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TABLE OF CONTENTS

Model 200 Pavement Cutter............................................................................................... 5
Safety Precautions...............................................................................................................6
Limited Warranty.................................................................................................................. 7
Warranty Claim Instructions.................................................................................................8
Specifications....................................................................................................................... 9
Introduction............................................................................................................................10

Operating Instructions

Machine Start Up..........................................................................................11-12
Engine Operating Instructions.....................................................................12-13
Storing the Machine..................................................................................... 14
Instructions for Ordering Parts.................................................................... 14
Stabilizer Mechanism.................................................................................. 15

Maintenance

Maintenance................................................................................................. 16-17
Periodic Maintenance................................................................................. 18
Maintenance Schedule................................................................................ 19
Service and Maintenance Instructions....................................................... 20-21
Changing Cutters......................................................................................... 22
Alternate Cutter Positioning........................................................................ 23
Installing New Cutter Head and Main Shaft............................................... 24
Changing Cutter Heads...............................................................................25
Changing V-Belts......................................................................................... 26
Electric Clutch...............................................................................................26

Trouble-Shooting

Trouble-Shooting Guide.............................................................................. 26

Parts

Cutter Head Assembly Complete - Diagram and Parts.......................... 27-28
Model 200 Pavement Cutter Diagrams and Parts................................... 29-32

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Summary of Contents for 200

Page 1: ...MODEL 200 PAVEMENT CUTTER PART MANUAL 26340 Rev B ...

Page 2: ...2 Revised 7 2002 ...

Page 3: ...3 MODEL 200 PAVEMENT CUTTER ...

Page 4: ...rdering Parts 14 Stabilizer Mechanism 15 Maintenance Maintenance 16 17 Periodic Maintenance 18 Maintenance Schedule 19 Service and Maintenance Instructions 20 21 Changing Cutters 22 Alternate Cutter Positioning 23 Installing New Cutter Head and Main Shaft 24 Changing Cutter Heads 25 Changing V Belts 26 Electric Clutch 26 Trouble Shooting Trouble Shooting Guide 26 Parts Cutter HeadAssembly Complete...

Page 5: ...h all specifically engineered equipment you can get best results at minimum costs if 1 You operate your machine as instructed in this manual and 2 Maintain your machine regularly as stated in this manual WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Operate in well ventilated area only Engin...

Page 6: ... down on handle 4 When cleaning joints near moving traffic always move in a direction away from traffic to protect the operator 5 Tires should be inflated to 45 psi to allow machine to roll easily 6 Never transport the router with the engine running 7 Never exceed maximum recommended engine RPM 8 Never leave router unattended while engine is running 9 Never stand on any part of the machine 10 The ...

Page 7: ...nd not that labor required to gain access to the part Crafco Inc shall only be liable when the equipment is used in compliance with those directions specified in the manufacturer s instructions The warranty provided herein extends only to the repair and or replacement of those components on the equipment covered above and does not extend to incidental or consequential damages incurred as a consequ...

Page 8: ...acturer and the date of purchase if available Serial Number ____________________ Model Number ____________________ Engine Model H P ____________________ Engine Manufacturer ____________________ Date of Purchase ____________________ 3 Should the cause of the malfunction be a defective part the Distributor will advise you of the procedure to follow for a replacement 4 The warranty is valid only for ...

Page 9: ...pth Depth gauge for precise depth control Safety Features Braking system safety guards electric clutch Depth Control Electric actuator for fingertip depth control Cutter Design 6 radially located sprocket shaped cutters on 11 3 4 diameter cutter head Cutter Style Hardened steel with carbide cutter tips Crack Cleaning Up to 1500 L F per hour ...

Page 10: ... NOT operate machine without reading operator s manual and being thoroughly familiar with controls 1 Check engine crankcase oil Add oil if low Refer to Engine Operators Manual 2 Fill engine gas tank with clean fresh unleaded gasoline See Fuel Recommendations in Engine Operators Manual 3 Check tire inflation Proper tire inflation is 45 psi Machine will be difficult to roll with under inflated tires...

Page 11: ...ts or hard aggregate may cause sudden machine movement toward operator This kickback could cause operator to lose his balance or control of 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 T handle which disengages electric clutch Push machine ...

Page 12: ...ctivating 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 leakdow...

Page 13: ...5 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 Cooling 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 i...

Page 14: ...INSTRUCTION FOR ORDERING PARTS Parts may 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 1 Part Number 2 Machine Model 3 Serial Number from Name Plate Write telephone or fax CRAFCO INC 235 SOUTH HIBBERT MESA AZ 85210 480 655 8333 480 655 1712 FAX Toll Free 1 800 528 8242 ...

Page 15: ...t Cutter to improve the stability of the machine and to act as a brake TO SLOW OR STOP THE MACHINE SIM PLY PUSH DOWN ON THE HANDLE For normal operation let wear plate drag on paved surface while machine is in operation Wear plate Part No 31065 should be replaced before wear reaches the attaching bar ...

Page 16: ... SH oil or extending oil change intervals longer than recommended can cause engine damage Refer to the Maintenance instructions on page 22 or the Kohler Owners Manual for detailed oil check oil change and oil filter change procedures and intervals Fuel Recommendations WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved contai...

Page 17: ...e and exhaust emissions are not regulated Be aware however that the cylinder heads may require more frequent service Gasoline Alcohol Blends 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 Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to maximum of 15 MTBE...

Page 18: ...t 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 WARNING 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 exhaus...

Page 19: ...ld be performed at the frequency stated in the chart below They should also be included as part of any seasonal tune up Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform this service ...

Page 20: ...ining clips Check the secondary element safety only if the primary air cleaner element was damaged 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 retain ing clips 6 When element replacement is n...

Page 21: ...ension after 8 hours and every 40 hours thereafter When installing new belts do not attempt to stretch over sheaves Always replace both belts and inspect sheaves for wear Clean machine each day using compressed air or by wiping with rags especially in area of engine cooling fins Periodically inspect the in line fuel filter and replace when dirty Use Crafco P N 31331 of Kohler P N 25 050 03 Always ...

Page 22: ...This will rotate cutter head for proper indexing Do not attempt to turn cutter head with hands 4 Remove wrench and place on bolt just exposed Loosen bolt at least one full turn Slide retainer back exposing pin 5 Using pin removal tool also supplied with machine push pin all the way out except when changing pins Remove worn cutters and or worn pins Pins should be replaced when worn in any area to a...

Page 23: ... Several different patterns are possible The main consideration in cutter arrangement 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 possible injury to the operator Call Crafco or your local Crafco Distributor for a list of cutter options ...

Page 24: ...ngs do not use a locking ring follow this procedure Using 1 4 electric drill and 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 Locktite Replace set screws and tighten until snug 9 Reinstall hub and lower sheave Be sure the sheaves are in alignment using straight edge 10 Tighten cap screws that pull th...

Page 25: ...rews 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 and progressively to separate sheave from bushing 6 Drive a wedge into the slot of bushing barely enough to free the bushing and slide bushing off shaft 7 Lift handle to set machine flat on ground then remove top three cap screws in each of th...

Page 26: ...e e d e k a T g n i s u a c r e d r a h e n i h c a m s n i p n o n i p s o t s r e t t u c s l l a t s e n i g n E k r a p s o N r o f m e t s y s c i r t c e l e k c e h C c t e s e h c t i w s s e r i w e v i t c e f e d o t l e u f f o y l p p u s e t a u q e d a n I r o t a r o b r a c e v l a v l e u f p m u p l e u f k c e h C s e n i l d n a r e w o l r o e s i a r o t s l i a f e n i h c ...

Page 27: ...27 CUTTER HEAD ASSEMBLY COMPLETE PART NUMBER 26576PB ...

Page 28: ...28 CUTTER HEAD ASSEMBLY PARTS LIST ...

Page 29: ...29 MODEL 200 PAVEMENT CUTTER 20990PB ...

Page 30: ...30 MODEL 200 PAVEMENT CUTTER 20990 PB1 ...

Page 31: ...31 25 HP ROUTER PARTS LIST ...

Page 32: ...32 25 HP ROUTER PARTS LIST ...

Page 33: ...33 Pioneering Leadership and Innovation in Quality Pavement Maintenance Materials 235 South Hibbert Mesa Arizona 85210 480 655 8333 Watts 1 800 528 8242 Fax 480 655 1712 Copyright 1999 by Crafco Inc ...

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