Ergon Crafco 100G Programming manual

CRACK-VAC
MODEL 100G
Operator/Parts Manual –26627N
Revision O

Fill in appropriate fields that apply to this machine
Machine S/N: ________________________________
Engine S/N: ________________________________
Blower S/N: _________________________________
Compressor Engine S/N: ______________________
Compressor S/N: _____________________________

Crack-Vac Model 100G Manual
Revisions
Revision
Date

CRACK-VAC MODEL 100G with COMPRESSOR
P/N 60900N
CRACK-VAC MODEL 100G
P/N 60800N

Crack-Vac Model 100G 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 ........................................................................................................2-2
2.4 California Proposition 65......................................................................................................................2-3
All Crafco Inc. Equipment...................................................................................................2-3
All Crafco Inc. Equipment using a gasoline engine ............................................................2-3
2.5 Safety Symbols and Notices.................................................................................................................2-4
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.....................................................................................................5-1
5.2 Starting the Blower Engine ..................................................................................................................5-5
5.3 Starting the Compressor Engine ..........................................................................................................5-6
5.4 Cold Weather Starting..........................................................................................................................5-7
5.5 Battery..................................................................................................................................................5-7
5.6 Stopping the Blower Engine.................................................................................................................5-7
5.7 Stopping the Compressor Engine.........................................................................................................5-7
5.8 Compressor Operating Principles ........................................................................................................5-8
Air Compressor...................................................................................................................5-8
Oil Separation and Cooling.................................................................................................5-8
Minimum Pressure Check Valve ........................................................................................5-8
Filtration.............................................................................................................................5-8
Automatic Overheat Shut Down........................................................................................5-8
5.9 Filtering System....................................................................................................................................5-9
Cyclonic Separator .............................................................................................................5-9
Main Cartridge Filter........................................................................................................5-10
HEPA after Filter...............................................................................................................5-12
5.10 Debris Storage Tank.........................................................................................................................5-14
5.11 EZ Glide Vacuum Wand....................................................................................................................5-15
5.12 Mounting CrackVac on a Truck or Trailer ........................................................................................5-17
6.0 Maintenance Instructions....................................................................................................................6-1
6.1 Engine Oil Recommendations..............................................................................................................6-1
Oil Type ..............................................................................................................................6-1
6.2 Fuel Recommendations .......................................................................................................................6-2

Crack-Vac Model 100G Manual
Table of Contents
General Recommendations ...............................................................................................6-2
Fuel Type............................................................................................................................6-2
Gasoline/Alcohol Blends ....................................................................................................6-2
Gasoline/Ether Blends........................................................................................................6-2
6.3 Evaporative Emission Control System..................................................................................................6-3
6.4 Battery..................................................................................................................................................6-3
Battery Recharging (compressor battery)..........................................................................6-3
6.5 Periodic Maintenance..........................................................................................................................6-4
6.6 Maintenance Schedule ........................................................................................................................6-5
6.7 Service Instructions..............................................................................................................................6-6
6.8 General Maintenance Parts .................................................................................................................6-6
6.9 Rotary Air Blower.................................................................................................................................6-7
Bearing Lubrication............................................................................................................6-7
Oil service...........................................................................................................................6-7
V-Belts................................................................................................................................6-7
Storing Procedures.............................................................................................................6-7
6.10 Hydraulic System................................................................................................................................6-8
6.11 Suction and Exhaust Hoses ................................................................................................................6-8
6.12 EZ Glide Wand Assembly ...................................................................................................................6-8
6.13 Compressor........................................................................................................................................6-8
Compressor Engine ............................................................................................................6-8
Compressor Oil...................................................................................................................6-9
Blowdown Muffler. ............................................................................................................6-9
Pressure Relief Valve........................................................................................................6-10
Coalescing Filter...............................................................................................................6-10
Air Intake Filter.................................................................................................................6-11
Compressor Drive Belt .....................................................................................................6-12
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 Troubleshooting...................................................................................................................................8-1
9.0 Illustrated Parts List .............................................................................................................................9-1
9.1 About the Illustrated Parts List ............................................................................................................9-1
9.2 Ordering Crafco Parts...........................................................................................................................9-1
9.3 CrackVac Parts List ...............................................................................................................................9-2
9.4 Blower Drive Components Parts List....................................................................................................9-8
9.5 Suction Wand Assembly Parts List.....................................................................................................9-12
9.6 Compressor Assembly Parts List ........................................................................................................9-14

Crack-Vac Model 100G Manual
List of Figures
Figure 5-1 Hydraulic Pump and Reservoir .................................................................................................5-3
Figure 5-2 Rotary Blower Fluid Level .........................................................................................................5-3
Figure 5-3 Compressor Fluid Level.............................................................................................................5-4
Figure 5-4 Filter Housing Cutaway.............................................................................................................5-4
Figure 5-5 Debris Storage Bucket.............................................................................................................5-10
Figure 5-6 HEPA Filter & Housing.............................................................................................................5-13
Figure 5-7 Debris Storage Tank Door.......................................................................................................5-14
Figure 5-8 Debris Storage Tank Switch ....................................................................................................5-15
Figure 5-9 Wand Wheel Spacers..............................................................................................................5-16
Figure 5-10 Wand Routed Crack Brush Location .....................................................................................5-16
Figure 5-11 Truck Mounted Unit..............................................................................................................5-17
Figure 6-1 Oil Viscosity Chart.....................................................................................................................6-1
Figure 6-2 Blowdown Muffler, Relief Valve, Coalescing Filter.................................................................6-11
Figure 6-3 Compressor Air Filter Housing................................................................................................6-11
Figure 6-4 Replacing Compressor Drive Belt............................................................................................6-12
Figure 7-1 Standard Multimeter ................................................................................................................7-2
Figure 7-2 Clamp-On Amp Meter/Multimeter...........................................................................................7-2
Figure 8-1 Compressor Wiring Schematic..................................................................................................8-5
Figure 8-2 Hydraulic Power Pack Wiring Schematic ..................................................................................8-6
Figure 9-1 Right, Front, ISO View...............................................................................................................9-2
Figure 9-2 Left, Rear ISO View ...................................................................................................................9-4
Figure 9-3 Bottom View.............................................................................................................................9-6
Figure 9-4 Blower Drive Components........................................................................................................9-8
Figure 9-5 Evaporative Emission System .................................................................................................9-10
Figure 9-6 Suction Wand Assembly .........................................................................................................9-12
Figure 9-7 Compressor Assembly (60802N).............................................................................................9-14

Crack-Vac Model 100G Manual
List of Tables
Table 2-1 Safety Symbols and Notices.......................................................................................................2-4
Table 2-2 Safety Symbols and Notices (continued) ...................................................................................2-5
Table 4-1 Machine Specifications ..............................................................................................................4-1
Table 5-1 Preparing the Machine for Start Up...........................................................................................5-1
Table 5-2 Preparing the Machine for Start Up (continued).......................................................................5-2
Table 5-3 Blower Engine Starting Instructions...........................................................................................5-5
Table 5-4 Starting the Compressor Engine ................................................................................................5-6
Table 5-5 Cold Weather Starting Hints ......................................................................................................5-7
Table 5-6 Stopping the Blower Engine.......................................................................................................5-7
Table 5-7 Stopping the Compressor Engine...............................................................................................5-7
Table 5-8 Cyclonic Separator .....................................................................................................................5-9
Table 5-9 Cyclonic Separator (continued)................................................................................................5-10
Table 5-10 Main Cartridge Filter..............................................................................................................5-10
Table 5-11 Main Cartridge Filter (continued) ..........................................................................................5-11
Table 5-12 Main Cartridge Filter (continued) ..........................................................................................5-12
Table 5-13 HEPA Filter Access..................................................................................................................5-12
Table 5-14 HEPA Filter Access (continued)..............................................................................................5-13
Table 5-15 Emptying the Debris Storage Tank.........................................................................................5-14
Table 5-16 Vacuum Wand Operation ......................................................................................................5-15
Table 5-17 Mounting CrackVac on a Truck or Trailer ..............................................................................5-17
Table 6-1 Maintenance Schedule...............................................................................................................6-5
Table 6-2 Service Instructions....................................................................................................................6-6
Table 6-3 General Maintenance Parts .......................................................................................................6-6
Table 6-4 Changing Compressor Oil...........................................................................................................6-9
Table 6-5 Testing the Blowdown Muffler ................................................................................................6-10
Table 6-6 Testing the Pressure Relief Valve.............................................................................................6-10
Table 6-7 Replacing the Coalescing Filter ................................................................................................6-10
Table 6-8 Replacing the Coalescing Filter (continued).............................................................................6-11
Table 6-9 Replacing the Compressor Drive Belt ......................................................................................6-12
Table 8-1 Trouble Shooting Guide Vacuum System...................................................................................8-1
Table 8-2 Trouble Shooting Guide Compressor System ............................................................................8-2
Table 8-3 Trouble Shooting Guide Compressor System (continued).........................................................8-3
Table 8-4 Trouble Shooting Guide Hydraulics ...........................................................................................8-4
Table 9-1 Right, Front ISO View Parts List..................................................................................................9-3
Table 9-2 Left, Rear ISO View Parts List .....................................................................................................9-5
Table 9-3 Bottom View Parts List...............................................................................................................9-7
Table 9-4 Blower Drive Components Parts List..........................................................................................9-9
Table 9-5 Evaporative Emission System Parts List...................................................................................9-10
Table 9-6 Suction Wand Assembly Parts List ...........................................................................................9-13
Table 9-7 Compressor Assembly Parts List ..............................................................................................9-14
Table 9-8 Compressor Assembly Parts List (continued) ..........................................................................9-15

Crack-Vac Model 100G Manual
List of Tables
Table 9-9 Compressor Assembly Parts List (continued) ..........................................................................9-16

Crack-Vac Model 100G Manual
Chapter 1 Introduction
©2020 by Crafco, Inc. All Rights Reserved Introduction 1-1
1.0 About This Manual
This manual is supplied with each new Crafco Crack-Vac Model 100G. The manual assists your
machine operators in the proper use of the Crack-Vac and provides information about the
machine’s mechanical functions for trouble-free operation.
Your Crafco Crack-Vac Model 100G 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.

Crack-Vac Model 100G Manual
Chapter 2 Safety
©2020 by Crafco, Inc. All Rights Reserved Safety 2-1
2.0 Safety Precautions
For more in-depth safety information, please see Safety Manual (P/N 26221) which comes with the
machine. Or contact your nearest authorized Crafco Distributor at crafco.com/Distributors.
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.

Crack-Vac Model 100G Manual
Chapter 2 Safety
©2020 by Crafco, Inc. All Rights Reserved Safety 2-2
2.3 Equipment or Operational Safety
•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.
•Check equipment before every use.
•Do not operate the equipment when fatigued or under the influence of alcohol or drugs.
•Do not modify the equipment.
•Know how to operate the equipment, fully read the manual.
•Refer to the Rotary Air Blower manual for operating procedures and safety precautions.
•Do not start the blower until you are sure oil is at the proper level in the gear housing.
•Blower heat can cause burns if touched. Blower casing and associated piping or
accessories may become hot enough to cause major skin burns on contact.
•The Chamber-Absorption Silencer will be hot to the touch. Do not touch hot surfaces.
•Check the compressor oil level and condition. Do not add or change oil while the system is
running.
•The compressor operates anytime the engine is running. Avoid contact with the compressor,
hoses, oil cooler, or engine during operation. These items can become hot enough to cause
major skin burns on contact.
•Avoid the entrance of water into any part of the machine.
•Shut down engine prior to refilling fuel tank.
•Keep hands, feet and clothing away from all moving parts.
•Replace any hoses or belts which show signs of wear, fraying, or splitting. Assure all fittings
and joints are tight and no leaks are present.
•Use only approved hoses and replacement parts.
•Tighten all bolts and screws every 100 hours of machine operation.
•Never attempt to make repairs to the equipment when the engine is running.
•Never operate the Crack-Vac without belt guards in place.
•Never transport the Crack-Vac with the engine running.
•Never exceed maximum recommended engine RPM.
•Never leave Crack-Vac unattended while engine is running.
•Never stand on any part of the machine.
•When cleaning cracks and joints near moving traffic, always move in a direction away from
traffic to protect the operator.

Crack-Vac Model 100G Manual
Chapter 2 Safety
©2020 by Crafco, Inc. All Rights Reserved Safety 2-3
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
All Crafco Inc. Equipment using a gasoline engine

Crack-Vac Model 100G Manual
Chapter 2 Safety
©2020 by Crafco, Inc. All Rights Reserved Safety 2-4
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
Warning
Refers to possible bodily injury or death.
CAUTION
Caution
Refers to possible equipment damage or operational
malfunction.
Severe Burn Hazard
Hot surfaces can cause severe burns.
Protective Shoes
Wear hard-soled work shoes.
Protective Gloves
Wear heat resistant gloves.
Protective Face or Eye Wear
Wear face shield or safety glasses.
Hearing Protection
Wear ear plugs or earmuffs.
Dust Mask
Wear a dust mask when appropriate.
Body Crush Hazard
Do not stand between trailer and hitch when hooking
a trailer mounted Crack-Vac to a truck.
Table 2-1 Safety Symbols and Notices

Crack-Vac Model 100G Manual
Chapter 2 Safety
©2020 by Crafco, Inc. All Rights Reserved Safety 2-5
Table 2-2 Safety Symbols and Notices (continued)
Symbol
Item
Remark
Crush Hazard
Keep feet and legs clear.
Pinch Hazard
Keep hands and feet clear.
Exhaust Hazard
Avoid breathing engine exhaust.
High Pressure Fluid Hazard
Do not use hands to search for leaks, use cardboard
instead.
Read Manual
Read and understand operator and safety manuals
before operating machine.

Crack-Vac Model 100G Manual
Chapter 3 Warranty Information
©2020 by Crafco, Inc. All Rights Reserved Warranty Information 3-1
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.

Crack-Vac Model 100G Manual
Chapter 3 Warranty Information
©2020 by Crafco, Inc. All Rights Reserved Warranty Information 3-2
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: material pumps, sealing tips, 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 [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.
For Warranty:
Crafco, Inc.
25527 South Arizona Avenue, Chandler, AZ
85248
Phone: [phone] or [phone]
Fax: [phone]
For all other inquires:
Crafco, Inc.
6165 W Detroit St,
Chandler, AZ 85226
Phone: [phone] or [phone]
Fax: [phone]
[e-mail]