Crafco MODEL 30 PAVEMENT ROUTER User manual

•MODEL 30 PAVEMENT ROUTER MANUAL
•SELF-PROPELLED ROUTER
•DUST CONTROL ROUTER
PART MANUAL - 21320
Rev. E

2
04/18

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MODEL 30 PAVEMENT ROUTER

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TABLE OF CONTENTS
MODEL 30 PAVEMENT ROUTER
Model 30 Pavement Router, Dust Control Router and Self-Propelled Router.... 5
Safety Precautions.................................................................................................... 6
Limited Warranty....................................................................................................... 7
Warranty Claim Instructions...................................................................................... 8
Contact Us................................................................................................................. 9
Specifications............................................................................................................ 10
Introduction................................................................................................................. 11
Operating Instructions for The Model 30 Pavement Router,
Dust Control Router and Self-Propelled Router.
Engine Operation Instructions.......................................................... 12-13
Operating Procedures...................................................................... 14-20
Storing the Machine.......................................................................... 20
Maintenance for The Model 30 Pavement Router,
Dust Control Router and Self-Propelled Router.
Maintenance...................................................................................... 21-23
Periodic Maintenance....................................................................... 23
Maintenance Schedule..................................................................... 24
Service and Maintenance Instructions............................................ 25-26
Changing Cutters.............................................................................. 27-29
Changing Cutter Head...................................................................... 30-31
Installing New Cutter Head and Main Shaft.................................... 32
Changing V-Belts.............................................................................. 33-34
Electric Clutch.................................................................................... 34
Trouble-Shooting for The Model 30 Pavement Router,
Dust Control Router and Self-Propelled Router.
Trouble-Shooting Guide................................................................... 35
Parts for The Model 30 Pavement Router
Cutter Head Assembly Complete - Diagram and Parts............... 36-37
Pavement Cutter Selection.............................................................. 38
Cutter Installation Warning................................................................ 39
Cutter Positioning............................................................................. 40-41
Model 30 Pavement Router Diagrams and Parts......................... 42-47
Self-Propelled Router
Drive Wheel Clutch Assembly.......................................................... 50-51
Self-Propelled Drive System........................................................... 52-53
Self-Propelled Hub/Wheel Spacer................................................. 54
Engine Support Frame/Cable Bracket Holder............................... 55
Dust Control Router
Dust Collection Bag Maintenance................................................... 58
Parts List Cutter Head Dust Shroud................................................ 59
Parts List Dust Control...................................................................... 60-61

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MODEL 30 PAVEMENT ROUTER
This manual is furnished with each new CRAFCO MODEL 30 PAVEMENT ROUTER.
This manual will help your machine operators learn to run the machine properly and
understand its mechanical functions for trouble-free operation.
Your CRAFCO MODEL 30 PAVEMENT ROUTER is designed to give excellent service
routing pavement. There are two additional router models that maintain the high performance
of the machine and improve worker safety.
The Dust Control Router:
•Meets EPA Visible Emissions Standards*
•Reduces dust by 96% vs. the standard model by emitting only 1.25% average
dust opacity.
•Provides a cleaner working environment.
•Improves worker safety due to less dust, flying debris, and clear line-of-sight.
•Contains the debris path for easier clean-up, saving time and money.
•Extends life to the air filter and engine.
The Self-Propelled Router:
•Reduces worker fatigue by moving the router effortlessly from one distressed
pavement area to another, and it works especially well on roads with inclines or
hills.
•Reduces physical strain associated with loading and unloading the router onto a
trailer during transport.
You can get the best results from this machine if:
•You operate your machine as instructed in this manual; and
•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. Engine exhaust is deadly.

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SAFETY PRECAUTIONS
MODEL 30 PAVEMENT ROUTER
1. Eye and ear protective devices along with a dust mask are required when operating the
CRAFCO MODEL 30 PAVEMENT ROUTER.
2. Observe all CAUTION AND WARNING signs posted on machine.
3. Care should be taken when operating machine on grades. It is usually best to operate
the machine going uphill, rather than downhill.
4. To stop or slow machine, push down on handle and/or release the clutch handle.
5. When cleaning cracks and joints near moving traffic, always move in a direction away
from traffic to protect the operator.
6. 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 thier
performance.
7. Tires should be inflated to 45 psi to allow machine to roll easily.
8. Never operate the router without belt guard in place.
9. Never transport the router with the engine running.
10 Never exceed maximum recommended engine RPM.
11. Never leave router unattended while engine is running.
12. Never stand on any part of the machine.
13. The only operating position is behind the pavement cutter with both hands on the
handle.
14. Wear long pants, work gloves and heavy leather boots or shoes.
15. Tighten all bolts and screws every 100 hours of operations.
Include these Safety Precautions with the Dust Control Router
16. Do not operate router without hose attached to blower.
17. Do not operate router without hose attached to Cutter Head Dust Shroud.
18. Do not route without Cutter Head Dust Shroud in place.

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LIMITED WARRANTY
MODEL 30 PAVEMENT ROUTER
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 in-service
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.
WARNING:
Use of replacement parts other than geniune Crafco parts
may impair the safety or reliability of your equipment and nullifies
any warranty.

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WARRANTY CLAIM INSTRUCTIONS
MODEL 30 PAVEMENT ROUTER
Crafco, Inc. warrants parts and machinery purchased through Crafco or one of its affiliated
distributors for two years from purchased or in-service date. Wear items are not covered
under the Crafco, Inc. limited warranty. A wear item is defined as but not limited to: cutters,
tires, etc.
If parts fail to function within the two years of purchase, a return authorization number (RA)
must be obtained. If the part was purchased through Crafco, Inc., please contact Crafco
returns department at [e-mail] for an RA number or if purchased through a
Crafco distributor please 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.
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.

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CONTACT US
MODEL 30 PAVEMENT ROUTER
For Warranty:
Crafco, Inc.
25527 South Arizona Avenue, Chandler, AZ 85248
Phone: [phone] or [phone]
Fax: [phone]
For all other inquiries:
Crafco, Inc.
6165 West Detroit Street, Chandler, AZ 85226
Phone: [phone] or [phone]
Fax: [phone]
[e-mail]

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SPECIFICATIONS
MODEL 30 PAVEMENT ROUTER
Engine.................................................................................. 2 Cylinder- CH752-3110
(27 HP) (20Kw)
Weight.................................................................................. 534 Lbs. (242 Kg)
Fuel....................................................................................... Unleaded Gasoline
Fuel Tank Capacity.............................................................. 6 Gallons (22.7 Liter)
Maximum Depth of Cut....................................................... 1 - 5/8” (41.3 mm)
Depth.................................................................................... 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”
(298.5 mm) diameter cutter
head
Cutter Style:.......................................................................... Hardened steel with carbide
cutter tips
Crack Cleaning................................................................... Up to 1500 Linear Feet (457
Linear Meters) per hour

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INTRODUCTION
MODEL 30 PAVEMENT ROUTER
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 exter-
nal 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 forward and route cracks at the
same time. The handle bar has two seperate 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.
CRAFCO, Inc. and its Distributors assume no liability for accident or injury incurred through
improper use of this machine.
DO 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.
4. Check engine cooling air intake and external surfaces of engine. Clean if dirty or
obstructed.
5. Check that the air cleaner components and all shrouds, equipment covers, and guards
are in place and securely fastened.

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ENGINE OPERATING INSTRUCTIONS
MODEL 30 PAVEMENT ROUTER
Cold Weather Starting Hints
1. Be sure to use the proper engine oil for the temperature expected. See Kohler Owners
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.
NOTE: Winter grade gasoline has a higher volatility to improve starting. Do not use
gasoline leftover from summer.
Starting
1. To start engine, place the throttle control midway in the “slow” position, and place
the 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.
2. 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.

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ENGINE OPERATING INSTRUCTIONS (Continued)
MODEL 30 PAVEMENT ROUTER
3. For a Cold Engine: Gradually return the choke control to the “off” position after the
engine starts and warms up. The engine/equipment may be operated during the
warm-up period, but it may be necessary to leave the choke partially on until the engine
warms up.
4. For a Warm Engine: Return the choke to “off” position as soon as engine starts.
Stopping
Place the throttle control midway between the “slow” and “fast” positions. Allow the engine
to run a minimum of 15 seconds; then stop the engine.
Battery
A 12 volt battery is used. If the battery charge is not sufficient to crank the engine, recharge the
battery.
OPERATING
Angle of Operation
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.
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
intake and cooling areas can cause extensive damage due to overheating.
WARNING: 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 oper-
ate the engine with heat shields or guards removed.
Engine Speed
NOTE: Do not tamper with the governor setting or increase the maximum engine speed.
Overspeed is hazardous and will void the engine warranty. The high idle speed
for this engine is 3750 RPM, no load.

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OPERATING PROCEDURES
MODEL 30 PAVEMENT ROUTER
WARNING: Lethal Exhaust Gases!
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.
NOTE: STEPS 1 THROUGH 6 APPLY ONLY TO THE DUST
CONTROL ROUTER. OTHERWISE MOVE DOWN TO
ITEM NUMBER 7.
ATTACHING CUTTER HEAD DUST SHROUD
1. To make attaching the cutter head dust shroud more accessible, raise the front of the
router. To raise the front of the router, push down on the handle bars until the router is
resting on the handleand the corner of the frame assembly. (Figure 1)
Figure 1
2. 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. Install the pin and secure with washer and 5/16” x 3/8”
hairpin.

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OPERATING PROCEDURE (Continued)
MODEL 30 PAVEMENT ROUTER
NOTE: ATTACHING CUTTER HEAD DUST SHROUD CONTINUED
3. 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. (Figure 2)
Figure 2
4. Lower the router back onto its wheels.
5. Make sure the large particle dust collection bin is empty and is securely attached to
mounting bracket before beginning your routing operation.
6. 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 over-tighten 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.
7. Raise the cutter mechanism by pushing the rocker switch to the up position.
8. Open fuel valve on bottom of fuel tank.
NOTE: ATTACHING CUTTER HEAD DUST SHROUD COMPLETED

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OPERATING PROCEDURE (Continued)
MODEL 30 PAVEMENT ROUTER
9. Start engine. Refer to page 12-13 for complete engine starting instructions.
NOTE: It is recommended that you read the Kohler Owners Manual before starting the
engine.
10. Black smoke from the exhaust and a rough running engine usually indicate
over-choking.
TO CLEAN JOINTS AND CRACKS
11. Open throttle for maximum engine speed. Position machine over joint and line up
pointer with joint. Engage electric clutch by pulling up on “Clutch” handle. Machine is
operated by manually guiding the machine while walking backwards. The stabilizer
mechanism is designed to stabilize the machine and to act as a brake. Always engage
electric clutch before lowering cutter head into the joint.
WARNING:
The Model 30 pavement router pushes toward operator when routing. Tightly
compacted surfaces, deep or wide cuts, 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 “Clutch”
handle, which disengages the electric clutch. Push machine handle away.
12. Engage electric clutch by pulling up on “Clutch” handle. Lower cutter head until
cutters slightly touch the surface. Notice shade and number on the depth indicator
(Figure 3). Each shade represents approximately 1/4 inch (6.35 mm) depth variation.
Figure 3

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OPERATING PROCEDURE (Continued)
MODEL 30 PAVEMENT ROUTER
13. 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 Section, page 35). 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 4) 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.
Figure 4

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NOTE: STEPS 14 THROUGH 17 APPLY ONLY TO THE DUST
CONTROL ROUTER. OTHERWISE MOVE DOWN TO
ITEM NUMBER 18.
WARNING:
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.
14. As you begin to route, the dust that is sucked up from the cutterhead 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)
When beginning a routing operation, check the large particle dust collection bin
frequently to gauge the 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. (Figure 5) Beyond this point, 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.
OPERATING PROCEDURE (Continued)
MODEL 30 PAVEMENT ROUTER
Figure 5

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OPERATING PROCEDURE (Continued)
MODEL 30 PAVEMENT ROUTER
NOTE: DUST CONTROL ROUTER OPERATING PROCEDURES CONTINUED
15. To empty the large particle dust collection bin, reduce engine speed to idle. Support the
bottom of the large particle dust collection bin with one hand, keeping the large particle
dust collection bin pressed up firmly against the mounting bracket. With your other
hand, unlatch the rubber latches on the large particle dust collection bin.
CAUTION:
(The large particle dust collection bin weighs approximately 30 lbs when full)
Dump the large particle dust collection bin in a larger receptacle where it
can be disposed of properly at a later time. Reattach the large particle dust collection
bin to the mounting bracket. Return engine to high speed and continue routing.
16. While the engine is at idle during the previous step, gently shake or lightly tap sides of
the dust collection bag with your hand.
NOTE: During router operation, what dust isn’t spun out by the cyclone, enters the 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 page 58)
17. 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. 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.
NOTE: DUST CONTROL ROUTER OPERATING PROCEDURES COMPLETED
18. As cutters wear , depth of cut will change. To compensate for cutter wear, repeat
step #2 as often as necessary to reset depth.
19. When cutters will no longer cut to desired depth, they must be replaced. Refer to
cutter changing section on Page 26.
20. Governor speed is set for the most efficient cutting action. Increasing engine
speed may hinder cutter action and also void warranty.

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OPERATING PROCEDURE (Continued)
MODEL 30 PAVEMENT ROUTER
NOTE: STEP 19 APPLIES ONLY TO THE SELF-PROPELLED
ROUTER
21. Reduce engine to idle, stand at the operators position, raise the handle sightly so the
router is not resting on the skid plate. 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 and release the drive handle when your ready to stop moving.
STORING THE MACHINE
MODEL 30 PAVEMENT ROUTER
CRAFCO Model 30 Pavement Router and Self-Propelled Router.
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 with engine in a near level position.
Dust Control Router
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.