Crafco 200 User manual

MODEL 200
PAVEMENT CUTTER
PART MANUAL - 26340
Rev. “B”

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Revised: 7/2002

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MODEL 200 PAVEMENT CUTTER

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TABLE OF CONTENTS
Model200PavementCutter............................................................................................... 5
SafetyPrecautions...............................................................................................................6
LimitedWarranty.................................................................................................................. 7
WarrantyClaimInstructions.................................................................................................8
Specifications.......................................................................................................................9
Introduction............................................................................................................................10
OperatingInstructions
MachineStartUp..........................................................................................11-12
EngineOperatingInstructions.....................................................................12-13
StoringtheMachine.....................................................................................14
InstructionsforOrderingParts.................................................................... 14
StabilizerMechanism.................................................................................. 15
Maintenance Maintenance.................................................................................................16-17
PeriodicMaintenance................................................................................. 18
MaintenanceSchedule................................................................................19
ServiceandMaintenanceInstructions.......................................................20-21
ChangingCutters......................................................................................... 22
AlternateCutterPositioning........................................................................23
InstallingNewCutterHeadandMainShaft...............................................24
ChangingCutterHeads...............................................................................25
ChangingV-Belts......................................................................................... 26
ElectricClutch...............................................................................................26
Trouble-Shooting
Trouble-ShootingGuide.............................................................................. 26
Parts CutterHeadAssemblyComplete -DiagramandParts.......................... 27-28
Model200PavementCutterDiagramsand Parts...................................29-32

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MODEL 200
PAVEMENT CUTTER
Thismanualis furnishedwith eachnew CRAFCO PAVEMENT CUTTER. Thismanual will
helpyour machineoperatorslearntorunthemachine properlyandunderstanditsmechanical
functionsfor trouble-freeoperation.
Your CRAFCO MODEL 200 isdesigned togiveexcellent serviceand savemaintenance
expense. However,as withall specificallyengineered equipment,you canget bestresultsat
minimumcosts if:
(1) Youoperate yourmachineasinstructedin thismanual, and
(2) Maintainyourmachine regularlyasstatedinthis manual.
WARNING:
Theengine exhaustfromthisproductcontains chemicalsknown tothe
Stateof Californiato causecancer, birthdefects orother reproductive
harm. Operatein wellventilated areaonly. Engine exhaustis deadly.
Manufacturedunder U.S.Patent Numbers4,175,788, and4,204,714, andCanadian Patent
Number1,098,355.
OtherPatents Pending.

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SAFETY PRECAUTIONS
1. Eye and ear protective devices are required when operating the CRAFCO Model 200
PavementCutter. Arespiratorshouldalso beworn ifthe surfacebeingworked withis
dry.
2. Careshouldbetakenwhenoperating machineon grades. Itis usuallybest tooperate
themachine goinguphill.
3. To stopor slowmachine,pushdownon handle.
4. Whencleaningjoints nearmoving traffic,always movein adirection awayfrom trafficto
protectthe operator.
5. Tires shouldbeinflated to45 psito allowmachine toroll easily.
6. Nevertransporttherouterwiththeenginerunning.
7. Neverexceedmaximum recommendedengine RPM.
8. Neverleaverouter unattendedwhileengine isrunning.
9. Neverstandon anypartofthemachine.
10. Theonly operatingposition isbehindthepavementcutterwithboth handson the
handle.
11. Wearlongpants,andheavyleatherbootsor shoes.

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MODEL 200 PAVEMENT CUTTER
LIMITED WARRANTY
Crafco,Inc., throughitsauthorized distributor, willreplace forthe originalpurchaserfreeof
chargeany partsfounduponexaminationbythefactoryatMesa,Arizona, tobe defectivein
materialorworkmanship. Thiswarrantyis fora periodwithin 60daysofpurchasedate, but
excludesengine orcomponents,tires,andbatteryastheseitemsaresubjecttowarranties
issuedbytheirmanufacturers.
TheresponsibilityofCrafcounder thiswarranty islimited toreplacementorrepairof defective
parts atCrafco’sChandler,Arizona factory,orat apoint designatedbyit, ofsuch partsasshall
appeartoCrafco, uponinspection atsuch point,tohave beendefective inmaterial or
workmanship,with expensefor transportationtobebornbytheoriginal purchaser. Thelabor
coveredby thiswarranty includesonly thatlabor whichis requiredto repairthe defectivepart
itself,andnot thatlabor requiredto gainaccessto thepart.
Crafco,Inc. shallonly beliable whenthe equipmentis usedin compliancewith thosedirections
specifiedin themanufacturer’sinstructions.
Thewarranty providedherein extendsonlytotherepair and/orreplacement ofthose
componentson theequipmentcoveredaboveanddoesnotextendtoincidentalor
consequentialdamages incurredas aconsequence ofany defectscoveredbythiswarranty.
Thiswarranty shallnot applyto anymachine orparts alteredand modifiedwithout Crafco’s
consent,nor shallitapplytonormalwearandtearorwhenmisuse,negligenceor accidentare
evident,or whenmachineshavebeenoperatedatspeedsorloads beyondfactory-rated
capacities or specifications.
Allwarrantiesexpressed orimplied arevoid ifotherthan genuineCrafco cuttersand pinsare
used.
Crafco,Inc. specificallydisavows anyotherrepresentation, warranty,orliabilityrelatedtothe
conditionor useof theproduct.
WARNING:
Useof replacementparts otherthan geniuneCrafco parts
mayimpair thesafety orreliability ofyour equipmentand nullifies
anywarranty.

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WARRANTY CLAIM INSTRUCTIONS
Pleasefollow theinstructions statedbelowwhencallingin aWarrantyClaim. Failuretofollow
theseprocedures maybe causeto voidthe warranty.
1. CallyourlocalCrafcoDistributor. Ifyoudonotknowwhoyourlocaldistributoris,call
aCrafcoCustomerServiceRepresentative,(TollFree1-800-528-8242)for name,
location,andtelephonenumber.
2. Oncontactingthedistributor, bepreparedto identifythe serialnumber,modelnumber,
enginemodel, enginemanufacturer,andthedateofpurchaseifavailable.
SerialNumber: ____________________
ModelNumber: ____________________
EngineModel (H.P.): ____________________
EngineManufacturer: ____________________
DateofPurchase: ____________________
3. Shouldthecause ofthe malfunctionbe adefective part,the Distributorwill adviseyou
ofthe procedureto followfor areplacement.
4. Thewarrantyis validonly forparts, whichhavebeensuppliedorrecommendedby
Crafco,Inc.
Ifyou haveany additionalquestions regardingwarranty repairsand parts,please donot
hesitatetocalltollfree 1-800-528-8242.
CRAFCO,INCORPORATED
235SOUTH HIBBERTDRIVE
MESA, AZ. 85210
480-655-8333
TollFree 1-800-528-8242

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SPECIFICATIONS
Engine.................................................................................. 2 Cylinder-CH25
(25HP)
Weight.................................................................................. 425 Lbs.
Fuel....................................................................................... UnleadedGasoline
FuelTankCapacity.............................................................. 6Gallons
MaximumDepthofCut....................................................... 1 - 5/8”
Depth.................................................................................... Depth gauge for precise
depthcontrol.
SafetyFeatures.................................................................. Brakingsystem, safetyguards,
electricclutch
DepthControl...................................................................... Electricactuator forfingertip
depthcontrol.
CutterDesign...................................................................... 6 radiallylocatedsprocket
shapedcutterson11 3/4”
diametercutter head
CutterStyle:.......................................................................... Hardenedsteelwithcarbide
cuttertips
CrackCleaning................................................................... Up to 1500 L.F.per hour

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MODEL 200 PAVEMENT CUTTER
OPERATING INSTRUCTIONS
INTRODUCTION
The CRAFCO Model 200 Pavement Cutter was designed specifically to widen and clean
joints and cracks in asphalt and concrete surfaces. The CRAFCO Model 200 is not intended
tobeused toclean oldsealant fromjointsand cracks.
CRAFCO,Inc. andits Distributorsassume noliability foraccident orinjuryincurredthrough
improperuseofthismachine.
DO NOT operatemachinewithoutreadingoperator’smanual andbeing thoroughlyfamiliar
withcontrols:
1. Checkenginecrankcase oil. Addoil iflow. RefertoEngine OperatorsManual.
2. Fillenginegastankwithclean, fresh,unleaded gasoline. See“Fuel
Recommendations”in EngineOperators Manual.
3. Checktireinflation. Proper tireinflation is45psi. Machine willbe difficulttoroll with
underinflated tires.
4. Checkenginecooling airintake andexternal surfacesofengine. Clean ifdirty or
obstructed.
5. Checkthatthe aircleaner componentsand allshrouds, equipmentcovers,andguards
arein placeand securelyfastened.

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MACHINE START UP
OPERATING PROCEDURE
WARNING: Lethal Exhaust Gases!
Engineexhaustgasescontainpoisonous carbonmonoxide. Carbon monoxideis odorless,
colorless,and cancause deathifinhaled. Avoidinhaling exhaustfumes, andneverrunthe
engineina closed buildingor confined area.
1. Raisethecutter mechanismby movingthe toggleswitch totheright.
2. Openfuelvalve onbottomof fueltank.
3. Startengine. Refer topage 12-13for completeengine startinginstructions.
NOTE: Itis recommendedthatyoureadtheKohlerOwnersManualbeforestarting the
engine.
4. Blacksmokefrom theexhaustandaroughrunningengine usuallyindicate
over-choking.
TO CLEAN JOINTS AND CRACKS
1. Openthrottleformaximumenginespeed. Positionmachineoverjointandlineup
pointerwith joint. Engageelectric clutchby pullingup on“T” handle. Machineis
operatedby manuallyguiding themachine whilewalking backwards. Thestabilizer
mechanism is designed to stabilize the machine and to act as a brake. Always engage
electricclutch beforelowering cutterheadintothejoint.
WARNING:
TheModel 200pavementcutter pushestowardoperatorwhencutting. Tightly
compactedsurfaces,deep orwide cuts,orhard aggregatemay causesudden
machinemovementtowardoperator. This “kickback”could causeoperatorto lose
hisbalance orcontrol ofmachine resultingin seriouspersonalinjury. When operating,
keepwear platein contactwith pavementand holdhandle withboth hands. For
EmergencyStop, pushdown firmlyonmachinehandleor releasesafety“T”handle
whichdisengages electricclutch. Push machinehandleaway.
2. Engageelectricclutchbypulling upon“T”handle. Lowercutterhead untilcuttersslightly
touchthesurface. Noticeshadeon thedepth indicator(Figure 1). Eachshade
representsapproximately 1/4inch depthvariation.
3. Do not try to go too fast. Do not overload the engine. Overloading the engine will
slowcuttingactionandcause damageto engineand drivecomponents. Abouncing
orhammering actionusually indicatesthe machineis movingtoo fastor thecutters
haveworn outof round(refer toTroubleshooting Section,page26). Let themachine
thoroughlyclean thejoint. For deepcuts (deeperthan 3/4inch) itmay benecessary to
make two passes. Use brake as required to keep machine under complete operator
control. For emergency stop, push down firmly on handle or release safety “T”
handle which disengages electric clutch. Push machine handle away.
4. Ascutterswear, depthof cutwill change. Tocompensate forcutter wear, repeatstep
#2asoften asnecessary toresetdepth.

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5. Whencutterswillnolongercuttodesireddepth,theymust bereplaced. Refer tocutter
changingsectionon Page25.
6. Governorspeedinfactorsetforthemostefficientcuttingaction. Increasingengine
speedmay hindercutter actionand alsovoid warranty.
ENGINE OPERATING INSTRUCTIONS
Cold Weather Starting Hints
1. Besureto usethe properengine oilforthe temperatureexpected. See KohlerOwners
Manualforrecommended SAEViscosity Grades.
2. Setspeedcontrolatpart throttleposition.
3. Awarmbattery hasmuch morestartingcapacitythanacoldbattery.
4. Usefreshwinter gradefuel. NOTE: Wintergrade gasolinehas ahighervolatility to
improvestarting. Donotusegasolineleftover fromsummer.
Starting
1. For a Cold Engine: Place the throttle control midway between the “slow” and“fast”
positions. Placethechoke controlinto the“on” position.
For a Warm Engine (normal operating temperatures): Place the throttle control
midwaybetweenthe “slow” and“fast” positions. Place thechokecontrol intothe
“on” position.
2. Starttheenginebyactivatingthekey switch. Releasethe switchas soonas theengine
starts.
NOTE: Do notcrank theengine continuouslyfor morethan 10seconds ata time.
Iftheenginedoesnot start,allow a60 secondcooldown periodbetween
startingattempts. Failure tofollow theseguidelines canburn outthe
startermotor.
NOTE: Upon startup ametallic tickingmay occur. This iscausedby the
hydrauliclifter leakdownduring storage. Runtheenginefor5 minutes.
Thenoise willnormallyceaseinthe firstminute. Ifnoisecontinues,run
theengineatmidthrottlefor20 minutes. Ifnoise persists,take theen-
gineto yourlocal KohlerService outlet.
NOTE: If theengine developssufficientspeed todisengagethestarter, butdoes
notkeep running(a falsestart), theengine rotationmust beallowed to
cometoacompletestop beforeattempting torestart theengine. Ifthe
starteris engagedwhile theflywheel isrotating, thestarter pinionand
flywheelring gearmay clash,resulting indamagetothestarter.
Ifthe starterdoesnotturntheengineover, shutoffstarterimmediately. Do notmake
furtherattempts tostart theengine untilthe conditionis corrected. Donot startusing
anotherbattery. Seeyour KohlerEngine ServiceDealer fortrouble analysis.

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ENGINE OPERATING INSTRUCTIONS (Continued)
3. For a Cold Engine: Graduallyreturn thechoke controlto the“off” position afterthe
enginestarts andwarms up. Theengine/equipment maybe operatedduring thewarm
upperiod, butit maybenecessarytoleavethechokepartiallyonuntiltheengine
warmsup.
4. For a Warm Engine: Return the choke to “off” position as soon as engine starts.
Stopping
Placethe throttlecontrolmidwaybetweenthe “slow”and “fast”positions. Allowtheengine
torun aminimum of15seconds;thenstoptheengine.
Battery
A12 voltbattery isused. If thebattery chargeis notsufficient tocrank theengine, rechargethe
battery.
OPERATING
Angle of Operation
Theenginewilloperatecontinuouslyatangles upto 25degrees. Check oillevel toassure
crankcaseoillevel isat the“F” mark onthe dipstick. Donotoperate theengine continuously
atanglesexceeding25degrees inany direction. Enginedamage couldresultfrom insufficient
lubrication.
Cooling
NOTE: If debris builds up on the screen or other cooling air intake areas, stop the engine
immediatelyandclean. Operatingtheengine withblocked ordirtyairintakeand cooling
areascan causeextensivedamageduetooverheating.
WARNING: Hot Parts!
Enginecomponents canget extremelyhot fromoperation. To preventsevereburns,donot
touchthese areaswhere theengine isrunning orimmediately afterit isturned off. Never
operatethe enginewithheatshieldsorguardsremoved.
Engine Speed
NOTE: Donottamper withthe governorsetting inincreasethe maximumengine speed.
Overspeedis hazardousandwillvoidtheenginewarranty. The highidle speedforthisengine
is 3750 RPM, no load.

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STORING THE MACHINE
DO NOT resttheweight ofthe machineon therubberrock deflectoror rubberwill become
deformedmaking deflectorunfunctional. Store withengineinanearlevelposition.
INSTRUCTION FOR ORDERING PARTS
Partsmaybe orderedfrom yourlocal CRAFCOdistributoror directlyfrom CRAFCO,Inc.if a
distributoris notavailable inyourarea. Whenorderingparts,givethefollowinginformation:
1. PartNumber
2. MachineModel
3. SerialNumberfromNamePlate
Write, telephone or fax:
CRAFCO,INC.
235SOUTH HIBBERT
MESA,AZ 85210
480-655-8333
480-655-1712 (FAX)
TollFree: 1-800-528-8242

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FIGURE 1
STABILIZER MECHANISM
Astabilizermechanism (SeeFigure 1)is usedonthe CrafcoPavement Cutterto improvethe
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
surfacewhile machineisinoperation.
Wearplate (PartNo. 31065)shouldbe replacedbefore wearreachesthe attaching bar.

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MAINTENANCE
Oil Recommendations:
Usingtheproper typeand weightof oilinthe crankcaseis extremelyimportant. So ischeck-
ingoildailyandchanging oilregularly. Failure touse thecorrectoil, orusing dirtyoil, causes
prematureengine wearand failure.
Oil Type:
Usehigh qualitydetergent oilofAPI (AmericanPetroleum Institute)serviceclassSGorSH.
Selecttheviscositybasedon theair temperatureatthetimeof operationas showninthe
followingtable.
NOTE: Using otherthan serviceclassSGorSH oilor extendingoil change
intervalslonger thanrecommended cancause enginedamage. Referto
theMaintenance instructionson page22 ortheKohlerOwnersManual for
detailedoilcheck, oilchange, andoil filterchangeprocedures and
intervals.
Fuel Recommendations:
WARNING: Explosive Fuel!
Gasolineisextremelyflammableand itsvapors canexplode ifignited. Store
gasolineonly inapproved containers,inwellventilated,unoccupiedbuildings
awayfromsparksorflames. Do notfill thefuel tankwhile theengine ishotor
running,sincespilledfuelcouldigniteif itcomes incontact withhot partsor
sparksfromignition. Donotstart theengine nearspilled fuel. Neveruse
gasolineasacleaningagent.

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MAINTENANCE (Continued)
General Recommendations:
Purchasegasolineinsmallquantitiesandstore inclean, approvedcontainers. A
containerwitha capacityof 2gallons orlesswith apouring spoutis recommended.
Suchacontaineriseasiertohandle andhelps eliminatespillage duringrefueling.
Tominimize gumdeposits inyour fuelsystem andtoinsureeasystarting. Donot use
gasolineleft overfrom theprevious season.
Do not add oil to the gasoline.
Donot overfillthe fueltank. Leave roomfor thefueltoexpand.
Fuel Type:
Forbest resultsuse onlyclean, fresh,unleaded gasolinewith apump stickeroctane
ratingof 87orhigher. Incountries usingthe Researchmethod, itshouldbe90octane
minimum.
Unleadedgasolineis recommendedas itleavesless combustionchamberdeposits.
Leadedgasolinemaybeused inareas whereunleaded isnotavailable andexhaust
emissionsare notregulated. Be aware,however, thatthe cylinderheads mayrequire
morefrequent service.
Gasoline/Alcohol Blends:
Gasoline(upto10%ethylalcohol,90% unleadedgasoline byvolume) isapproved asa
fuelfor Kohlerengines. Other gasoline/alcoholblends arenot approved.
Gasoline/Ether Blends:
MethylTertiaryButyl Ether(MTBE)andunleadedgasoline blends(uptomaximumof
15%MTBE byvolume)areapprovedasafuelforKohler engines. Othergasoline/ether
blendsare notapproved.
BATTERY
Checkcharge condition. Checkelectrolyte level. Add distilled water to keep
electrolyteat itsproperlevel. In freezingweather,runengineimmediatelyafteradding
water. Keepbattery connectionstight andclean.
WARNING: Explosive Gas!
Batteriesproduceexplosivehydrogengas whilebeing charged. Toprevent afire or
explosive,charge batteriesonlyinwellventilatedareas. Keepsparks, openflames,
andothersources ofignition awayfrom thebatteryat alltimes. Keep batteriesout of
thereach ofchildren. Removealljewelrywhen servicingbattery.

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PERIODIC MAINTENANCE
Followaregularscheduleof inspectionand servicing,basedonoperatinghours. Keep an
accuratelogbook ofmaintenance,servicing,andoperatingtime. Usethe factory
recommendedPeriodicMaintenanceSchedule(based onfavorable operatingconditions) to
serveasa guide toget long andefficientengine life.
Forsevere duty,extreme temperature,etc.,servicemorefrequently. Neglectingroutine
maintenancecan resultin enginefailure orpermanentdamage.
Foranyabnormalitiesinoperation,unusualnoises fromthe engineor accessories,loss of
power,overheating,etc.,contactyournearestKohlerServiceCenter.
WARNING:
Inhalationof exhaustgasescanresultin seriouspersonalinjuryordeath.
DO NOT usetheair cleaneror exhaustelbowas asupporting step.
Damageof theseandconnectingpartsmightcauseanexhaustleak.
WARNING: Accidental Starts!
Beforeservicing theengine orequipment onthe machine,always
disconnectthe sparkplug leadsto preventthe enginefrom starting
accidentally. Groundthe leadsto preventsparks thatcouldcausefires.

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MAINTENANCE SCHEDULE
Theserequired maintenanceprocedures shouldbe performedat thefrequency statedin the
chartbelow. Theyshould alsobe includedaspartof anyseasonal tune-up.
*Performthese maintenanceprocedures morefrequently underextremely dusty, dirtyconditions.
**HaveaKohler EngineServiceDealer perform thisservice.

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SERVICE AND MAINTENANCE INSTRUCTIONS
For longer engine life the Model 200 has been fitted with a High CapacityAir Cleaner
(primary)andsecondaryelement. Duetothedusty conditionscreated duringoperation, itis
necessarytoservicetheair cleanerwhen itbecomes cloggedwithdirt.
Tochange theprimary aircleanerelement,loosentheclampandremovetheaircleanercap.
1. Serviceelementonly whenrestrictionindicatorreaches theservicelevel(indicator
popsup). Itisonlyabove thatpoint thatair cleanerrestriction beginstoreduceengine
performancelevel. When restrictionfinally indicatesachange,removetheprimary
elementcarefully. When elementreplacementisneededuseCrafco31334(Kohler25-
083-01)
2. Donotattempt to cleanthe dirtyelement. Rapping, orpoundingdirtoutis dangerous
and could cause damage to the element.
3. Carefullychecknew element fordamagebeforeinstalling.
4. Reinstallnewelement, replaceaircleanercapandfastenretainingclips.
Checkthe secondaryelement (safety)only if theprimary aircleaner elementwas damaged.
1. Removetheair cleanercover.
2. Removetheprimaryelement.
3. Removethesafetyelement
4. Handlenewelementscarefully: donotuseifthesealingsurfaces arebent ordamaged.
5. Reinstallthenewsafetyelement,primaryelement andair cleanercap. Fastenretain-
ing clips
6. Whenelementreplacementisnecessary, orderCrafco P/N31345 (Kohler
25-083-04)
Checkengineoildaily. Changeoil afterevery 100hours ofoperation. Change oilfilterevery
200hours. UseCrafco P/N 31330orKohler P/N12-050-01. (Referto engine owners
manual).
Checkengineoildaily. Changeoil afterevery 100hours ofoperation. Change oilfilterevery
200hours. UseCrafco P/N 31330orKohler P/N12-050-01. (Referto engine owners
manual.)
Checkfluidlevelinbattery regularly.
Every50 hoursof operationclean outcooling finson engine. Ifdust isallowedtoaccumulate
overheatingmay occur, causingdamage tothe engine.
Lubricatecutter shaftbearings every100 hoursusingmulti-purposegrease.
Lubricateframe pivotevery 50hours usingmulti-purpose grease.
Tightenall boltsonmachinefrequently.