment (continued) ...................................................... 9-34

Model 30 Pavement Router Manual

Chapter 1

Introduction

1.0 About This Manual

This manual is supplied with each new Crafco Model 30 Pavement Router. The manual assists your machine operators in the proper use of the melter applicator and provides information about the machine’s mechanical functions for trouble-free operation.

Your Crafco Model 30 Pavement Router is specially made to give excellent service and save maintenance expense. However, as with all specially engineered equipment, you get best results at minimum cost if you:

Operate your machine as instructed in this manual. Maintain your machine regularly as stated in this manual.

1.1 How to use this manual:

This manual is formatted to start each new chapter on the right page. There may be a blank page on the left page if the previous chapter ends on the right page.

If you are viewing this in a digital format (PDF) the following features are available:

1. The Table of Contents, List of Tables, and List of Figures are all hyperlinks, when left mouse clicked on section, table, or figure you will be sent to that page.

2. The blue highlighted text throughout the manual is a hyperlink, when left mouse clicked you will be sent to that page, table, or figure.

3. The panel to the left in the PDF is a bookmarks panel, if you left mouse click on any section/heading in the bookmarks panel you will be sent to that page.

Model 30 Pavement Router Manual

Chapter 2

Safety

2.0 Safety Precautions

For more in-depth safety information, please see Safety Manual (PN 26221) which comes with the machine. Or contact your nearest authorized Crafco Distributor at

purchase/.

2.1 General Safety

• Crafco, Inc. assumes no liability for an accident or injury incurred through improper use of the machine.

• Read this manual thoroughly before operating the machine.

• Obey all CAUTION and WARNING signs posted on the machine.

• Make sure an operator fully knows how to operate the machine before using the machine.

2.2 Personal Safety

• Eye and ear protection devices along with a dust mask are required when operating the machine.

• Wear long pants, work gloves and heavy leather boots or shoes.

• When cleaning cracks and joints near moving traffic, always move in a direction away from

traffic to protect the operator.

• Never allow fatigued operators to run the machine. Due to the nature of running this machine, the crew leader should rotate operators as they see fit according to their performance.

• Keep hands, feet, and clothing away from all moving parts.

https://crafco.com/where-to-

Model 30 Pavement Router Manual

Chapter 2

Safety

2.3 Equipment or Operational Safety for All Routers

• Do not operate the machine in buildings or work areas that do not have sufficient airflow.

• Always keep a correctly maintained fire extinguisher near the machine and know how to use

it.

• Tighten all bolts and screws every 100 hours of machine operation.

• Care should be taken when operating machine on grades. It is usually best to operate the

machine going uphill, rather than downhill.

• To stop or slow machine, push down on handle and/or release the clutch handle.

• When cleaning cracks and joints near moving traffic, always move in a direction away from

traffic to protect the operator.

• Tires should be inflated to 45 psi to allow machine to roll easily.

• Never operate the router without belt guard in place.

• Never transport the router with the engine running.

• Never exceed maximum recommended engine RPM.

• Never leave router unattended while engine is running.

• Never stand on any part of the machine.

• The only operating position is behind the pavement cutter with both hands on the handle.

Operational Safety for Dust Control Router 2.3.1

• Do not operate router without hose attached to blower.

• Do not operate router without hose attached to Cutter Head Dust Shroud.

• Do not route without Cutter Head Dust Shroud in place.

2.4 California Proposition 65

The state of California currently maintains a list of chemicals that can cause cancer, birth defects or other reproductive harm. Your Crafco, Inc. equipment comes with the following warnings:

All Crafco, Inc. Equipment 2.4.1

All Crafco, Inc. Equipment using a gasoline engine 2.4.2

Model 30 Pavement Router Manual

Chapter 2

Table 2-1 Safety Symbols and Notices

Safety

2.5 Safety Symbols and Notices

Important safety symbols and notices are marked on the machine and in this manual. Failure to comply could result in equipment damage, operational malfunction, serious injury, or death. Please read and comply with all symbols and notices. The table below includes the most commonly used symbols and notices.

Symbol Item Remarks

WARNING

CAUTION

Warning

Caution

Severe Burn Hazard Hot material can cause severe burns.

Protective Shoes Wear ha rd-soled work shoes.

Protective Gloves Wear heat resistant gloves.

Protective Face or Eye Wear Wear face shield or safety glasses.

Refers to possible bodily injury or death.

Refers to possible equipment damage or operational malfunction.

Body Crush Hazard

Do not stand between trailer and hitch when hooking melter to truck.

Model 30 Pavement Router Manual

Chapter 2

Table 2-2 Safety Symbols and Notices (continued)

Safety

Symbol Item Remark

Crush Hazard Keep feet and legs clear.

Pinch Hazard Keep hands and feet clear.

Exhaust Hazard Avoid breathing engine exhaust.

Read Manual

Read and understand operator and safety manuals before operating machine.

Model 30 Pavement Router Manual

Chapter 3

Warranty Information

3.0 Limited Warranty

Crafco, Inc. (Manufacturer), or one of its affiliated distributors, will replace for the original purchaser free of charge any parts found upon examination by the Manufacturer, to be defective in material or workmanship. This warranty is for a period two years from the invoice date, but excludes engine or components, tires, and battery as these items are subject to warranties issued by their manufacturers.

Crafco, Inc. shall not be liable for parts that have been damaged by accident, alteration, abuse, improper lubrication/maintenance, normal wear, or other cause beyond our control.

The warranty provided herein extends only to the repair and/or replacement of those components on the equipment covered above and does not cover labor costs. The warranty does not extend to incidental or consequential damages incurred as a result of any defect covered by this warranty.

All transportation and labor costs incurred by the purchaser in submitting or repairing covered components must be borne by the purchaser. Crafco, Inc. specifically disavows any other representation, warranty, or liability related to the condition or use of the product.

CAUTION

Use of replacement parts other than genuine Crafco parts may impair the safety or reliability of your equipment and nullifies any warranty.

Model 30 Pavement Router Manual

Chapter 3

Warranty Information

3.1 Warranty Claim Instructions

Crafco, Inc. warrants parts and machinery purchased through Crafco or one of its affiliated distributors for two years from the invoice date. Wear items are not covered under the Crafco, Inc. limited warranty. A wear item is defined as but not limited to: cutters, cutter pins, tires, etc.

If parts fail to function within two years of invoice date, a return authorization number (RA) must be obtained. If the part was purchased through Crafco, Inc., please contact Crafco returns department at Returns@Crafco.com contact your distributor.

Note: if the part has a serial number associated with it, for example; a machine or electric hose or wand, this must be furnished when requesting the RA number. The customer will be emailed or faxed an RA form with all instructions to return the item to Crafco, Inc. See example. If the part is found to be within the two year warranty period and has not been abused or modified, a credit will be issued to the customer’s account or credit card. The customer may request the part be replaced instead of a credit, if desired.

Note: All engine warranties are covered through the engine manufacturer. If you need information for a distributor in your area please contact us and we will direct you to the closest engine distributor.

for an RA number or if purchased through a Crafco distributor please

All parts returned are tested and evaluated. If the part has been modified in any way without prior consent from a Crafco, Inc. representative, warranty is void.

Please follow the instructions stated below when calling in a Warranty Claim. Failure to follow these procedures may be cause to void the warranty.

Call your local Crafco Distributor. If you do not know who your local distributor is, call a Crafco Customer Service Representative, (Toll Free 1-800-528-8242) for name, location and telephone number.

On contacting the distributor, be prepared to identify the serial number, model number, engine number, engine manufacturer, and the date of purchase if available.

Should the cause of the malfunction be a defective part, the Distributor will advise you of the procedure to follow for a replacement.

The warranty is valid only for parts, which have been supplied or recommended by Crafco, Inc. If you have any additional questions regarding warranty repairs and parts, please do not hesitate to

call toll free 1-800-528-8242.

For Warranty: Crafco, Inc. 25527 South Arizona Avenue, Chandler, AZ

85248 Phone: (480) 655-8333 or (800) 528-8242 Fax: (480) 655-1712

.

For all other inquires: Crafco, Inc. 6165 W Detroit St, Chandler, AZ 85226 Phone: (602) 276-0406 or (800) 528-8242 Fax: (480) 961-0513

CustomerService@crafco.com

Machine Specifications

Chapter 4

Table 4-1 Machine Specifications

4.0 Machine Specifications

Model 30 Pavement Router Manual

Specification

PN 21300, 21330 ROUTER WITH CLUTCH AND NON-CLUTCH

PN 21340 SELF PROPELLED ROUTER

PN 21350 DUST CONTROL ROUTER

PN 21360 SELF PROPELLED WITH DUST CONTROL

Engine 2 Cylinder – Kohler PA-CH752-3125 (27HP) (20 Kw) Fuel Unleaded Gasoline Fuel Tank

Capacity Approximate

550 Lbs.

6 Gallons (22.7 Liters)

600 Lbs.

650 Lbs.

Shipping Weight

Maximum Depth of Cut

Safety

(249.5 Kg)

1-5/8” (41.3 mm) 1-1/2” (38.1mm)

Braking system, Safety guards, Electric clutch (excluding PN 21330 non-clutch)

(272 Kg)

(295 Kg)

Features Depth

Control Cutter

Design

Electric actuator for fin gertip depth control, Depth gauge for precise depth

control.

6 radially located sprocket shaped cutters on 11-3/4” (298.5 mm) diameter

cutter head Cutter Style Hardened steel with carbide cutter tips Crack

Up to 1500 Liner Feet (457 Linear Meters) per hour

Cleaning

Model 30 Pavement Router Manual

Chapter 5

Operating Instructions

5.0 Operating Instructions

The CRAFCO Model 30 Pavement Router was designed specifically to widen and clean joints and cracks in asphalt and concrete surfaces. The Crafco Model 30 Pavement Router is NOT intended to be used to clean old sealant from joints and cracks.

The CRAFCO Model 30 Pavement Dust Control Router is a self-contained unit; no external power source is needed to operate the dust collection system. It was designed to reduce the amount of fugitive dust particles being introduced into the air when widening and cleaning joints and cracks in asphalt surfaces. The CRAFCO Model 30 Pavement Dust Control Router was not intended to pick up all dirt and debris from the joint or crack after routing.

The CRAFCO Model 30 Pavement Self-Propelled Router is a self-contained unit; no external power source is needed to operate the drive system. It was designed to reduce worker fatigue from moving from one distressed area to another. The Crafco Model 30 Pavement Self-Propelled Router was not intended to drive forwards and route cracks at the same time. The handle bar has two separate drive handles, standing at the operators position the drive handle on the left works the electric clutch and the drive handle on the right works the drive wheels.

The CRAFCO Crack Saw Attachment is designed to offer a secondary use for our Model 30 Pavement Router. This tool will allow the transformation of the standard Model 30 to a random crack saw for use on concrete or asphalt pavement in less than 1 hour. Diamond or abrasive blade (not included) may be used wet or dry on the Model 30. Crafco part number 31350, Random Crack Saw Cutting Kit, may be ordered for the Model 30 Router with the initial order, or as an add on kit. The kit includes all parts necessary to transform a Crafco Model 30 Pavement Router into a saw. Instructions for installing this kit are included in Section 5.9

CRAFCO, improper use

I

nc.

and its Distributors assume

of this machine.

no liability

for accident or injury incurred through

DO NOT w

ith controls:

Note: DO NOT attempt to operate the machine without using these and all other instructions.

operate machine wit

hout reading operator’s manual and being thor

oughly fam

iliar

Model 30 Pavement Router Manual

Chapter 5

Table 5-1 Preparing the Machine for Start Up

Operating Instructions

5.1 Preparing the Machine for Start Up

Step Action

1 Check engine crankcase oil. Add oil if low. Refer to Engine Operators Manual. 2

3

4

5

6

Fill engine gas tank with clean, fresh, unleaded gasoline. See “Fuel Recommendations” in Engine Operators Manual.

Check tire inflation. Proper tire inflation is 45 psi. Machine will be difficult to roll with under-inflated tires.

Check engine cooling air intake and external surfaces of engine. Clean if dirty or obstructed.

Check that the air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened.

Check and/or open the fuel valve on the bottom of the fuel tank so that the engine will get fuel.

The safe operation of this machine is the operator’s responsibility. Use extreme care when operating this machine; safety is the result of being careful

and paying attention to details. Always put on protective clothing, long pants, gloves, hard-soled shoes, safety

glasses, dust mask, and ear protection. Tighten all bolts, nuts, and screws every 100 hours.

WARNING

Model 30 Pavement Router Manual

Chapter 5

Table 5-2 Engine Starting Instructions

Operating Instructions

5.2 Starting

It is recommended that you read the Engine Operators Manual before starting the engine.

Step Action

To start engine, place the throttle control midway in the “slow” position, and place the

1

2

choke control into the “on” position.

Note: With non-electric clutch you must pull and hold the engine stop switch at the

operator’s position for the engine to start and run. Start the engine by activating the key switch. Release the switch as soon as the

engine starts.

Note: Do not crank the engine continuously for more than 10 seconds at a time. If the

engine does not start, allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out the starter motor.

Note: Upon start-up a metallic ticking may occur. This is caused by the hydraulic

lifter leakdown during storage. Run the engine for 5 minutes. The noise will normally cease in the first minute. If noise continues, run the engine at mid throttle for 20 minutes. If noise persists, take the engine to your local Kohler Service Engine Dealer.

Note: If the engine develops sufficient speed to disengage the starter, but does not

keep running (a false start), the engine rotation must be allowed to come to a complete stop before attempting to restart the engine. If the starter is engaged while the flywheel is rotating, the starter pinion and flywheel ring gear may clash, resulting in damage to the starter.

If the starter does not turn the engine over, shut off starter immediately. Do not make further attempts to start the engine until the condition is corrected. Do not start using another battery. See your Kohler Engine Service Dealer for trouble analysis.

For a Cold Engine: Gradually return the choke control to the “off” position after the

3

4 For a Warm Engine: Return the choke to “off” position as soon as engine starts. 5

engine starts and warms up. The engine/equipment may be operated during the warm-up per iod, but it may be necessary to leave the choke partially on until the engine warms up.

Black smoke from the exhaust and a rough running engine usually indicate overchoking.

CAUTION

Model 30 Pavement Router Manual

Chapter 5

Table 5-3 Cold Weather Starting Hints

Table 5-4 Stopping the Engine

Operating Instructions

5.3 Cold Weather Starting

Step Action

1 Be sure to use the proper engine oil for the temperature expected. See Engine Operators

Manual for recommended SAE Viscosity Grades.

2 Set speed control at part throttle position. 3 A warm battery has much more starting capacity than a cold battery.

4 Use fresh winter grade fuel.

Winter grade gasoline has a higher volatility to improve starting. Do not use gasoline leftover from summer.

5.4 Battery

A 12 volt battery is used. If the battery charge is not sufficient to crank the engine, recharge the battery. See Section 6.3.1 f or battery charging instructions.

5.5 Stopping the Engine

Step Action

1 Place the throttle control midway between the “slow” and “fast” positions. 2 Allow the engine to run a minimum of 15 seconds.

3 Stop the engine by turning off the key switch.

4

5.6 Operation Guidelines

Follow these guidelines to ensure proper operation of your CRAFCO Model 30 Pavement Router.

The engine will operate continuously at angles up to 25 degrees. Check oil level to assure crankcase oil level is at the “F” mark on the dipstick. Do not operate the engine continuously at angles exceeding 25 degrees in any direction. Engine damage could result from insufficient lubrication.

If not using the router for longer periods, turn off the fuel valve under the fuel tank

to avoid flooding the carburetor when not in use.

Angle of Operation 5.6.1

CAUTION

Model 30 Pavement Router Manual

Chapter 5

and cooling areas can cause extensive damage due to overheating.

Operating Instructions

Cooling 5.6.2

Hot Parts!

Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas when the engine is running or immediately after it is turned off. Never operate the engine with heat shields or guards removed.

Note: If debris builds up on the screen or other cooling air intake areas, stop the

engine immediately and clean. Operating the engine with blocked or dirty air intake

Engine Speed 5.6.3

The high idle speed for this engine is 3750 RPM, no load.

WARNING

CAUTION

Do not tamper with the governor setting or increase the maximum engine speed. Overspeed is hazardous, may hinder cutter action, and will void the warranty.

Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

WARNING

Model 30 Pavement Router Manual

Chapter 5

Table 5-5 Attaching Cutter Head and Dust Shroud

Operating Instructions

5.7 Attaching Cutter Head Dust Shroud

For Model 30 Pavement Dust Control Router, follow these procedures to attach all dust control mechanisms before starting or operating the machine.

Step Action

To make attaching the cutter head dust shroud more accessible, raise the front of the

1

router. To raise the front of the router, push down on the handle bars until the router is resting on the handle and the corner of the frame assembly. See Figure 5.1

2

3

4 Install the pin and secure with washer and 5/16” x 3/8” hairpin.

5

6

7

8

9

Remove cutter head dust shroud from the storage bracket and bring around to front of router.

Bring the shroud up from the bottom of the housing and align the pin hole with the slots in the mounting brackets.

Use the Brush Manipulation Tool to push the Seal Brushes on both sides of shroud up above the cutter housing. The brushes should be in an upward position. See Figure 5.2

Lower the router back onto its wheels. Make sure the large particle dust collection bin is empty and is securely attached to

mounting bracket before beginning your routing operation. Make sure the dust collection bag is clean and securely clamped to filter mounting bracket

with adjustable quick release gear clamp. The quick release gear clamp is adjustable and should be adjusted so that it holds the dust collection bag securely in place. Do not overtighten the clamp as this may damage the dust collection bag. The support rod was designed so it could be slid into a rearward position for transportation of router where space is limited. The support rod should be fully extended in its forward position before routing begins.

Raise the cutter mechanism by pushing the rocker switch to the up position.

10

Open fuel valve on bottom of fuel tank.

Model 30 Pavement Router Manual

Chapter 5

Figure 5.1 Model 30 Router Raised for Dust Shroud Installation

Figure 5.2 Using the Brush Manipulation Tool

Operating Instructions

Model 30 Pavement Router Manual

Chapter 5

Table 5-6 Cleaning Joints and Cracks

Operating Instructions

5.8 Cleaning Joints and Cracks

Once your machine is ready to begin operation, start the engine as in Table 5-2 Engine Starting

Instructions, and then use these instructions to begin cleaning joints and cracks.

Step Action

1 2 Position machine over joint and line up pointer with joint. 3 Engage electric clutch by pulling up on “Clutch” handle (Figure 5.4)

4 5 Always engage electric clutch before lowering cutter head into the joint.

6 Engage electric clutch by pulling up on “Clutch” handle. 7

8

Open throttle for maximum engine speed.

Machine is operated by manually guiding the machine The stabilizer mechanism is designed to stabilize the machine and to act as a brake.

WARNING

The CRAFCO Model 30 Pavement Router pushes toward the operator when routing. Tightly compacted surfaces, deep or wide cuts, or hard aggregate may cause sudden machine movement toward operator. This “kickback” could cause the operator to lose balance or control of the machine resulting in serious personal injury. When operating, keep wear plate in contact with pavement and hold handle with both hands. For Emergency Stop, push down firmly on machine handle or release safety “Clutch” handle, which disengages the electric clutch. Push machine handle away.

Lower cutter head, using Actuator switch (Figure 5.4), until cutters slightly touch the surface.

Notice shade and number on the depth indicator (Figure 5.3). Each shade represents approximately 1/4 inch (6.35 mm) depth variation.

while walking backwards.

9

10

11

12

13

CAUTION

Do not try to go too fast. Do not overload the engine. Overloading the engine will slow cutting action and cause damage to engine and drive components. A bouncing or hammering action usually indicates the machine is moving too fast or the cutters have worn out of round (refer to troubleshooting on page 8-1).

Let the machine thoroughly clean the joint. For deep cuts (deeper than 3/4 inch (19 mm)) it may be necessary to make two passes.

A stabilizer mechanism (Figure 5.5) is used on the Crafco Pavement Router to improve the stability of the machine and to act as a brake.

TO SLOW OR STOP THE ROUTER, simply push down on the handle or release safety “clutch” handle which disengages the electric clutch.

For normal operation, let skid plate drag on paved surface while machine is in operation.

Skid plate (Part No. 20919) should be replaced before wear reaches the vertical leg of the bent angle.

As cutters wear, depth of cut will change. To compensate for cutter wear, repeat step #7 as often as necessary to reset depth.

Model 30 Pavement Router Manual

Chapter 5

Figure 5.3 Depth Indicator

Figure 5.4 Model 30 Router Handle

Cutter Depth Actuator Switch

Clutch Handle

Operating Instructions

Model 30 Pavement Router Manual

Chapter 5

Figure 5.5 Stabilizer Mechanism

Operating Instructions

Model 30 Pavement Router Manual

Chapter 5

Table 5-7 Routing with Dust Control Router

Operating Instructions

Routing with Dust Control 5.8.1

The following applies the Router’s with the Dust Control Router. As you begin to route, the dust that is sucked up from the cutter head shroud enters the cyclone where a majority of the debris is spun out of the air stream and deposited in the large particle dust collection bin. The amount of time or distance that can be routed before the large particle dust collection bin will need to be emptied will vary depending on the condition of the asphalt, approximately 500 to 1000 feet (150 to 300 meters).

If you have ordered the Dust Control Retrofit Kit (PN 31550K) please see the separate installation instructions provided.

Step Action

Never operate the unit without all the dust control components attached, in particular the cutter head dust shroud. This could cause injury or damage from flying debris.

1 When beginning a routing operation, check the large particle dust collection bin

frequently to gauge t he distance that can be routed before empting the large particle dust collection bin. The large particle dust collection bin should be emptied at approximately 3/4 to 7/8 full.

If the large particle dust collection bin becomes overfilled the debris will be sucked up through the cyclone and deposited in the dust collection bag, reducing the run time of the dust collection bag.

2 To empty the large particle dust collection bin, reduce engine speed to idle. 3 Support the bottom of the large particle dust collection bin with one hand, keeping the

bin pressed up firmly against the mounting bracket.

4 With your other hand, unlatch the rubber latches on the large particle dust collection

bin.

The large particle dust collection bin weighs approximately 30 lbs. when full

WARNING

CAUTION

5 Dump the large particle dust collection bin in a larger receptacle where it can be

disposed of properly at a later time. 6 Reattach the large particle dust collection bin to the mounting bracket. 7 Lightly tap sides of the dust collection bag with your hands.

Note:

dust collection bag. This dust forms a “Dust Cake” on the inside wall of the dust

collection bag and will restrict the amount of air that can escape through the dust

collection bag, reducing the overall suction of the system. Tapping on the side of the

dust collection bag will knock this dust cake loose from the sides of the dust collection

bag, increasing the amount of time that can be routed before the dust collection bag

will need to be serviced. (see Section 6.11) 8 Return engine to high speed and continue routing.

During router operation, what dust isn’t spun out by the cyclone, enters the

Model 30 Pavement Router Manual

Chapter 5

Table 5-8 Routing with Dust Control Router (continued)

Table 5-9 Moving the Self Propelled Router

Operating Instructions

Step Action

9 At the end of the day remove the cutter head dust shroud and store on the Shroud

Storage Bracket located on top of the cyclone.

WARNING

DO NOT leave the router resting on the seal brushes as they will deform. Excessive deformation of the seal brushes will hinder the shrouds ability to trap dust behind the shroud, reducing the efficiency of the dust collector.

Moving the Self Propelled Router 5.8.2

Use the self-propelled function only for ease of moving the router from one distressed area to another.

Step Action

1 Reduce engine speed to idle 2 Stand at the operators position 3 Raise the handle slightly so the router is not resting on the skid plate. 4 Pull up on the right hand drive handle to engage the self-propelled drive system and walk

behind the router towards the next distressed area.

5 Release the drive handle when you are ready to stop moving.

Model 30 Pavement Router Manual

Chapter 5

The Saw Cut Attachment will still cu t while moving backward, with the saw blade spinning in the

Figure 5.6 Model 30 with Saw Cut Attachment

Operating Instructions

5.9 Saw Cut Attachment

The Crafco Random Crack Saw Attachment is designed to offer a secondary use for our Model 30 Pavement Router. This tool will allow the transformation of the standard Model 30 Pavement Router to a random crack saw for use on concrete or asphalt pavement in less than 1 hour. The Saw Cut Attachment may also be used on a Dust Control Router, though the dust control feature does not work with the saw cut attachment. Ask your Crafco customer service representative for Part Number 31350. This kit includes all parts necessary to transform a Crafco Model 30 Pavement Router into a saw.

Diamond or abrasive blade (not included) may be used wet or dry. Contact your local concrete or pavement supply store for saw blades.

Operate the Model 30 Router with the Saw Cut Attachment in the same way as described in Sections 5.2, and 5.8. To perform wet cuts, attach a hose to the hose connector, turn on water supply, and open the ball valve. Then cut as normal.

CAUTION

same direction as the router cutters. It is important to make sure that the saw blade is oriented in the correct direction to cut while the machine moves backwards.

The Saw Cut Attachment may be installed by Crafco at the Chandler AZ manufacturing plant, or installed by the operator. If you choose to install it yourself follow the instructions in Table 5-10, Table 5-11, and Table 5-12.

Model 30 Pavement Router Manual

Chapter 5

Table 5-10 Removing Cutter Head

Operating Instructions

Step Action

1

2

3

4

5

6

Turn the key to the on position, use the up/down toggle switch to lower the cutter head until it is resting on the ground then turn the key back to the off position.

Remove power from unit by disconnecting negative battery cable to prevent accidental startup.

Remove 4 bolts holding the belt guard in place and set belt guard aside. Back off belt tension by backing off adjusting nuts on belt adjuster located under the

engine mounting channel. Remove the belts and retain for later use. (If belts are showing signs of wear, replace with a new set of belts).

Remove the top 3 bolts in each of the two main shaft bearings. It is not necessary to remove the bottom bolt from the main shaft bearings, they can be left

intact. This will retain the filler plates. It is also not necessary to remove or loosen the set screws holding the bearings to the main shaft, nor is it necessary to remove the belt sheave.

Once the 6 main shaft bearing bolts have been completely removed, slowly lift up on the handle to raise the back of the router. Do not raise the cutter head assembly more than a ½” off of the ground without verifying that the cutter head assembly has broken free of the housing and will easily slid out. This will prevent the cutter head assembly from having a “long fall” to the ground, preventing damage to the cutters or the cutter head itself.

If the cutter head fails to immediately slide out of the housing lower the handle back down to the ground. Loosen the set screws on one shaft bearing only. Leaving one bearing in

7

8

place will help with realignment if you were to choose to reinstall the cutter assembly at a later time. If necessary, lightly tap on the end of the main shaft to free the cutter head assembly from the housing.

Once the cutter head assembly has broken free of the housing, slowly lift the handle up until the cutter head assembly is clear of the housing and the router is resting on the front support strip. The cutter head can now be rolled out from underneath of the router and stored until needed.

Model 30 Pavement Router Manual

Chapter 5

Table 5-11 Saw Cut Attachment Installation

Operating Instructions

Step Action

Mount the two side mounting angles to the cutter housing using 1/2”-13 x 1-3/4” long

bolts and 1/2” lock washers, hand tight only. Install the mounting angles where the main

1

shaft bearings were located with the two-hole flange at the bottom of the router. The mounting angle with the saw blade guard mounting tab should be located on the side opposite of the belts.

2

3

4 Tighten the 6 bolts for the bearing mounting angles and the 4 pillow block bearing bolts.

5

6

7

8

Mount a 1-3/4” pillow block bearing to each one of the mounting angles with 1/2”-13 x 1-

3/4” long bolts, 1/2” flat washers, and 1/2”-13 upset nuts, hand tight only.

Install the main shaft loosely through the two pillow block bearings. The side that has a

shoulder for the blade mounting collars and a center bolt hole should go on the side opposite of the belts.

Install inner collar, drive pin, and outer collar onto main shaft using 1/4” x 7/8” long

keyway, 5/8” SAE flat washer, 5/8” lock washer, and 5/8”-11 x 4” left hand thread bolt.

Install two 1/4” x 90° barbed fittings onto the blade guard. The barbs should point to the

rear of the router when the guard is installed onto the router. Place the guard onto the router. It may be necessary to cut a notch out of the frame gusset, and cut a couple of links out of the chain deflector to accommodate the blade guard.

Align the main shaft in the pillow block bearings so that the concrete blade will be

centered in the blade guard (No blade is supplied with kit). Tighten the set screws on the bearings to hold the main shaft in place.

Install the tapered lock bushing and the belt sheave onto the main shaft using hardware

that comes with the taper lock bushing. Align the belt sheave with the clutch assembly on the engine.

9 Install the belts and tighten to 1/4” deflection at 10 lbs. of pressure.

Install the water pipe assembly. Align the two tabs with two holes in the switch cover

10

11

bracket on the handle bar. Attach with 1/4” x 3/4” bolt, 1/4” flat washer, and 1/4” nylon lock nut.

Install 3/8” pipe elbow and hose connector to water pipe assembly. Locate on the belt

side of router; orientation should follow the line of the handle.

Model 30 Pavement Router Manual

Chapter 5

Table 5-12 Saw Cut Attachment Installation (continued)

Operating Instructions

Step Action

Install 3/8” street elbow, 3/8” bronze ball valve, 3/8 x 1/4” reducing bushing, and straight

12

13

hose connector on opposite side of water tube assembly. Orientation should follow line of handle bar, pointing towards the blade guard.

Cut 1 piece of 3/8” plastic tube approximately 8” long. Connect it to the barbed tee fitting and the inside barb on the blade guard. Cut another piece that will go between the barbed tee and the shutoff valve. Use the remainder of the tube to cut a piece that goes between the outside barb on the blade guard and the barb tee.

14

15

Inspect the machine; make sure there are no loose or missing parts. Reconnect the battery cable. Run the Router for a few minutes to insure proper operation.

Install the belt guard.

Model 30 Pavement Router Manual

Chapter 5

Operating Instructions

5.10 Storing the Machine

Follow these instructions when storing the CRAFCO Model 30 Pavement Router

CRAFCO Model 30 Dust Control Router 5.10.1

DO NOT leave the machine resting on the seal brushes or the brushes will become deformed, causing them not to function properly. The dust collection bag should be stored in a covered area out of direct sunlight and away from moisture. Store the dust collection bag in a place where it won’t be inadvertently torn or damaged.

CRAFCO Model 30 Pavement Router and Self-Propelled Router (without dust control) 5.10.2

DO NOT rest the weight of the machine on the rubber rock deflector or rubber will become deformed, causing them not to function properly. Store the machine with engine in a near level position.

Model 30 Pavement Router Manual

Chapter 6

Figure 6.1 Recommended Engine Oil Viscosity

Maintenance Instructions

6.0 Maintenance Instructions

This chapter contains all normal maintenance instructions to properly maintain your machine.

6.1 Oil Recommendations

Using the proper type and weight of oil in the crankcase is extremely important. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure. Check engine oil daily. Change oil after every 100 hours of operation. Change oil filter every 200 hours. Use Crafco part number 31330. Refer to engine owner’s manual for more information.

Oil type 6.1.1

Use high quality detergent oil of API (American Petroleum Institute) service class SG or SH. Select the viscosity based on the air temperature at the time of operation as shown in Figure 6.1.

Note: Using oil other than service class SG or SH or extending oil change intervals longer than

recommended can cause engine damage. Refer to the engine owner’s manual for detailed oil check, oil change, and oil filter change procedures and intervals.

Model 30 Pavement Router Manual

Chapter 6

Maintenance Instructions

6.2 Fuel Recommendations WARNING

Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved

containers, in well ventilated, unoccupied buildings away from sparks or flames. Do not fill the fuel tank while the engine is hot or running since spilled fuel could ig n ite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent.

General Recommendations 6.2.1

Purchase gasoline in small quantities and store in clean, approved containers. A container with a capacity of 2 gallons or less with a pouring spout is recommended. Such a container is easier to handle and helps eliminate spillage during refueling.

To minimize gum deposits in your fuel system and to insure easy starting, do not use gasoline left over from the previous season.

Do not add oil to the gasoline.

Do not over-fill the fuel tank. Leave room for the fuel to expand.

Fuel Type 6.2.2

For best results use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum.

Unleaded gasoline is recommended as it leaves less combustion chamber deposits. Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated. Be aware, however, that the cylinder heads may require more frequent service.

Gasoline/Alcohol Blends 6.2.3

Gasoline (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends are not approved.

Gasoline/Ether Blends 6.2.4

Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are

not approved.

Model 30 Pavement Router Manual

Chapter 6

Maintenance Instructions

6.3 Battery

Check charge condition. Keep battery connections tight and clean. Check the fluid level in battery regularly.

Battery Recharging 6.3.1

When recharging, do not use a battery charger rated for more than 8 AMP’s. If the battery has fallen below 10.5 volts, a charger made specifically for charging AGM batteries is required. Do not overcharge the battery.

WARNING

Explosive Gas! Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge

batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing battery.

6.4 Periodic Maintenance

Follow a regular schedule of inspection and servicing, based on operating hours. Keep an accurate logbook of maintenance, servicing, and operating time. Use the factory recommended Periodic Maintenance Schedule (based on favorable operating conditions) to serve as a guide to get long and efficient engine life.

For severe duty, extreme temperature, etc., service more frequently. Neglecting routine maintenance can result in engine failure or permanent damage.

For any abnormalities in operation, unusual noises from the engine or accessories, loss of power, overheating, etc., contact your nearest Kohler Service Center.

Periodically inspect the in-line fuel filter and replace when dirty using Crafco part number 31331.

Inhalation of exhaust gases can result in serious personal injury or death. DO NOT use the air cleaner or exhaust elbow as a supporting step. Damage of these and connecting parts might cause an exhaust leak.

WARNING

Accidental Starts! Before servicing the engine or equipment on the machine, always disconnect the spark plug leads to

prevent the engine from starting accidentally. Ground the leads to prevent sparks that could cause fires.

Model 30 Pavement Router Manual

Chapter 6

Table 6-1 Maintenance Chart

Maintenance Instructions

6.5 Maintenance Schedule

These required maintenance procedures should be performed at the recommended intervals. They should also be included as part of any seasonal tune-up. Refer to Table 6-1 for regularly scheduled maintenance. The following guidelines should also be followed:

• Check fluid level in battery regularly.

• Tighten all bolts on machine frequently.

• Clean machine each day using compressed air or by wiping with rags, especially in area of

engine cooling fins.

Frequency Maintenance require d

• Fill fuel tank

• Check oil level

Daily or before starting engine

• Check air cleaner for dirty, loose, or damaged parts *

• Check air intake and cooling areas, clean as necessary *

• Grease cutter shaft bearings.

• Blow loose dust/dirt off engine

Every 25 Hours

Every 50 Hours

Every 100 Hours

Every 200 Hours

Annually or every 500 hours

* Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ** Have a Kohler Engine Service Dealer perform this service.

• Service air cleaner dust cap *

• Service primary air cleaner element *

• Clean out cooling fins on engine. If dust is allowed to

accumulate, overheating may occur, causing damage to the engine.

• Lubricate frame pivot using multi-purpose grease

• Change Oil

• Remove cooling shrouds, and clean as necessary *

• Check oil cooler fins

• Check spark plug condition and gap if necessary

• Lubricate cutter shaft bearings

• Change oil filter

• Check secondary air cleaner element and foam wrap *

• Have starter drive serviced **

• Have solenoid shift starter disassembled and cleaned **

• Repack wheel bearings.

Model 30 Pavement Router Manual

Chapter 6

Table 6-2 Changing Primary Air Cleaner Element

Table 6-3 Changing Secondary (safety) Air Cleaner Element

Maintenance Instructions

6.6 Air Cleaners

For longer engine life, the Model 30 Pavement Router has been fitted with a High Capacity Air Cleaner (primary) and secondary element. Due to the dusty conditions created during operation, it is necessary to service the air cleaner when it becomes clogged with dirt. Follow the steps in Table

6-2 to service the primary air cleaner. Check the secondary element (safety) only if the primary air

cleaner element was damaged. Follow the steps in Table 6-3 to change the secondary air cleaner.

Step Action

1 Service element only when restriction indicator reaches the service level (indicator pops

up). It is only above that point that air cleaner restriction begins to reduce engine performance level. When restriction finally indicates a change, remove the primary element carefully. When element replacement is needed use Crafco part number 31344.

2 Do not attempt to clean the dirty element. Rapping or pounding dirt out is dangerous and

could cause damage to the element. 3 Carefully check new element for damage before installing. 4 Reinstall new element, replace air cleaner cap and fasten retaining clips.

Step Action

1 Remove the air cleaner cover. 2 Remove the primary element. 3 Remove the safety element. 4 Handle new elements carefully: Do not use if the sealing surfaces are bent or damaged. 5 Reinstall the new safety element, primary element and air cleaner cap. Fasten retaining

clips. 6 When safety air cleaner element replacement is necessary, order Crafco part number

31345.

Model 30 Pavement Router Manual

Chapter 6

Step

Action

Raise cutter mechanism to maximum height. Push machine forward while holding handle

(Figure 6.2)

2

Remove click pin on rear stand, lower support strip, and reinstall click pin to lock strip in

Place wrench supplied with machine on exposed bolt in cutter window. (Figure 6.4). for proper indexing.

WARNING

Remove wrench and place on bolt just exposed. Loosen bolt at least one full turn. Slide retainer back exposing pin.

Using pin removal tool (also supplied with machine) push pin all the way out, except when

Warni ng page 39 .

6

Slide retainer back into position and tighten bolt.

CAUTION

It is most important that retainer is always put back in the locked position. As the bolt is tightened, the cutter head will rotate clockwise exposing next cutter.

7

Repeat steps 3 through 6 for other five cutter positions.

Remove click pin from rear stand, move support strip to upper position and reinstall click pin.

9

Lower machine to operating position. See section 9.11 for cutter configurations.

Table 6-4 Cutter Changing

Maintenance Instructions

6.7 Changing Cutters

Always use genuine Crafco cutters and other replacement parts. Failure to do so will void warranty and possibly cause damage to machine or injury to operator. The procedure outlined in Table 6-4 will greatly simplify cutter changing. Call Crafco or your local Crafco Distributor for any additional questions you may have.

WARNING

Engine must not be running when changing cutters, or working on any part of machine. Serious injury or death could result. Do not allow anyone to pull on handle, start engine, or do any other maintenance while working on cutter head.

Note: With the Dust Control Router the cutter housing shroud must be in the stored position before

moving to the next step.

1

3

4

5

up. This will allow rock deflector to fold up and machine to tilt forward exposing cutters for

easy accessibility. Make sure front stand is supporting machine before releasing handle.

place. (Figure 6.3)

Turn clockwise to rotate cutter head to end of cutter window. This will rotate cutter head

Do not attempt to turn cutter head with hands.

changing pins. (Figure 6.5). Remove worn cutters and/or worn pins. Pins should be

replaced when worn in any area to a diameter less than 3/4 inch. Use pin as a pilot to

mount spacers and cutters. Make sure carbide tips are positioned per Cutter Installation

8

Model 30 Pavement Router Manual

Chapter 6

Figure 6.2 Router on Front Stand

Figure 6.3 Raised Rear Support Strip

Maintenance Instructions

Model 30 Pavement Router Manual

Chapter 6

Figure 6.4 Wrench in Cutter Window

Figure 6.5 Pin Removal Tool

Maintenance Instructions

Model 30 Pavement Router Manual

Chapter 6

Table 6-5 Removing Old Cutter Head and Main Shaft

Step

Action

1

Remove belt guard. (Figure 6.7)

2

Back off belt tension, adjusting bolt jam nuts all the way and remove the V-belts. (Figure

3

Tip the router back, lowering handle all the way to the ground.

4

Remove wheels.

Remove lower sheave. The sheave has a built in puller. Loosen and remove the three

and progressively to separate sheave from bushing.

Drive a wedge into the slot of bushing, barely enough to free the bushing and slide bushing off shaft.

Lift handle to set machine flat on ground, and then remove top three cap screws in each bearing but leave it intact.

Push handle down all the way to the ground again, this will lift the front of the router, under the router.

Figure 6.6 Belt Tensioner

Maintenance Instructions

6.8 Changing Cutter Heads

It is recommended that the cutter head be changed when holes for pins are worn to 1.000 in diameter or larger. Follow the steps in Table 6-5 to remove the cutter head and main shaft, and Table 6-6 to install the new cutter head and main shaft. The cutter head and main shaft are sold in matched sets and must be installed together.

6.6).

5

6

7

8

mounting cap screws. Insert these same cap screws in the threaded jack-screw holes. Starting with the screw farthest from the bushing saw slot; tighten all screws alternately

of the two main shaft bearings. It is not necessary to remove bottom cap screw in each

freeing the cutter head assembly from the cutter housing. Then roll the cutter head from

Model 30 Pavement Router Manual

Chapter 6

Figure 6.7 Belt Guard

Maintenance Instructions

Model 30 Pavement Router Manual

Chapter 6

Table 6-6 Installing New Cutter Head and Main Shaft

Line up bearings with cutout sections in the flywheel housing, fitting each into its slot as machine is lowered over flywheel.

Center cutter head in housing and move main shaft so that it is flush with bearing on side opposite sheaves.

If bearings do not use a locking ring, follow this procedure: Using 1/4” electric drill and

screws and tighten until snug.

Reinstall hub and lower sheave. Be sure the sheaves are in alignment using straight edge.

Tighten cap screws that pull the sheave onto bushing alternately and progressively until necessary before tightening cap screws to recommended torque value of 15 ft. - lbs. each.

Install V-belts and tighten tension using the jam nuts underneath motor mount. Correct belt tension is 1/4” deflection per belt when 10 lbs. pressure is applied.

Install cutters, shafts and spacers as outlined in changing cutters, Table 6-4 Cutter

Changing.

Maintenance Instructions

Step Action

1 Slip the bearings on to the main shaft in the new cutter head. 2 Push the handle down all the way to the ground to raise the front of machine. 3 Roll new cutter head assembly under machine and into position.

4 5 Reinstall three cap screws that attach bearings to flywheel housing. 6 7 Replace locking ring mechanism on each bearing (if equipped).

8

9

10

11 Reinstall wheel and tire assemblies. 12 13 Install belt guard. 14

13/64” drill bit, make dimple in shaft under one or more set screws. Remove two set screws on each bearing and coat with a thread adhesive such as Loctite. Replace set

tapers are seated. Check alignment and sheave run out or wobble and correct as

Model 30 Pavement Router Manual

Chapter 6

Table 6-7 Changing V-Belts

Maintenance Instructions

6.9 V-Belts

Check and tighten the V-belts as required after 2 hours of operation. To tighten V-belts, adjust jam nuts under engine mount. (Figure 6.6). The V-belts should be changed once they can no longer be tightened to the correct tension, or when showing signs of excessive wear. Follow the steps in

Table 6-7 to change the V-Belts. Recheck belt tension after 8 hours and every 40 hours thereafter.

Always replace both belts and inspect sheaves for wear.

CAUTION

Do not over-tighten belts as damage will occur to belts and bearings. Belts that are too loose will shorten the life of the belts and sheaves. When installing new belts do not attempt to stretch over sheaves.

Step Action

1 Remove belt guard by removing 4 bolts. (Figure 6.7). 2 Loosen belt tensioner until bottomed out. (Figure 6.6).

3 Remove old belts. Install new belts.

Tighten belt tensioner. Correct tension is 1/4” deflection per belt when 10 lbs. pressure is

4

5 Install belt guard.

applied. Incorrect belt tension will cause poor belt life, damage to bearings, and engine crankshaft bearing failure.

Model 30 Pavement Router Manual

Chapter 6

Caution

Dust may collect between the elements or “teeth” of the zipper, making it difficult to open. DO NOT

opened.

Figure 6.8 Electric Clutch

Maintenance Instructions

6.10 Electric Clutch

The CRAFCO Model 30 Router is equipped with an electric clutch which can be engaged independently of engine operation. Under normal operation, no service of this clutch is required. If the V-grooves should become worn, a completely new clutch assembly (Crafco part number 31289) must be installed (Figure 6.8).

6.11 Dust Control Router Specific Maintenance

The following maintenance instructions are for parts used on dust control equipped Model 30 Pavement Routers.

Dust Collection Bag Maintenance 6.11.1

The dust collection bag should be cleaned on a daily basis or more frequently depending on asphalt conditions to ensure maximum dust collector efficiency. To clean the dust collection bag, remove the dust collection bag from the router. Open the zipper on the dust collection bag to access the inside of the dust collection bag.

try to forcibly open the zipper or damage to the dust collection bag may occur. Gently work the slider of the zipper back and forth to work the dust out of the elements until the zipper is completely

Use a Shop Vac to vacuum the entire inside of the dust collection bag. If shop air is to be used to blow dust off of the dust collection bag, use a nozzle that restricts air pressure to no more than 30 psi. Higher pressure than 30 psi. may damage the dust collection bag.

Model 30 Pavement Router Manual

Chapter 6

Step

Action

1

Remove the long aluminum brush holders from the sides of the shroud.

2

After their removal you will be able to slide the short brushes out of their holders and slide new brushes in.

3

The ends of the aluminum holders for the long brushes have been crimped at the ends. Use a screwdriver or a pair of pliers to spread the ends of the holders apart,

4

Then slide the brushes out of the holder.

5

After installing new brushes in the holder, re-crimp the ends in a vice to keep the brushes from sliding out.

6

Reinstall the holders on the shroud.

7

To replace the flexible brush on top of shroud, drill out the rivets with a #30 drill bit.

8

Replace the flexible brush and secure with new 1/8” wide domed blind rivets. (PN

28549)

Table 6-8 Changing Seal Brushes

Maintenance Instructions

Do Not try to clean the dust collection bag with water. Keep the dust collection bag dry at all times,

whether when in use or during transport and storage. Water, rain or significant moisture may cause the bag to shrink and not function appropriately.

Cutter Head Dust Shroud 6.11.2

When seal brushes become worn and stop trapping dust behind the shroud, they should be replaced. If brushes become deformed they can be soaked in hot water for approximately 20 min. This will aid in the brushes regaining their shape. Allow brushes to dry before using. If the shroud is showing wear or damage beyond the extent of brush wear, the entire shroud should be replaced.

Replacing Seal Brushes 6.11.3

Follow the steps in Table 6-8 to replace the seal brushes on the dust shroud.

Model 30 Pavement Router Manual

Chapter 6

Table 6-9 Common Add On, Optional, and Maintenance Parts

Maintenance Instructions

6.12 Common Maintenance Parts and Kits

Table 6-9 contains some parts and kits for the Model 30 Pavement Router that has been put

together for your convenience as add on, or maintenance parts.

PART NO. DESCRIPTION

24259 ROUTER GAUGE PACKAGE OPTION 31293 FUEL TANK FOR PRE MARCH 2011 ROUTERS 31442 FUEL TANK FOR POST MARCH 2011 ROUTERS 31326 FUEL TANK PETCOCK 31327 FUEL TANK GROMMET FOR 31326 31334 FUEL TANK CAP 31450 SELF-PROPELLED KIT 31478 SELF-PROPELLED BELT A-43 31480 SELF-PROPELLED MECHANISM ONLY

31550K DUST CONTROL RETROFIT KIT

20919 CARBIDE SKID PLATE 31344 OUTER AIR CLEANER ELEMENT 31345 SAFETY AIR CLEANER ELEMENT 31330 ENGINE OIL FILTER 31331 ENGINE FUEL FILTER 32078 V-BELT 5VX-560 31289 ELECTRIC CLUTCH 31414 DUST COLLECTION BAG, 12 SQ. FT. 31575 LARGE PARTICLE DUST COLLECTION BIN 31591

31592 31593 31594 31595

31350 CRACK SAW ATTACHMENT

DUST CONTROL SHROUD BRUSHES

Model 30 Pavement Router Manual

Chapter 7

How to use a Multimeter

7.0 How to Use a Multimeter

The Model 30 Pavement Router uses 12-volt dir ect current (DC) to power the engine, and actuator motor. The DC power is from a 12-volt battery.

12-volt DC power has little danger of electrical shock. Care must still be taken when dealing with DC power systems because it is capable of producing large amounts of current.

7.1 Checking DC Voltage with a Multimeter

Connect the probes to the meter. Set the range to a position that includes 12-volts or higher. Touch the red probe to the positive side of accessory and black probe to ground. If the item you are checking has a ground wire attached then use that ground or you can use the grounding stud on the engine channel assembly.

7.2 Checking Resistance (Ohms)

Connect probes to the meter (See Figure 7.1 Standard Multimeter).

Note: When checking Ohms the circuit cannot be completed. This means one end of the wire will

need to be disconnected.

7.3 Checking Wire Continuity

Set the meter to “Audible Continuity”. Now touch the probe to each end of the wire in question. The meter will read “0” on the screen and

make an audible beep if the wire has continuity from end to end.

How to use a Multimeter

Chapter 7

Figure 7.1 Standard Multimeter

AC Volta ge ~

Audible Continuity

Ohms Ω

Use these ports. Do not amps

DC Voltage

• Wire connection

Model 30 Pavement Router Manual

use the fuse port, it is for

Model 30 Pavement Router Manual

Chapter 7

Figure 7.2 Clamp – On Amp Meter/Multimeter

Ohms Ω

• Burner Ignition Coil

Audible Continuity

wire connection

DC Voltage

except Generator

AC Voltage ~

• Generator Output

AC Amps ~

• Hose Current

How to use a Multimeter

• Everything

• Sensors

• Hyd. Coils

• Hose, Wand, and

Model 30 Pavement Router Manual

Chapter 8

Table 8-1 Trouble Shooting Guide Model 30 Pavement Router

Troubleshooting

8.0 Model 30 Pavement Router Troubleshooting

Use the guides in Table 8-1 to help you troubleshoot problems you may encounter with the Model 30 Pavement Router, including self-propelled and dust control models. Also see the Engine Operators Manual for further engine troubleshooting.

Problem Possible Cause Remedy

• Don’t cut so deep. Take two passes to get to the required

Cutters wear out of round

Engine Stalls.

Cutters not spinning on pins thereby creating uneven wear.

No Spark

Inadequate supply of fuel to carburetor.

depth.

• Check t o see if washer count is correct. Ref er to Section 9.11

Cutter Positioning

• Check electric system for defective wires, switches, etc. See Engine Operators Manual.

• Check f uel pump, fuel valve and lines. See Engine Operators Manual.

Machine fails to raise or lower.

Defective or worn linear actuator.

Damaged rocker switch, wiring, or fuse.

• Check for 12Vdc to the actuator in the red and yellow wires. Flipping the rocker switch one way, will cause voltage in the red wire, while flipping it the opposite direction will cause the voltage in the yellow wire.

• If t he voltage is good, replace the linear actuator.

• If t he voltage is bad, check voltage going to the rocker switch.

• Check for 12Vdc going to rocker switch from the brown wire.

• If voltage is good, check switch connections. Replace bad connection or switch.

• If voltag e to the switch is bad, replace wiring.

Model 30 Pavement Router Manual

Chapter 8

Table 8-2 Trouble Shooting Guide Model 30 Pavement Router (Continued)

Troubleshooting

Engine doesn’t spin properly when cranking.

Engine missing or loss of power.

Engage drive system pulling up on the handle and nothing happens.

The Dust Control System is not controlling the dust as well as it once did.

Starter problems.

Low battery.

Dirty carburetor.

Defective fuel pump.

Pulling the wrong handle

Drive cable has too much slack.

Both tires are not at the correct tire pressure.

Hoses and guards are not properly positioned.

Either the dust collection bag or the large particle dust collection bin needs to be cleaned.

• Repair or replace starter. See Engine Operators Manual.

• Charge or replace battery. See

Battery Recharging

• Clean/Service Carburetor. See Engine Operators Manual.

• Replace fuel pump. See Engine Operators Manual.

• The drive system is controlled by the right hand handle.

• Adj ust t he cable so that the drive system starts to move as you begin to pull the handle.

• Make sure both tires are at the recommended P.S.I. rating.

• Review the operating procedures and make sure everything is properly placed.

• Clean the dust collection bag and/or dump out the large particle dust collection bin.

Old brushes on the cutter head dust shroud.

• Replace all the brushes on the cutter head dust shroud.

Model 30 Pavement Router Manual

Chapter 9

Illustrated parts Lists

9.0 About the Illustrated Parts List

The Illustrated Parts List (IPL) is designed to help technical service or maintenance personnel correctly identify orderable replacement parts.

The figure and table titles reference the part number (PN) to which they apply. The PNs for each of the

Model 30 Pavement Router machine models are as follows:

• Model 30 Pavement Router with electric clutch PN 21300

• Model 30 Pavement Router non-clutch PN 21330

• Model 30 Self-Propelled Router PN 21340

• Model 30 Pavement Router with Dust Control PN 21350

• Model 30 Self-Propelled with Dust Control PN 21360

Illustrations are designed to show general shape and size of a part and the relationship that part has to other parts. Actual size and shape of parts or components may differ or vary from the actual part or component.

9.1 Ordering Crafco Parts

Crafco distributors and Crafco Pavement Preservation Supply Centers are strategically located throughout the United States. Parts can be ordered from your local Crafco distributor or directly from Crafco, Inc. if a distributor is not available in your area. When ordering parts, give the following information:

• Part Number

• Machine Model

• Serial Number

Write, call, or Fax Crafco, Inc. at the following: Crafco, Inc. Headquarters 6165 W Detroit St. Chandler, AZ 85226 Phone: (602) 276-0406 Toll Free: (800) 528-8242 Fax: (480) 961-0513

Visit our website at www.crafco.com

Illustrated parts Lists

Chapter 9

5

8

7

9

4

2

3

1

10

6

Figure 9.1 Model 30 Pavement Router: PN 21300,

21330 Non-Clutch

9.2 Model 30 Pavement Router

Model 30 Pavement Router Manual

Chapter 9

Table 9-1 Model 30 Pavement Router: PN 21300

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure 9.1 1

2 3 4 5 6 7 8 9

10

20914 ENGINE: KOHLER PA-CH752-3125(27HP)(20 Kw) 1 31442 F UEL TANK 1 20946 GAS TANK STRAP ASSEMBLY 2

20945 GAS TANK GUARD 1 31102 RUBBE R ROCK DEFLECTOR 1 31104 DEFLECTOR CHAIN ASSEMBLY 1 20910 ENGINE CHANNEL ASSEMBLY 1 20940 BELT GUARD ASSEMBLY 1

20920 HANDLE BAR ASSEMBLY 1 20903 ROCKER SWITCH WIRING HARNESS 1

Model 30 Pavement Router Manual

Chapter 9

11

12

13

14

15

19

20

18

16 17

22

23

262524

21

27

Figure 9.2 Model 30 Pavement Router: PN 21300

Illustrated parts Lists

Model 30 Pavement Router Manual

Chapter 9

Table 9-2 Model 30 Pavement Router: PN 21300

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure

9.2

11 31338 SWITCH 1 12 28685 STAR WASHER 1 13 31100 PIN REMOVAL TOOL 1 14 31101 PIN RETAINING WRENCH 1 15 32119 LIFTING BRACKET ASSEMBLY 1 16 28504 1/2-13 HEX NUT 1 17 28674 SAE 1/2” WASHER 9 18 31052 CLEVIS ASSEMBLY 1 19 29480 CLEVIS PIN 3/8 X 1 1/4” 1 20 29638 COTTER PIN 1/8 X 1” 2 21 31031 FILLER PLATE - RH 1 22 32078 V-BELT 5VX-560 2 23 31210 HANDLE BRACKET 2 24 28759 1/2-13 X 1 1/4” GRADE 8 BOLT 6 25 28642 1/2” GRADE 8 HARDENED FLAT WASHER 8 26 28540 1/2” – 13 UPSET TYPE LOCK NUT 7

27 31289 ELECTRIC CLUTCH 1

Model 30 Pavement Router Manual

Chapter 9

28

31

34

32

33

36

35

40

41 42 43

29

30

44

38

37

39

Figure 9.3 Model 30 Pavement Router Back Side: PN 21300

Illustrated parts Lists

Model 30 Pavement Router Manual

Chapter 9

Table 9-3 Model 30 Pavement Router: PN 21300

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure

9.3

28 20915 ROCKER SWITCH 1 29 51614 14 Ga. SPADE TERMINAL 4 30 51592 10 Ga. SPADE TERMINAL 2 31 20916 FOAM HAND GRIP 2 32 32109 RUBBER BUSHING 2 33 31068 SHOCK ABSORBER ASSEMBLY 1 34 32001 ACTUATOR 1 35 20919 CARBIDE SKID PLATE 1 36 29345 ½ X 2” CLEVIS PIN 1 37 29638 1/8 X 1” COTTER PIN 2 38 31033 FILLER PLATE – LH 1 39 31342 SUPPORT STRIP 1 40 37620 BATTERY – 12V 1 41 24003 BATTERY BOX 1 42 20949 BATTERY CABLE GROUND 2 43 20948 BATTERY CALBE POSITIVE 1

44 24037 BATTERY STRAP WITH BUCKLE 1

Model 30 Pavement Router Manual

Chapter 9

BLU-1

ACTUATOR

(GREY)

BRN-1

RED-1

ACTUATOR

(BLACK)

YEL-1

CLUTCH

(GREEN)

CLUTCH

(BLACK)

BLK-1

GROUNDING STUD

ON ENGINE CHANNEL

ASSEMBLY

BLK-2

GRN-1

3

4

5

6

7

8

9

10

11

BLK-1

1 2

ENGINE AUX

(YELLOW)

Figure 9.4 Electrical Diagram Model 30 Router with Electric Cl utch

Illustrated parts Lists

9.3 Electrical Schematic Model 30 Pavement Router with Clutch

Model 30 Pavement Router Manual

Chapter 9

Table 9-4 Electrical Diagram Model 30 Router with Clutch

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure

9.4

1 31514 IN-LINE FUSE HOLDER 2 2 32510 FUSE, 20 AMP (NOT SHOWN) 1 3 20948 BATTERY CABLE POSITIVE 1 4 20949 ENGINE GROUND (BATTERY CABLE GROUND) 2 5 20910 ENGI NE CHA NNEL ASSE MBLY 1 6 20949 BATTERY CABLE GROUND 2 7 37620 BATTERY 12V 1 8 32001 ACTUATOR 1

9 31289 ELECT RIC CLUTCH 1 10 31338 CLUTCH SWITCH 1 11 20915 ROCKER SWITCH 1

Model 30 Pavement Router Manual

Chapter 9

POSITIVE BATTERY CABLE

BATTERY GROUND

ENGINE GROUND

ENGINE AUX

(YELLOW)

BLU-1

ACTUATOR

(GREY)

FUSE

(RED)

BLU-1

ACTUATOR

(BLACK)

GROUNDING STUD

ON ENGINE CHANNEL

ASSEMBLY

BRN-1

RED ENGINE WIRE

GRN-1

YEL-1

RED-1

BLK-1

Figure 9.5 Electrical Diagram Model 30 Router Non Clutch

Illustrated parts Lists

9.4 Electrical Diagram Model 30 Pavement Router Non-Clutch

The following wiring diagram applies to the Model 30 Pavement Router non-clutch PN 31330.

Model 30 Pavement Router Manual

Chapter 9

Figure 9.6 Model 30 Self-Propelled Router PN 21340

Illustrated parts Lists

9.5 Model 30 Self Propelled Router

This section illustrates the unique parts for the self-propelled system.

Model 30 Pavement Router Manual

Chapter 9

Figure 9.7 Self-Propelled Router Mechanisms

Illustrated parts Lists

Model 30 Pavement Router Manual

Chapter 9

Table 9-5 Self-Propelled Router Mechanisms

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure 9.7

1 31478 BELT A-43 1 2 31480 SELF-PROPELLED MECHANISM ASSEMBLY 1 3 31479 DRIVE CHAIN 1 4 20878 LOWER CABLE HOLDER 1 5 31488 CABLE AND CABLE GUIDE CLEVIS ASSEMBLY 1 6 28906 7/16 – 20 X 3 1/2” GRADE 8 BOLT 1 7 28648 7/16 LOCK WASHER 1 8 28673 7/16 FLAT WASHER 1

9 20860 CLUTCH ASSEMBLY W/ STUB SHAFT 1 10 37032 BRUSH SHAFT KEY 1/4” X 1 1/8” 1 11 31482 CAST IRON FINISHED BORE V-BELT PULLEY 1

Model 30 Pavement Router Manual

Chapter 9

Figure 9.8 Self-Propelled Router Wheel Spacer

Table 9-6 Self-Propelled Router Mechanisms

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure 9.8 --- 31483 WHEEL SPACER SELF-PROPELLED ROUT ER 1

Illustrated parts Lists

Chapter 9

Figure 9.9 Model 30 Self-Propelled Router Drive Wheel Clutch Assembly

Model 30 Pavement Router Manual

Chapter 9

Figure 9.10 Model 30 Self-Propelled Router Drive System

Illustrated parts Lists

Model 30 Pavement Router Manual

Chapter 9

ACTUATOR

(GREY)

BRN-1

RED-1

ACTUATOR

(BLACK)

CLUTCH

(GREEN)

CLUTCH

(BLACK)

BLK-1

GROUNDING STUD

ON ENGINE CHANNEL

ASSEMBLY

JUMPER

WIRE

YEL-1

BLK-2

BLU-1

3

4

5

7

8

6

9

10

11

12

1 2

ENGINE AUX

(YELLOW)

Figure 9.11 Electrical Diagram Self-Propelled Router

Illustrated parts Lists

9.6 Electrical Diagram Model 30 Self Propelled Router

Model 30 Pavement Router Manual

Chapter 9

Table 9-7 Electrical Diagram Self-Propelled Router

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure 9.11

1 31514 IN-LINE FUSE HOLDER 2 2 32510 FUSE, 20 AMP (NOT SHOWN) 1 3 20948 BATTERY CABLE POSITIVE 1 4 20949 ENGINE GROUND (BATTERY CABLE GROUND) 2 5 20910 ENGINE CHANNEL ASSEMBLY 1 6 20949 BATTERY CABLE GROUND 2 7 37620 BATTERY 12V 1 8 32001 ACTUATOR 1

9 31289 ELECTRIC CLUTCH 1 10 31338 CLUTCH SWITCH 1 11 31339 SWITCH 1

12

20915 ROCKER SWITCH 1

Model 30 Pavement Router Manual

Chapter 9

Figure 9.12 Model 30 Router with Dust Control, PN 21350,

21360 (Self-Propelled with Dust Control)

Illustrated parts Lists

9.7 Model 30 Pavement Router with Dust Control

This section illustrates the unique parts for the dust control system. Self-Propelled with dust control machines will also contain the parts from sections 9.5 and 9.6.

Model 30 Pavement Router Manual

Chapter 9

Figure 9.13 Dust Shroud Assembly

Illustrated parts Lists

Model 30 Pavement Router Manual

Chapter 9

Table 9-8 Dust Shroud Assembly

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure 9.13 1 31730N DUST SHROUD WELD ASSEMBLY 1

2 31586 BRUSH HOLDER A 2 3 31591 STRIP BRUSH A 2 4 31587 BRUSH HOLDER B 1 5 31592 STRIP BRUSH B 2 6 31588 BRUSH HOLDER C 2 7 31593 STRIP BRUSH C 2 8 31589 BRUSH HOLDER D 1

9 31594 STRIP BURSH D 1 10 31599 BRUSH HOLDER E 1 11 31595 STRIP BRUSH E 1 12 31596 FLEX BRUSH SEAL 1 13 28554 10/32 HEX NUT 14 14 28644 #10 SPRING LOCK WASHER 14 15 28819 10/32 X 3/8” ROUND HEAD SCREW 6 16 28893 10/32 X ½” ROUND HEAD SCREW 8 17 28549 1/8 WIDE DOME BLIND RIVET 11 18 31538 REINFORCMENT ANGLE 1

Model 30 Pavement Router Manual

Chapter 9

A

B

D

E

H

I

K

L

O

P

Q

R

S

V

W

Figure 9.14 Dust Control Router

Figure 9.15 Dust Control Router Parts

A

B CD E F

G H I

J K L M N O P

Q R S T U V W

Illustrated parts Lists

Model 30 Pavement Router Manual

Chapter 9

,

Table 9-9 Dust Control Router Parts

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure 9.14

Figure 9.15

A 31735N CUTTER HEAD DUST SHROUD 1 B 31411 BLOWER HOUSING ASSEMBLY 1 C 31412 BLOWER FAN 1 D 31415 90° X 4” ID RUBBER ELBOW 1 E 31410 BRUSH MANIPULATION TOOL 1 F 31726N DUST SHROUD MOUNTING BRACKET LEFT SIDE 1 G 31727N DUST SHROUD MOUNTING BRACKET RIGHT 1 H 31535 SUPPORT STRIP ASSEMBLY 1

I 31555 CYCLONE 1

J 31570 BLOW ER MOUNTING BRACKET ASSEMBLY 1

K 31560 CYCLONE MOUNTING BRACKET ASSEMBLY 1

L 31414 DUST COLLECTION BAG, 12 SQ. FT. 2

M 31417 PIN REMOVAL HOLE COVER 1 N 31416 PIN RETAINING HOLE COVER 1 O 31409 LO CKING KNOB 1

P 31575 LARGE PARTICLE DUST COLLE CTION BIN 1 Q 31433 RUBBER GASKET, CYCLONE 1 R 31565 FILTER BAG SUPPORT ASSEMBLY 1

S 31567 FILTER SUPPORT ROD 1

T 31545 DUST SHROUD RETAINING PIN 1 U 31413 KOHLER FRONT DRIVE SHAFT 1

V 31437 1 1/2” SUCTION HOSE 1 W 31438 4” SUCTION HOSE 1

Model 30 Pavement Router Manual

Chapter 9

ADJUSTABLE QUICK RELEASE GEAR CLAMP

Table 9-10 Dust Control Router Hardware (Not Shown)

Illustrated parts Lists

PART NO. DESCRIPTION QTY.

26092 28500 28502 28538 28540 28642 28645 28646 28647 28670 28672 28732 28735 28764 29041

31738N

31407

GEAR C 1/4" - 20 HEX NUT 1/8" - 16 HEX NUT 1/ 8" - 16 UP 1/2” UP 1/2" GRADE 8 F 1/4" LOCK WA 5/16" LOCK WA 3/8" LOCK WA 1/4" F 3/8" F 3/8" - 6 X 1 1/4" BO 3/8" - 16 X 2" BO 1/ 2" - 13 X 2" BO M8 - 1.25 X 25 MM BO B

L

3/ 8" - 16 X 1 1/4 " F

L

AMP, SAE # 64

S

ET NUT

S

ET NUT

L

AT WASHER

S

HER

S

HER

S

HER

L

AT WASHER

L

AT WASHER

L

T

L

T L

T

L

OWER FAN KEYWAY

L

AT HEAD SOCKET CAP SCREW

T

4 6 8 8 2 4 6 4 8 6

25

4 4 2 4 1

4 31408 31418

31739N 29657N 31736N 31737N

28992

3/8" - 16 X 1 1/2" THREADED STU

CLAMP, 2 - 1/2" SDBC COILED BENT - WIRE LOCKING PIN BLOWER SHAFT, INNER SEAL BLOWER SHAFT, OUTER SEAL 3/16 BLIND RIVET, 7/8 LG

D

4

1

2

1

4

Model 30 Pavement Router Manual

Chapter 9

1

2

3

4

5

6

Figure 9.16 Cutter Head and Drive Assembly

Illustrated parts Lists

9.8 Cutter Head and Drive Components

Model 30 Pavement Router Manual

Chapter 9

Table 9-11 Electrical Diagram Model 30 Router with Clutch

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure 9.4

1 31145 WIDE HUB CARBIDE TIPPED CUTTER 6 2 31032 CUTTER HEAD 1 3 31120 RETAINING TAB 6 4 32061 3/8 X 3/4 ROLL PIN 6 5 32039 3/8” – 16 X 3/4” BOLT 6 6 28672 3/8” FLAT WASHER 6 7 28688 CLUTCH INNER WASHER (NEXT TO ENGINE) 1 8 31289 ELECTRIC CLUTCH 1

9 31004 KEY, 1/4 X 2 3/4 1 10 28689 RETAINING WASHER (NEXT TO CL UT CH) 1 11 28897 BOLT, 7/16 X 1 1/4 1 12 28684 WASHER 1 13 31073 MAIN SHAFT 1 14 32043 BEARING 2 15 31114 CUTTER PIN 6 16 28847 1/2 - 13 X 1 SQUARE HEAD SET SCREW 2

17 31072 KEY – 3/8 X 4 1 18 32072 SHEAVE 1 19 32071 1 ¾ BUSHING 1 20 31071 3/8 X 1 5/8 SQUARE KEY 1

Illustrated parts Lists

Chapter 9

31134

PCC Pavement

Cast steel cutter for use with 11

31136, 31137

AC Pavement

Cast Steel Cutter with a Carbide insert

31149

AC Pavement

Hardened Cast Steel Cutter with a

31135

AC Pavement

Cast Steel Cutter with a Carbide insert

3145

AC Pavement

Cast Steel cutter with a Carbide insert

31138

AC Pavement

Cast Steel Cutter with a Carbide insert

Table 9-12 Cutter Options and Selection Guide

9.9 Pavement Cutter Selection

Model 30 Pavement Router Manual

Standard Steel Standard Hub

Carbide Tip Standard Hub

Carbide Tip Standard Hub Extended Life

AC Pavement

hardened steel spacers. Able to be configured to cut ½” wide to 1 ½” wide. (See

cutting surface. For use with 11 hardened steel spacers. Able to configure to cut ½” to 1 ½” wide. (See

Figure 9.17).

Carbide insert cutting surface for extended cutting life. For use with 11 hardened steel spacers. Able to configure to cut ½ to 1 ½” wide. (See

Figure 9.17)

Figure 9.17 )

Carbide Tip Wide Cut

Carbide Tip Wide Hub (Patent Pending)

Carbide Tip Extra Long

cutting surface. Hub removed to allow the cutter to be stacked for wider cuts. For use with up to 15 hardened steel spacers. Able to be configured to cut ½ to 2” wide. (see

cutting surface. For use with 2 hardened steel spacers (cutters come with 2 spacers). Able to be configured to cut ½” to ¾” wide. Designed to provide a cleaner cut. (See

9.19)

cutting surface. Longer teeth for cutting depth up to 2”. For use with 12 hardened steel spacers. Able to be configured to cut ½ to 1 ½” wide. (See

Figure 9.20).

Figure 9.18)

Figure

Model 30 Pavement Router Manual

Chapter 9

FRONT OF ROUTER REAR OF ROUTER

ROTATION OF CUTTER HEAD

Illustrated parts Lists

9.10 Cutter Positioning

WARNING

Install replacement cutters as shown. Failure to install correctly will result in rapid deterioration of carbide tip.

Model 30 Pavement Router Manual

Chapter 9

Figure 9.17 Cutter Positioning for 31134, 31136, 31137, 31149

Figure 9.18 Cutter Positioning for 31135

1/2” Cut

Staggered for wide cut

Add center cutter for wide cut

1/2” Cut

3/4” Cut

Illustrated parts Lists

9.11 Cutter Positioning

The following sections illustrate the spacing options for the different types of cutter heads available.

Cutter Positioning for Cutter Part Numbers 31134, 31136, 31137, 31149 9.11.1

Cutters can be aligned or staggered to configure the desired cut width. For wider cutting additional cutter can be added to a single pin to achieve a smoother finished cut. Always use enough Hardened Spacers to keep cutters appropriately positioned on the pin while still allowing the cutter to turn completely free.

Cutter Position for Cutter Part Number 31135 Shaved Cutter 9.11.2

Cutters can be aligned to configure the desired cut width. For wider cutting additional cutters can be added to a single pin to achieve a smoother finished cut. Always use enough Hardened Spacers to keep cutters appropriately positioned on the pin while still allowing the cutter to turn completely free. The main consideration is placing equal number of cutters and spacers on opposite pins to maintain balance. Failure to do so could result in permanent damage to the machine and possibly injury to the operator.

Model 30 Pavement Router Manual

Chapter 9

Figure 9.19 Cutter Positioning for 31145 (Patent Pending)

Figure 9.20 Cutter Positioning for 31138

1/2” Cut

Staggered for wide cut

1/2” Cut

Staggered for wide cut

Illustrated parts Lists

Cutter Positioning for Part Number 31145 (Patent Pending) 9.11.3

Cutters can be aligned or staggered to configure the desired cut width. Two Hardened Spacers are used with this cutter. Cutter produces a cleaner cut and causes less cutter bore wear.

Cutter Positioning for Part Number 31138, 6 1/2” Cutter 9.11.4

Cutters can be aligned or staggered to configure the desired cut width. For wider cutting additional cutters can be added to a single pin to achieve a smoother finished cut. Always use enough Hardened Spacers to keep cutters appropriately positioned on the pin while still allowing the cutter to turn completely free.

Illustrated parts Lists

Chapter 9

Figure 9.21 Model 30 Router with Crack Saw Attachment

9.12 Crack Saw Attachment

Model 30 Pavement Router Manual

Chapter 9

1

2

3

4

5

7

12

8

11

14

15

17

19

20

27

28

22

29

22

23

26

25

24

32

31

30

21

6

10

9

16

18

13

33

Figure 9.22 Crack Saw Attachment Parts

Illustrated parts Lists

Model 30 Pavement Router Manual

Chapter 9

Table 9-13 Parts List for Crack Saw Attachment

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure 9.22 1 31367 1 – 3/4 TAPERLOCK BUSHING 1

2 32068 SHEAVE 2G5V 4.65 DIAMETER 1 3 31361 1 – 3/4” PILLOW BLOCK BEARING 2 4 31360 MAIN SHAFT 1 5 31364 INNER COLLAR 1 6 31362 OUTER COLLAR 1 7 31363 DRIVE PIN 1 8 31351 SIDE MOUNTING ANGLE 1

9 31368 1/4 SQUARE X 1.0” LONG KEY 1 10 31352 SIDE MOUNTING ASSEMBLY 1 11 29953 1/4" FEMALE FITTING – 90 2 12 31355 BLADE GUARD ASSEMBLY 1 13 29954 3/8 PUSH ON T-FITTING 1 14 29957 3/8 INNER DIAMETER PLASTIC TUBING 1 15 28237 3/8 STREET ELBOW 1 16 29202 3/8 BRONZE BALL VALVE 1 17 28342 3/8” X 1/4" BUSHING 1 18 29956 STRAIGHT CONNECTOR 1 19 31399 WATER PIPE ASSEMBLY 1 20 29955 HOSE CONNECTOR 1 21 28207 3/8” PIPE ELBOW 1 22 28674 SAE 1/2” WASHER 8 23 28540 1/2 - 13 UPSET TYPE LOCK NUT 4 24 28676 5/8 SAE FLAT WASHER 1 25 28650 5/8” LOCK WASHER 1 26 28820 5/8 – 11 X 4.0 LH THREAD 1 27 28761 1/2-13 X 1 1/2 HEX HEAD BOLT 6 28 28649 1/2" LOCK WASHER 6 29 28763 1/2 - 13 X 1 3/4 H EX HEAD BOLT 4 30 28701 1/4 - 20 X 3/4” HEX HEAD BOLT 2

Model 30 Pavement Router Manual

Chapter 9

Table 9-14 Parts List for Crack Saw Attachment (continued)

Illustrated parts Lists

FIG. ITEM PART NO. DESCRIPTION QTY.

Figure 9.22 31 28524 1/4 -20 NYLON LOCK NUT 2

32 28670 1/4" FLAT WASHER 4 33 45671 1/4 – 20 X 3/8 ALLEN SET SCREW 1

Crafco 30 Pavement Router, 30 Self Propelled Pavement Router, 30 Dust Control Router, 30 Saw Cut Router Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.0 About This Manual

1.1 How to use this manual:

2.0 Safety Precautions

2.1 General Safety

2.2 Personal Safety

2.3 Equipment or Operational Safety for All Routers

Operational Safety for Dust Control Router 2.3.1

2.4 California Proposition 65

All Crafco, Inc. Equipment 2.4.1

All Crafco, Inc. Equipment using a gasoline engine 2.4.2

2.5 Safety Symbols and Notices

3.0 Limited Warranty

3.1 Warranty Claim Instructions

4.0 Machine Specifications

5.0 Operating Instructions

5.1 Preparing the Machine for Start Up

5.2 Starting

5.3 Cold Weather Starting

5.4 Battery

5.5 Stopping the Engine

5.6 Operation Guidelines

Angle of Operation 5.6.1

Cooling 5.6.2

Engine Speed 5.6.3

5.7 Attaching Cutter Head Dust Shroud

5.8 Cleaning Joints and Cracks

Routing with Dust Control 5.8.1

Moving the Self Propelled Router 5.8.2

5.9 Saw Cut Attachment

5.10 Storing the Machine

CRAFCO Model 30 Dust Control Router 5.10.1

CRAFCO Model 30 Pavement Router and Self-Propelled Router (without dust control) 5.10.2

6.0 Maintenance Instructions

6.1 Oil Recommendations

Oil type 6.1.1

6.2 Fuel Recommendations WARNING

General Recommendations 6.2.1

Fuel Type 6.2.2

Gasoline/Alcohol Blends 6.2.3

Gasoline/Ether Blends 6.2.4

6.3 Battery

Battery Recharging 6.3.1

6.4 Periodic Maintenance

6.5 Maintenance Schedule

6.6 Air Cleaners

6.7 Changing Cutters

6.8 Changing Cutter Heads

6.9 V-Belts

6.10 Electric Clutch

6.11 Dust Control Router Specific Maintenance

Dust Collection Bag Maintenance 6.11.1

Cutter Head Dust Shroud 6.11.2

Replacing Seal Brushes 6.11.3

6.12 Common Maintenance Parts and Kits

7.0 How to Use a Multimeter

7.1 Checking DC Voltage with a Multimeter

7.2 Checking Resistance (Ohms)

7.3 Checking Wire Continuity

8.0 Model 30 Pavement Router Troubleshooting

9.0 About the Illustrated Parts List

9.1 Ordering Crafco Parts

9.2 Model 30 Pavement Router

9.3 Electrical Schematic Model 30 Pavement Router with Clutch

9.4 Electrical Diagram Model 30 Pavement Router Non-Clutch

9.5 Model 30 Self Propelled Router

9.6 Electrical Diagram Model 30 Self Propelled Router

9.7 Model 30 Pavement Router with Dust Control

9.8 Cutter Head and Drive Components

9.9 Pavement Cutter Selection

9.10 Cutter Positioning

9.11 Cutter Positioning

Cutter Positioning for Cutter Part Numbers 31134, 31136, 31137, 31149 9.11.1

Cutter Position for Cutter Part Number 31135 Shaved Cutter 9.11.2

Cutter Positioning for Part Number 31145 (Patent Pending) 9.11.3

Cutter Positioning for Part Number 31138, 6 1/2” Cutter 9.11.4

9.12 Crack Saw Attachment