Page 1 NOTE Use only Vanair Vanguard™ Making unauthorized modifications to Premium Synthetic Oil and Genuine the system components WILL VOID THE Vanair Parts. Inspect and replace WARRANTY! damaged components before Always inform Vanair Manufacturing, operation. Substituting non- Inc., before beginning any changes to Vanguard™...
Page 2 TO THE GREAT EXTENT PERMITTED BY APPLICABLE LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE Vanair must be noti ed in writing within thirty (30) days of any REMEDIES APPLICABLE TO THE VANAIR EQUIPMENT. IN NO such defect or failure. No warranty work or returns without prior EVENT SHALL VANAIR BECOME LIABLE FOR DIRECT, INDIRECT, authorization is allowed.
Page 3: Table Of Contents
WARRANTY CLAIMS PROCEDURE ......XIII CLAIMS PROCESS FOR WARRANTED PARTS..................XIII PROCEDURE ............................XIII RETURN MATERIAL AUTHORIZATION FORM..................XVI INTRODUCTION..............1 EXPERIENCE THE VANAIR ADVANTAGE .....................1 A NOTE ON MANUAL NAVIGATION ......................2 SECTION 1: SAFETY ............3 GENERAL INFORMATION ......................3 DANGERS, WARNINGS, CAUTIONS, AND NOTES ..............3 INTERNATIONAL SAFETY SYMBOL ....................4...
Page 4 ® ® TABLE OF CONTENTS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY (CONTINUED) 1.4.11 CYLINDERS CAN EXPLODE IF DAMAGED .......................9 1.5 ENGINE HAZARDS........................... 10 1.5.1 BATTERY EXPLOSION CAN BLIND ........................10 1.5.2 FUEL CAN CAUSE FIRE OR EXPLOSION ......................10 1.5.3 MOVING PARTS CAN CAUSE INJURY ......................11 1.5.4...
Page 5 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM TABLE OF CONTENTS SECTION 1: SAFETY (CONTINUED) 1.12 DISPOSING OF MACHINE FLUIDS ....................19 SECTION 2: DESCRIPTION ..........21 FIGURE 2-1: MAJOR MACHINE COMPONENTS LOCATIONS.............20 GENERAL DESCRIPTION......................21 COMPRESSED AIR SYSTEM .......................21 2.2.1 COMPRESSOR UNIT ............................
Page 6 ® ® TABLE OF CONTENTS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 2: DESCRIPTION (CONTINUED) 2.6.14 ENGINE CONTROL (ON/OFF/START) SWITCH....................32 2.6.15 HIGH TEMPERATURE INDICATOR LAMP......................32 2.6.16 LOW OIL PRESSURE INDICATOR LAMP......................32 2.6.17 PREHEAT/START CONDITION INDICATOR LAMP ....................32 2.6.18 FUEL GAUGE/HOUR METER ..........................32 SECTION 3: SPECIFICATIONS.........
Page 7 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM TABLE OF CONTENTS SECTION 5: OPERATION (CONTINUED) 5.4.1.3 CV (CONSTANT VOLTAGE) MODE - USING A SPOOL GUN........51 OPERATING THE GENERATOR ....................53 OPERATING THE AIR COMPRESSOR ..................53 OPERATING THE BATTERY BOOSTER/CHARGER..............54 5.7.1 CONNECTION - DISCONNECTION SEQUENCE AND OPERATION ...............
Page 8 ® ® TABLE OF CONTENTS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE (CONTINUED) 6.6.5 CHANGING THE COMPRESSOR OIL ........................78 6.6.6 REPLACING THE SPIN-ON AIR/OIL COALESCER ....................79 6.6.7 REPAIRING THE COMPRESSOR SHAFT SEAL ....................80 6.6.7.1 PART I - REMOVING THE COMPRESSOR SERPENTINE BELT ......80 6.6.7.2 PART II - ACCESSING THE COMPRESSOR UNIT SHAFT SEAL ......
Page 9 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM TABLE OF CONTENTS SECTION 8: DIAGRAMS ..........115 GENERAL INFORMATION ......................115 WIRING DIAGRAM - AIR N ARC 300 SERIES (DIESEL) .............116 WIRING DIAGRAM - SWITCHES & LIGHTS.................117 TRUNK LINE ASSEMBLY HARNESS ...................118 COMPRESSOR FLOW SCHEMATIC DIAGRAM ................119 SECTION 9: ILLUSTRATED PARTS LIST .....
Page 10 ® ® TABLE OF CONTENTS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM APPENDIX A: ADDITIONAL INFORMATION (CONT.) AIR TOOL AIR CONSUMPTION CHART ..................182 AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM AVAILABLE OPTIONS LIST ....183 HOSE INSTALLATION GUIDE ...................... 185 ELECTRODE IGNITION PROCEDURE ..................
Page 11: Glossary
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM GLOSSARY GLOSSARY: TERMS AND DEFINITIONS G.1 GENERAL TERMS AND Constant Current (CC) Welding Machine - These welding machines have limited DEFINITIONS maximum short circuit current, with consistent amperage regardless of the Air/Oil Separator - Coalescer element.
Page 12: Air Compressor Terms And Definitions
® ® GLOSSARY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM minutes and then must be allowed to cool work. This process can cut all metals that with the fan motor running for 4 minutes. conduct electricity. Pounds Per Square Inch (psi) - A Flux Cored Arc Welding (FCAW) - An arc welding process which melts and joins measurement equal to a mass or weight...
Page 13 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM GLOSSARY compression is completed. They are one of the most effective means of removing moisture from compressed air. Air Receivers - tanks into which the compressed air is discharged from the air compressor.
Page 14 ® ® GLOSSARY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - XII 090012-OP_r0...
Page 15: Warranty Claims Procedure
PROCEDURE LAIMS PROCESS FOR WARRANTED ANAIR PARTS ® This process must be used by owners of Vanair equipment in situations where a warranted item needs repair or replacement under the terms of the purchase warranty. Do not return items to Vanair without prior authorization from the Vanair Warranty Administrator.
Page 16 ® ® WARRANTY PROCEDURE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 800-526-8817 www.vanai r .com MODEL NUMBER SERIAL NUMBER PSIG MAXIMUM PRE SSURE COMPRE SSOR INPUT RPM 260940 Figure W-1: Machine Serial Number Location Part No. MOD No. D902 SER No.
Page 17 6. If the unit cannot be returned to service, and Vanair determines this matter is a warranty issue, the Service Technician will assign an RMA (Return...
Page 18: Return Material Authorization Form
Any invoice issued for labor claims must include the RMA number assigned on this form, the 30-XXXXX number for the unit, and be invoiced for any labor claims within 30 days of the work completion. The allowable Vanair labor rate is $65.00 per hour for all authorized work done in the United States.
Page 19: Introduction
POWER SYSTEM ADVANTAGE! Due to the caustic nature of “un-sealed” lead acid batteries Vanair Mfg., Inc. does not recommend the use of this style of The Air N Arc All-In-One Power System is designed to battery. Acid fumes can cause damage to provide compressed air, DC welding output, AC power, the machine and void the warranty.
Page 20: A Note On Manual Navigation
Manufacturing, Inc. takes no responsibility for errors or consequential damages caused by reliance on the information contained herein. Vanair Manufacturing, Inc. reserves the right to make design change modifications or improvements without prior notification. A NOTE ON MANUAL LAYOUT NAVIGATION Refer to Figure M-1.
Page 21: Section 1: Safety
SECTION 1: SAFETY 1.1 GENERAL INFORMATION IMPORTANT ® The products provided by Vanair Manufacturing, Inc., are designed and manufactured for safe operation and maintenance. But it is ultimately the responsibility of the users and maintainers for safe use of this equipment.
Page 22: International Safety Symbol
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 1.3 INTERNATIONAL SAFETY SYMBOL The symbols shown and defined in Section 1: Safety are used throughout this manual to call attention to and identify possible hazards. The international warning symbol shown above is used on all decals, labels and signs that concern information pertaining to bodily harm.
Page 23 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY Do not work alone! Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tag out input power according to OSHA29 CFR1910.147 (see Section 1.9, Principal Safety Standards).
Page 24: Fumes And Gasses Can Be Hazardsous
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 1.4.2 FUMES AND GASES CAN BE HAZARDOUS Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes.
Page 25: Enclosed Spaces Can Cause Abuild-Up Of Noxious Fumes And Overheating
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY 1.4.4 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING Do not use in enclosed spaces where deadly exhaust gases can build up and machine can overheat, causing fire. 1.4.5 ARC RAYS CAN BURN EYES AND SKIN Arc rays from the welding process...
Page 26: Flying Metal Can Injure Eyes
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
Page 27: Hot Parts Can Cause Severe Burns
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY 1.4.8 HOT PARTS CAN CAUSE SEVERE BURNS Do not touch hot parts bare handed. Allow cooling period before working on equipment. 1.4.9 NOISE CAN DAMAGE HEARING To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
Page 28: Engine Hazards
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve.
Page 29: Moving Parts Can Cause Injury
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY 1.5.3 MOVING PARTS CAN CAUSE INJURY Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing connecting unit.
Page 30: Battery Acid Can Burn Skin And Eyes
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 1.5.7 BATTERY ACID CAN BURN SKIN AND EYES Do not tip battery. Replace damaged battery. Flush eyes and skin immediately with water. 1.5.8 ENGINE HEAT CAN CAUSE FIRE Do not locate unit on, over, or near combustible surfaces or flammables.
Page 31: Compressed Air Can Cause Injury
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY 1.6.3 COMPRESSED AIR CAN CAUSE INJURY Wear approved safety goggles. Do not direct air stream toward self or others. 1.6.4 TRAPPED AIR PRESSURE AND WHIPPING HOSES CAN CAUSE INJURY Release air pressure from tools and system before servicing, adding or changing...
Page 32: Additional Symbols For Installation, Operation And Maintenance
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 1.7 ADDITIONAL SYMBOLS FOR INSTALLATION, OPERATION AND MAINTENANCE 1.7.1 FALLING UNIT CAN CAUSE INJURY Use lifting bail to lift unit and properly installed accessories only. Lift and support unit only with proper equipment and correct procedures.
Page 33: Enclosed Spaces Can Cause Abuild-Up Of Noxious Fumes And Overheating
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY 1.7.5 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING Do not use in enclosed spaces where deadly exhaust gases can build up and machine can overheat, causing fire. 1.7.6 TILTING OF TRAILER CAN CAUSE INJURY Use tongue jack or blocks to support...
Page 34: Arc Welding Can Cause Interference
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM grounding and shielding to minimize the possibility of interference. 1.7.9 ARC WELDING CAN CAUSE INTERFERENCE Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots.
Page 35: Principal Safety Standards
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY PRINCIPAL SAFETY STANDARDS Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWSF4.1, from Global Engineering Documents (phone: 1-877-413-5184, web...
Page 36: Emf Information
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 1.10 EMF INFORMATION Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields.
Page 37: Disposing Of Machine Fluids
1.12 DISPOSING OF MACHINE FLUIDS Always dispose of machine fluids under the guidance of all applicable local, regional and/or federal law. ® Vanair encourages recycling when allowed. additional information, consult the container for information. For further information on machine fluid maintenance,...
Page 38 ® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM Figure 2-1: MAJOR MACHINE COMPONENTS LOCATIONS DESCRIPTION DESCRIPTION INSTRUMENT PANEL COMPRESSOR FLUID FILL PORT (MAY BE REMOTELY MOUNTED) AIR OUTLET SERVICE PORTS COMPRESSOR OIL FILTER FUEL FILL AIR TANK RESERVOIR (4 GAL.) (located under frame) AC GENERATOR ENGINE COOLANT RECOVERY TANK...
Page 39: Section 2: Description
SECTION 2: DESCRIPTION SECTION 2: DESCRIPTION 2.1 GENERAL DESCRIPTION NOTE ® Vanair Manufacturing, Inc.’s Air N Arc 300 Series All-In- One Power System offers superior performance and reliability, as well as limited maintenance requirements. The Power System package is designed to provide...
Page 40: Electronic Inlet Valve
® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM Figure 2-2: Compressor Unit and eliminates the need for a separate air reservoir. Internal porting also lubricates the bearings and seals by using pressure differentials. The oil has three primary functions: coolant, sealant, lubricant.
Page 41: Air Inlet Filter
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 2: DESCRIPTION internal air pressure reduces the power requirement considerably during this unloaded state. The pressure switch will re-activate the solenoid valve allowing the inlet valve to open upon sensing an air demand (reduced pressure).
Page 42: Adjustable Pressure Switch
® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM approach 200 psig, it will crack open to slowly relieve pressure. If pressure continues building through this venting, it will be fully open at 200 psig. Both air and oil will be expelled from this valve.
Page 43 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 2: DESCRIPTION DESCRIPTION GENERATOR SUPPORT BRACKET (reference) PRESSURE SWITCH GENERATOR SERPENTINE BELT (reference) Figure 2-6: Pressure Switch Location DESCRIPTION ENGINE AUXILIARY OIL COOLER ENGINE RADIATOR FAN HYDRAULIC SYSTEM COOLER FAN MOTOR (HYDRAULIC) COMPRESSOR...
Page 44: Compressor Temperature And Pressure Switches
® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM minimum of approximately 160°F (71°C). The elevated temperature forces the moisture, which may be ingested into the compressor system due to atmospheric humidity, to stay in a state of vapor. This prevents the moisture from condensing out in the system and contaminating the lubricant.
Page 45 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 2: DESCRIPTION replaceable cylinders, grindable crankshaft, replaceable valve guides and seats, and heavy-duty engine bearings. The engine is preset to a fixed speed. The adjustment for the engine can be attained by setting the speed adjustment screws.
Page 46: Ac Generator
® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM the instrument panel. The fuel level gauge receives its level signal from the fuel sender that is located in the fuel tank. The fuel system contains a filter, which is located at the lower right when facing the muffler side of the engine ( Figure 2-10, [D]) .
Page 47: Volts/Amps Meter
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 2: DESCRIPTION System Component or Manual Location IMPORTANT Component Group Section DO NOT OPEN the instrument panel box. Generator Control ON/OFF Toggle 2.6.9 page 31 Opening the instrument panel box will Switch void the warranty.
Page 48 ® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION DESCRIPTION VOLTS/AMPS METER (2.6.1) AC VOLTAGE OUTLETS (2.6.10) WELDER CC/CV TOGGLE SWITCH (2.6.2) CIRCUIT BREAKER TRIP/RESET BUTTONS (2.6.11) DC CHARGER/WELDER TOGGLE SWITCH (2.6.2) DOOR OPEN INDICATOR LAMP (2.6.12) DC CHARGER MODE TOGGLE SWITCH (2.6.3) ALTERNATOR FAIL INDICATOR LAMP (2.6.13) VOLTS/AMPS MANUAL ADJUSTMENT DIAL (2.6.4)
Page 49: Dc Charger Mode Toggle Switch
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 2: DESCRIPTION 2.6.3 DC CHARGER MODE TOGGLE SWITCH The three-position DC charger mode toggle switch lets the operator choose the type of charge needed from 12V center (default), 12V boost or 24V boost options. This is a momentary switch;...
Page 50: Door Open Indicator Lamp
If trouble persists, consult Section not reset, this is an indication of a ® system problem. 7, Troubleshooting , or the Vanair Service Department. 2.6.12 DOOR OPEN INDICATOR LAMP The door open indicator lamp signals that the front panel is not in place, or not fastened properly;...
Page 51: Section 3: Specifications
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 3: SPECIFICATIONS SECTION 3: SPECIFICATIONS TABLE 3A: WELDER, GENERATOR, AND ENGINE SPECIFICATIONS SYSTEM INFORMATION SPECIFICATION Rated Welder Output 300A High Frequency DC/CC, DC/CV; 100% Duty Cycle @ 280 Amps Welding Leads 25 or 50 Ft Optional (Refer to Section A.5 for Optional Parts Listing) AC Generator...
Page 52 ® ® SECTION 3: SPECIFICATIONS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM TABLE 3C: SPECIFICATIONS -— UNIT WEIGHT AND DIMENSIONS Dimensions Length Width Height Weight (wet) Weight (dry) Overall Package 47.5" 21" 33" 980 lbs. 870 lbs. See Diagram 4.5 (parts 1 and 2) for full dimension drawing, and Figure 4-1 for location space requirements. Weight listed includes battery and fuel tank, but not instrument panel: Add 25 lbs.
Page 53 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 3: SPECIFICATIONS TABLE 3E: VARIOUS FUNCTION FACTORY SETTING RANGES FUNCTION FACTORY SETTING Engine No-Load Hi RPM 3660 Engine Idle RPM 2000 Air Cut-in pressure Air Cut-out pressure AC generator Hz (no load) AC generator 240 plug AC generator 120 plug AC generator 120 plug...
Page 54 ® ® SECTION 3: SPECIFICATIONS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - 36 090012-OP_r0...
Page 55: Section 4: Installation
37 the installation. Service Body Prep page 37 NOTE Machine Package Mounting page 39 Contact Vanair at Installation and Dimensions Dia- page 42 (219) 879-5100 / (800) 526-8817 gram (Part 1 of 2) Service Fax: (219) 879-5335 www.vanair.com Installation and Dimensions Dia-...
Page 56 Installation must adhere to the safety precautions listed in the Safety Section of this manual for cooling and noxious fume ventilation. If mounting footprint is tighter than the recommended minimum requirements, consult the Vanair Service Department for application installation recommendations. DESCRIPTION 47 inches 45° angle 65°...
Page 57: Machine Package Mounting
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 4: INSTALLATION as possible. Mount the electric fuel pump a maximum distance of 24 inches from the bottom of the tank (Figure 4-2). • Install the pick-up and return fuel lines. •...
Page 58 ® ® SECTION 4: INSTALLATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM and circulation, and also package access for performing NOTE maintenance (see Figure 4-1). 1. Refer to Figure 4-4. Remove the truss screws For safety reasons the front access panel [B], nylon flat washers [C] in order to remove contains a shut-off switch.
Page 59 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 4: INSTALLATION 4. Route the control trunk-line through the grommeted opening. Connect the ½” air line via the JIC fitting on the end of the air tank, and connect and secure the weather proof connectors.
Page 60: Installation And Dimensions Diagram (Part 1 Of 2)
® ® SECTION 4: INSTALLATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 4.5 INSTALLATION AND DIMENSIONS DIAGRAM (PART 1 OF 2) 050590 (1 of 2) _r1 PAGE - 42 090012-OP_r0...
Page 61: Installation And Dimensions Diagram (Part 2 Of 2)
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 4: INSTALLATION 4.6 INSTALLATION AND DIMENSIONS DIAGRAM (PART 2 OF 2) 050590 (2 of 2) _r1 090012-OP_r0 PAGE - 43...
Page 62 ® ® SECTION 5: OPERATION AIR N ARC 300 ALL-IN-ONE POWER SYSTEM DESCRIPTION (Section Located) DESCRIPTION (Section Located) VOLTS/AMPS METER (2.6.1) AC VOLTAGE OUTLETS (2.6.10) WELDER CC/CV TOGGLE SWITCH (2.6.2) CIRCUIT BREAKER TRIP/RESET BUTTONS (2.6.11) DC CHARGER/WELDER TOGGLE SWITCH (2.6.2) DOOR OPEN INDICATOR LAMP (2.6.12) DC CHARGER MODE TOGGLE SWITCH (2.6.3) ALTERNATOR FAIL INDICATOR LAMP (2.6.13)
Page 63: Section 5: Operation
WARNING Before starting, performing maintenance, ® Before starting the Vanair Air N Arc 300 or replacing parts, relieve the entire All-In-One Power System, read this system pressure by opening the air tank section thoroughly and familiarize...
Page 64: Engine Start-Up And Shutdown Procedure
® ® SECTION 5: OPERATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM System Operation Group Manual Location WARNING Section Operating the Battery/Boost Charger page 54 Follow all applicable safety recommendations as outlined in Section Connection - Disconnection Sequence 5.7.1 page 55 1: Safety of this manual.
Page 65: Engine Shutdown
OFF position. However, this method is best reserved for emergency Compressors and engines generate heat ® shutdown situations only. Vanair recommends that the and create hot surfaces. Use caution following procedure is used for routine shutdowns in...
Page 66: Engine Throttle Control Functions
® ® SECTION 5: OPERATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM left in working mode(s) or had auxiliary power draws left intact (such as a tool receptacle left plugged into the generator, etc.). To prepare the machine for shutdown: 1.
Page 67: Welder Operating Procedure
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION TABLE 5A: ENGINE THROTTLE CONTROL FUNCTION CONDITIONS Pressure Setting Compressor Generator Welder Engine Speed Condition Result Switch Switch Switch Tank Pressure Below (<) Engine runs at full throttle (3600 RPM). 100 PSI or Set Pressure Engine runs at idle speed (2000 RPM), ready for application.
Page 68 If a longer welding lead is desired, connection ports on the control panel. For optional 25 and 50 ft. lead segments may be purchased from Vanair Direct Current Electrode Positive (DCEP) Manufacturing, Inc. for a maximum lead connect the electrode holder to the positive length of 100 ft.
Page 69: Cv (Constant Voltage) Mode - Using A Voltage Sensing Suitcase Feeder
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION high idle and deliver the selected amperage through the electrode. Now you may begin to weld. 8. After a weld has been completed, and there is no contact between the electrode and the metal for 30 seconds, the engine will return to idle.
Page 70 ® ® SECTION 5: OPERATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 2. Place the ground clamp from the Air N Arc 300 on the work piece. 3. Start the engine ( See Section 5.2, Engine Start-up and Shutdown Procedure ). 4.
Page 71: Operating The Generator
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION 5.5 OPERATING THE GENERATOR WARNING IMPORTANT Do not rely on the thermal overload circuit breakers on the generator to protect personnel, power tools, or the The Power System is designed to generator.
Page 72: Operating The Battery Booster/Charger
5.7 OPERATING THE BATTERY BOOSTER/CHARGER WARNING ® NEVER disconnect boosting The Vanair state-of-the-art battery charging module and connections or cables while charging / the optional battery charging cables add further versatility boosting. This will cause a voltage spike to the 300 Series Power System. The battery charging on the machine.
Page 73: Connection - Disconnection Sequence And Operation
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION 5.7.1 CONNECTION - DISCONNECTION SEQUENCE IMPORTANT AND OPERATION Never leave the machine unattended IMPORTANT while charging a battery. Always carefully monitor the charging system Never attach boost cables to the panel while it is in use;...
Page 74: Cold Weather Operation
-40°F (-18°C to -40°C). Consult influenced. Appendix Section A.5 (options list) and Vanair for details. It is necessary to consider the balance between the output compensation in accordance with the ambient conditions, and actions to adapt the engine to the operating conditions.
Page 75 -40°F (-18°C to -40°C). Consult GELLING Appendix Section A.5 (options list) and Vanair for details. Diesel fuel turns to a gel-like consistency at temperatures around 0°F (-18°C) the diesel forms wax crystals when TABLE 5E: REQUIREMENTS FOR COLD STARTING...
Page 76: Machine Operation
® ® SECTION 5: OPERATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM the temperatures drop below 15°F (-9°C). As it gets colder, these wax crystals turn to gel. This thicker substance cannot pass the fuel filter, so the engine may run intermittently, or may not start at all.
Page 77: Machine Operation
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION TABLE 5F: REQUIREMENTS FOR HIGH TEMPERATURE OPERATION Temperature Extremely high 40°C (104°F) High 30° to 40°C (86° to 104°F) Item or higher Type No.2-D No.2-D Combustion Fuel (ASTM D975-94) (ASTM D975-94) Temperature...
Page 78: Machine Operation
® ® SECTION 5: OPERATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM monitoring of the air filter and radiator coolers when operating in areas that contain a high dust content. If the package is not being used for an extended period of time, an additional precaution, such as covering the machine with a tarp, will help to keep the inside of the machine free of dust particle accumulation.
Page 79: Section 6: Maintenance
RED COMPRESSOR FILL CAP order to protect the warranty of the machine package. FILL CAP BLEED VENT GROOVE Vanair Manufacturing, Inc. especially requires that a consistent service regimen be established for engine oil Open/crack cap slightly to allow changes, and engine and compressor air filter servicing.
Page 80 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM and compressor air filters are serviced, and the engine oil NOTE is changed. Operating the machine package in a WARNING severe environment may require more frequent service intervals. Follow all applicable safety recommendations as outlined in Section 1: Safety of this manual.
Page 81 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 090012-OP_r0 PAGE - 63...
Page 82 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM PAGE - 64 090012-OP_r0...
Page 83 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 090012-OP_r0 PAGE - 65...
Page 84: Replacement Parts
List. 6.4 REPLACEMENT PARTS Replacement parts should be purchased through your local Vanair representative or where the 300 Series Power System was purchased. If, for any reason, parts are not available in this manner, they can be purchased through Vanair directly.
Page 85 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE DESCRIPTION DESCRIPTION DESCRIPTION BACK PANEL MOUNTING BOLTS SUPPORT, CROSS BRACE LEFT SIDE PANEL* TRUSS SCREW, 5/16-18 x 3/4 RIGHT SIDE PANEL* SCREW, SER WASH 5/16-18 x 1/2 WASHER, NYLON 5/16-18 CAPSCREW, #10-24 x 3/8 PANEL, FRONT...
Page 86 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION MAINTENANCE ISSUE LOCATION Compressor oil filter (easier to access with 6.6.4 panels removed) Engine Oil Filter Change Engine Drive Belt Replacement Engine Hydraulic Pump Drive Belt 6.6.15.5 Replacement Pressure Switch Adjustment...
Page 87 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 2. Remove the three (3) truss screws [B ] and three (3) washers [B ] from the bottom edge of the base cover [B 3. Set the base cover [B ] and hardware aside.
Page 88: Parts Replacement And Adjustment Procedures
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM STEP 6 - REMOVE THE RADIATOR COOLANT RECOVERY TANK Refer to inset [F] in Figure 6-2. 1. Remove both hoses [F ] from radiator coolant recovery tank [F ] cap.
Page 89 92 components before operation with Genuine Vanair Replacement Parts. Replacing and Re-tensioning the 6.6.15 page 93 Using replacement parts other than Serpentine Drive Belts Genuine Vanair Replacement Parts will Continued on next page void the warranty. 090012-OP_r0 PAGE - 71...
Page 90: Compressor Air Filter
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM System Component or Manual WARNING Location Part Group Task Section Relieve pressure from the compressor Re-tensioning the Air Compressor 6.6.15.1 page 93 system before removing any Serpentine Drive Belt components.
Page 91: Compressor Air Filter Inspection
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 5. Re-seat the filter element [C] onto the air filter mounting posts [D]. 6. Replace cover [B] and wing nuts [A]. 7. Close hood. 6.6.1.2 COMPRESSOR AIR FILTER INSPECTION Consult Figure 6-4 and the following procedure to inspect the compressor air filter REPLACEMENT...
Page 92: Repairing The Air Inlet Valve
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 3. Remove worn air filter element [C] from the air filter mounting posts [D]. 4. Seat a new filter element [C] onto the filter mounting posts [D]. 5.
Page 93 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE DESCRIPTION DESCRIPTION - ASSEMBLY PART - KIT (REPLACEMENT) PART WING NUT (x 2) PISTON (COMPLETE with RING) AIR FILTER MOUNTING COVER V-RING AIR FILTER ELEMENT GOVERNOR HOUSING AIR INLET VALVE - COMPLETE ASSEMBLY O-RING NUT (x 2)
Page 94: Checking The Compressor Oil
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 6.6.1, Compressor Air Filter for air filter inspection check, etc.). 10. Replace the cover [B]. 11. Replace the two (2) wing nuts [A], and secure tightly. 6.6.3 CHECKING THE COMPRESSOR OIL WARNING DANGER DO NOT remove caps, plugs and/or other...
Page 95: Replacing The Compressor Oil Filter Element
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE service to perform on the 300 Series All-In-One Power WARNING System package. Consult Section 6.3, Maintenance Schedule Table for routine compressor oil inspection Compressor oil can ignite if it comes in intervals.
Page 96: Changing The Compressor Oil
TOOLS NEEDED REPLACEMENT PART(S) Refer to Figure 6-1. Open fill cap SLOWLY (contents under pressure) to Clean Utility Hose ® Vanair Vanguard™ make sure all pressure has been (18” in length) Premium Synthetic Oil relieved. No. 264626-1GAL Clean Utility Funnel Oil Filter Element No.
Page 97: Replacing The Spin-On Air/Oil Coalescer
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 1. With the machine off and the ignition key NOTE removed, place a suitable receptacle under the compressor drain tube end and remove DO NOT overfill the compressor system; the drain cap.
Page 98: Repairing The Compressor Shaft Seal
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 3. With the aid of a strap wrench, remove the old element [A] by turning it counterclockwise. 4. Apply a thin coat of compressor oil to the new seal [C] on the new element.
Page 99 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE U V W X DESCRIPTION DESCRIPTION - ASSEMBLY PART - KIT (REPLACEMENT) PART CLUTCH AIR END TENSIONER PLATE TENSIONER PLATE ADJUSTMENT (refer to CLUTCH RETAINING CABLE Section 6.6.15.1) WASER PAN HEAD SCREW LOCK WASHER...
Page 100: Part Ii - Accessing The Compressor Unit Shaft Seal
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM maximum position will loosen the serpentine belt [F] enough to be removed. 5. Remove serpentine belt [F]. 6.6.7.2 P II – A CCESSING THE OMPRESSOR HAFT 1. Loosen and remove the drive sheave capscrew [G], washer [H] and sheave washer [J] securing drive sheave [K] into place.
Page 101: Part Iii - Replacing The Compressor Serpentine Belt
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 14. Place o-ring [S] within the groove on the inside of the compressor cover [R]. 15. Place the compressor cover [R] over its seating position on the compressor unit NOTE body.
Page 102 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM - ASSEMBLY PART - KIT (REPLACEMENT) PART DESCRIPTION DESCRIPTION SCREW VALVE MOUNTING BLOCK INLET-SIDE SCREW CONNECTOR HEAD PRY SLOT SET COLLAR (CONNECTOR HEAD) SEAL CONNECTOR HEAD BASE CONNECTION PINS PIN RE-CONFIGURATION SEATING THE CONNECTOR BASE...
Page 103: Solenoid Valve - Preparation Before Mounting
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE REPLACEMENT TOOLS NEEDED PART(S) Screwdriver Solenoid Replacement Kit No. 270775 6.6.8.1 SOLENOID VALVE – PREPARATION BEFORE MOUNTING Before installing the new solenoid, the connector’s base needs to be rotated so that the connector situates correctly with the wire direction once it is plugged into the solenoid block.
Page 104: Draining The Air Tank
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 1. With the machine off and the ignition key removed, locate the inlet solenoid valve [Q] mounted on the compressor’s control manifold. 2. Remove the top securing screw [A] of the valve connected to the unit, and gently pull the connector away from the solenoid block’s connection pins [E].
Page 105 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE DESCRIPTION DESCRIPTION DRAIN VALVE MACHINE FRAME ENGINE DRAIN OUTLET AIR STORAGE TANK Figure 6-13: Air Tank Drain valve located at the lower right corner of the base frame on the back end of the machine.
Page 106: Rebuilding The Minimum Pressure/Check Valve
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 6.6.10 REBUILDING THE MINIMUM PRESSURE/ CHECK VALVE Should a condition occur that requires the minimum pressure/check valve to be serviced (see Section 7.2, Troubleshooting Guide ), a repair kit is available. To repair minimum pressure/check...
Page 107: Inspecting The System Coolers
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE DESCRIPTION DESCRIPTION - ASSEMBLY PART - KIT (REPLACEMENT) PART MINIMUM PRESSURE/CHECK VALVE O-RING LOCK NUT PISTON (with o-ring) GRUB SCREW (COMPLETE) SPRING VALVE BODY VALVE HEAD (with o-ring) SPRING GUIDE O-RING PRESSURE SPRING...
Page 108: Checking The Engine Oil
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION DESCRIPTION ENGINE OIL COOLER ENGINE COOLER FAN HYDRAULIC SYSTEM COOLER ENGINE RADIATOR DRAIN VALVE COMPRESSOR RADIATOR Figure 6-15: Cooler Maintenance dirt or contamination. Should any residue appear during NOTE inspection, clear with the use of air blown across the surface of the cooler fins.
Page 109 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE DESCRIPTION DESCRIPTION ENGINE TEMPERATURE SWITCH ENGINE PRESSURE SWITCH ENGINE AIR FILTER ENGINE OIL FILTER ENGINE OIL FILL PORT ENGINE OIL DIPSTICK FUEL FILTER ENGINE OIL LOW LEVEL MARK ENGINE OIL DRAIN: TUBE &...
Page 110: Adjusting The Engine Speed
6.6.13 ADJUSTING THE ENGINE SPEED for engine service and maintenance recommendations that are not provided ® in this manual. Consult the Vanair Service Department for issues relating to adjustment of engine speed. NOTE Do not tamper with the governor setting to increase the maximum engine speed.
Page 111: Replacing And Re-Tensioning The Serpentine Drive Belts
3. After making your adjustments, position and NOTE re-fasten the cover to the pressure switch body with the cover retaining screw. ® Vanair recommends that the air 4. Close the hood, and cycle the compressor compressor and generator serpentine several times to ensure the correct belts both be changed at the same time pressures are set.
Page 112 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION DESCRIPTION TENSIONER PLATE MOUNTING AND Loosen bolts to allow tensioner plate to pivot man- ADJUSTMENT BOLTS ually to achieve new belt-tensioned position. IDLER Pivot plate by applying torque wrench to tension- ing hole.
Page 113: Replacing The Air Compressor Serpentine Belt
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE TABLE 6B: MEASURING BELT DEFLECTION P - Span Length c - Center Distance F - Deflection Force q - Deflection Distance SPAN LENGTH (in) DEFLECTION DEFLECTION FORCE (lbs) DISTANCE (in) ALL RIBS TORQUE TO IN-LB TENSION...
Page 114 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION DESCRIPTION ENGINE WASHER ENGINE CLUTCH ASSEMBLY CLUTCH RETAINING CABLE RETAINING CABLE BOLT CABLE CONNECTION HOLE LOCK WASHER Figure 6-19: Clutch Retaining Cable DESCRIPTION ENGINE CLUTCH ASSEMBLY AIR COMPRESSOR SERPENTINE BELT COMPRESSOR UNIT IDLER SHEAVE...
Page 115: Re-Tensioning The Generator Serpentine Belt
[ C ]. Loosen enough to allow the tensioner plate to pivot while still retaining belt path position. ® Vanair recommends rotating the tensioner plate to its maximum position. 3. Once the position is achieved that accounts for a satisfactory tension in the belt, torque the bolt [ C ] to 12 ft-lbs.
Page 116: Replacing The Generator Serpentine Belt
To replace the generator serpentine belt consult Figures NOTE 6-19 and 6-22 , and the following procedure: ® Vanair recommends that the air 1. With the machine off and the ignition key compressor and generator serpentine removed, open and remove the front access belts both be changed at the same time panel.
Page 117 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE DESCRIPTION DESCRIPTION DC GENERATOR SHEAVE ENGINE CLUTCH ASSEMBLY AC GENERATOR SHEAVE COMPRESSOR SERPENTINE BELT (ref) GENERATOR IDLER SHEAVE GENERATOR BELT TENSIONER PLATE GENERATOR SERPENTINE BELT TENSIONER PLATE MOUNTING AND ADJUSTMENT BOLT Figure 6-22: Generator Serpentine Belt Positioning the cable to the floor.
Page 118: Re-Tensioning The Engine Hydraulic Pump Drive Belt
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 6.6.15.5 RE-TENSIONING THE ENGINE HYDRAULIC PUMP DRIVE BELT REPLACEMENT TOOLS NEEDED PART(S) Wrench - Size 5/16” Serpentine Belt No. DR270393 Tension Tester Torque Wrench, 1/2” Drive The hydraulic pump can only be accessed when the machine’s maintenace access panels are removed.
Page 119: Replacing The Engine Hydraulic Pump Drive Belt
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 2. Loosen, but do not remove, the three (3) tensioner plate bolts [ D ] mounting the tensioner plate/pump sheave [ A ] in place. Loosen only enough to allow tensioner plate to pivot along the grooves in the plate while still remaining in position.
Page 120: Servicing The System Fuses And Circuit Breakers
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 6. Once a position is achieved that accounts for a satisfactory tension in the belt, torque the three (3) tensioner plate bolts [ D ] to 12 ft-lbs (16.3 Nm) to secure the tensioner into position.
Page 121 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE AC GENER ATOR DESCRIPTION DESCRIPTION RELAYS ( x7) - 40 AMP 15 AMP FUSE - ENGINE START ENGINE SHUTDOWN TIMER RELAY 10 AMP FUSE - COMPRESSOR GROUND STUD 10 AMP FUSE - INSTRUMENT PANEL 10 AMP FUSE - THROTTLE Figure 6-25: Power System Fuse Locations...
Page 122 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM Depressurize the air tank and open the drain valve on the tank. Cover the unit with a tarp or plastic to prevent the accumulation of dust, but leave the bottom open for air circulation.
Page 123: Section 7: Troubleshooting
Engine Operator’s Manual and the Generator Operator’s Manual. Should the situa- tion remain unresolved after exhausting available sources, contact the Vanair Service Department at: Phone: 800-526-8817 (toll free) Phone: 219-879-5100, ext. 400 Fax: 219-879-5335...
Page 124: Troubleshooting Guide
® ® SECTION 7: TROUBLESHOOTING AIR IN ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 7.2 TROUBLESHOOTING GUIDE Fault/Malfunction Possible Cause Corrective Action ENGINE Engine will not crank Faulty battery connection. Check for proper battery connections and battery charge. Battery out of power Recharge or replace battery.
Page 125 ® ® AIR IN ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 7: TROUBLESHOOTING 7.2 TROUBLESHOOTING GUIDE Fault/Malfunction Possible Cause Corrective Action ENGINE (CONTINUED) Improper Control Operation: Operating pressure too high Adjust to proper pressure setting. Refer to Engine does not speed up Section 2.2.7, Adjustable Pressure (continued) Switch, and Section 6.6.14, Adjusting the...
Page 126 ® ® SECTION 7: TROUBLESHOOTING AIR IN ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 7.2 TROUBLESHOOTING GUIDE Fault/Malfunction Possible Cause Corrective Action ENGINE (CONTINUED) Engine overheats (continued) Fault with engine cooling system Consult Engine Operator’s Manual. Compressor oil level low (fan Check oil level and refill to proper level if hydraulics depend on compressor oil necessary (ensure machine is parked on a...
Page 127 Replacing the Compressor Oil Filter Element. Clutch faulty Inspect; replace if necessary. Plugged or restricted cooler core Flush cooler. Consult the Vanair Service Department for assistance in cleaning/ flushing the cooler core. Contaminated cooler fins Clean cooler fins. Refer to Section 6.6.11, Inspecting the System Coolers.
Page 128 ® ® SECTION 7: TROUBLESHOOTING AIR IN ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 7.2 TROUBLESHOOTING GUIDE Fault/Malfunction Possible Cause Corrective Action COMPRESSOR (CONTINUED) Compressor will not build up Air demand too high Check for leaks and take corrective action. pressure (continued) Check air tools for wear, damage, or malfunctions.
Page 129 ® ® AIR IN ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 7: TROUBLESHOOTING 7.2 TROUBLESHOOTING GUIDE Fault/Malfunction Possible Cause Corrective Action COMPRESSOR (CONTINUED) Compressor system over- Pressure switch setting too high Reset pressure switch. Refer to Section pressures 2.2.7, Adjustable Pressure Switch, and Section 6.6.14, Adjusting the Pressure This condition will cause a Setting.
Page 130 ® ® SECTION 7: TROUBLESHOOTING AIR IN ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 7.2 TROUBLESHOOTING GUIDE Fault/Malfunction Possible Cause Corrective Action COMPRESSOR (CONTINUED) No service air output (See aslo If equipped, OSHA valve/velocity fues, Reset or replace OSHA valve. Compressor will not build up not functioning properly pressure) Low service air output (See aslo...
Page 131 Carefully wipe off any contaminants to receptacle connectors before re-connecting. Replace any worn or damaged cables or receptacles. Contact ® Vanair Mfg., Inc. Service Department if behavior persists. Welding function is not drawing enough If running more than one function operating power simultaneously, turn off competing function.
Page 132 ® ® SECTION 7: TROUBLESHOOTING AIR IN ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 7.2 TROUBLESHOOTING GUIDE Fault/Malfunction Possible Cause Corrective Action WELDER (CONTINUED) No welder output in CC mode Bad ground connect Make sure of connection. Clean welding surface. Faulty electrical circuit Check electrical circuit.
Page 133: Section 8: Diagrams
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 8: DIAGRAMS SECTION 8: DIAGRAMS 8.1 GENERAL INFORMATION The diagrams located in this section of the manual are designed to assist the service technician with troubleshooting any problems that may arise while operating the All-In-One Power System within its intended use.
Page 134: Wiring Diagram - Air N Arc 300 Series (Diesel)
® ® SECTION 8: DIAGRAMS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 8.2 WIRING DIAGRAM - AIR N ARC 300 SERIES (DIESEL) ID270405-S1_r3 PAGE - 116 090012-OP_r0...
Page 135: Wiring Diagram - Switches & Lights
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 8: DIAGRAMS 8.3 WIRING DIAGRAM - SWITCHES & LIGHTS ID270405-S2_r1 090012-OP_r0 PAGE - 117...
Page 136: Trunk Line Assembly Harness
® ® SECTION 8: DIAGRAMS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 8.4 TRUNK LINE ASSEMBLY HARNESS MA269937-XX_r1 PAGE - 118 090012-OP_r0...
Page 137: Compressor Flow Schematic Diagram
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 8: DIAGRAMS 8.5 COMPRESSOR FLOW SCHEMATIC DIAGRAM DESCRIPTION DESCRIPTION ADJUSTABLE PRESSURE SWITCH INSTRUMENT PANEL COMPRESSOR HYDRAULIC OIL COOLER COMPRESSOR OIL COOLER AIR FILTER AIR ACCUMULATOR TANK COALESCER HYDRAULIC PUMP W / RELIEF VALVE MINIMUM PRESSURE VALVE OIL FILTER AIR OUT...
Page 138 ® ® SECTION 8: DIAGRAMS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - 120 090012-OP_r0...
Page 139: Section 9: Illustrated Parts List
SECTION 9: ILLUSTRATED PARTS LIST SECTION 9: ILLUSTRATED PARTS LIST ® 9.1 PARTS ORDERING PROCEDURE VANAIR MANUFACTURING, INC. 10896 West 300 N. Part orders should be placed through the distributor Michigan City, IN 46360 from whom the unit was purchased. If, for any reason...
Page 140 Use only Vanair Vanguard™ Premium Synthetic Oil and Genuine Vanair Parts. Inspect and replace damaged com- ponents before operation. Substituting non-Vanguard™ Oil or non-genuine Vanair filter components WILL VOID THE COMPRESSOR WARRANTY! Air filter element (270764) is enclosed within air filter house #11(269660) on assembly drawing in Section 9.11.
Page 141 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST NOTES 090012-OP_r0 PAGE - 123...
Page 142: Air N Arc 300 Systems Assemblies
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.2 AIR N ARC 300 SYSTEMS ASSEMBLIES PA6130014ID_r0 PAGE - 124 090012-OP_r0...
Page 143 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.2 AIR N ARC 300 SYSTEMS ASSEMBLIES REFERENCE ITEM DESCRIPTION PART NUMBER SECTION AIR STORAGE ASSEMBLY PA6000040ID 9.12 ID, COMPRESSOR & PARTS PA6010028ID 9.3 & 9.4 ID, COOLER ASSEMBLY PA6020024ID ID, FRAME &...
Page 144: Compressor And Parts Assembly (1 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.3 COMPRESSOR AND PARTS ASSEMBLY (1 OF 2) Refer to SECTION 9.4 (PART 2 OF 2) for machines with check valve configuration PA6010028ID_r4 PAGE - 126 090012-OP_r0...
Page 145 OIL, VANGUARD 3.5 QUARTS 264626 NIPPLE, HEX G3/8BSPP x 3/8 NPT 267334 ELBOW, 1/2MPT X 1/2FJIC SWVL 90 268929-008 COMPR & PART VANAIR 31 EMC, 12VDC STD SHAFT 269761 TAG, COMPR VANAIR 31 270610 ELBOW, PIPE GALV 90 DEG 3/8 803515-015...
Page 146 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.3 COMPRESSOR AND PARTS ASSEMBLY (1 OF 2) Refer to SECTION 9.4 (PART 2 OF 2) for machines with check valve configuration PA6010028ID_r4 PAGE - 128 090012-OP_r0...
Page 147 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.3 COMPRESSOR AND PARTS ASSEMBLY (1 OF 2) ITEM DESCRIPTION PART NUMBER WASHER, FLAT 1/2 838208-112 WASHER, LOCK 3/8 838506-094 WASHER, LOCK 1/2 838508-125 WASHER, LOCK METRIC M8 838808-200 WASHER, LOCK METRIC M10 838810-220...
Page 148: Compressor And Parts Assembly (2 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.4 COMPRESSOR AND PARTS ASSEMBLY (2 OF 2) This assembly is representative of machines with a check valve. Refer to SECTION 9.3, COMPRESSOR AND PARTS ASSEMBLY (1 OF 2) for machine configuration without check valve.
Page 149 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.4 COMPRESSOR AND PARTS ASSEMBLY (2 OF 2) ITEM DESCRIPTION PART NUMBER SWITCH, TEMP 240 DEG F NC NASON 264325 WASHER, SEALING FOR PARKER G3/8 BSPP 264449-002 ADAPTER, 1/2 FEMALE PIPE X 3/8 BSPP LESS WASHER 263748-011...
Page 150: Cooling System
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.5 COOLING SYSTEM PA6020024ID_r4 PAGE - 132 090012-OP_r0...
Page 151 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.5 COOLING SYSTEM ITEM DESCRIPTION PART NUMBER ELBOW, 90 DEG 3/8P X 1/2J LONG 044832-007 ELBOW, 90 DEG #8 MJIC x #8 MSAE 260403-104 FAN, COOLER, 16 DIA, 8 BLADE (REVERSE ROTATION) 270366 RADIATOR, ENGINE &...
Page 152 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.5 COOLING SYSTEM (CONTINUED) PA6020024ID_r4 PAGE - 134 090012-OP_r0...
Page 153 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.5 COOLING SYSTEM (CONTINUED) ITEM DESCRIPTION PART NUMBER CLAMP, HOSE, #20, 1.75DIA. FA47720 MOTOR, HYD BI-ROT HY270358 GASKET, SEAL AND TRIM, EXTRUDE 17-1/4" LG. PR35734 HOSE, MOTOR TO COOLER TU270453-009 AA - NO FASTENER...
Page 154: Frame And Canopy (1 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.6 FRAME AND CANOPY (1 OF 2) INSERT AA INSERT AA PA6030013ID_r2 PAGE - 136 090012-OP_r0...
Page 155 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.6 FRAME AND CANOPY (1 OF 2) ITEM DESCRIPTION PART NUMBER WASHER, NYLON FLAT 1/4 262704 WASHER, NYLON 5/16-18 262943 SCREW, TRUSS HD 5/16-18 x 3/4 SS 262945 SCREW, TRUSS HD 1/4-20 x 3/4 262953...
Page 156 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.6 FRAME AND CANOPY (1 OF 2) (CONTINUED) INSERT AA INSERT AA PA6030013ID_r2 PAGE - 138 090012-OP_r0...
Page 157 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.6 FRAME & CANOPY ASSEMBLY (1 OF 2) (CONTINUED) ITEM DESCRIPTION PART NUMBER A1270550 PANEL, ENGINE INLET EXHAUST, OUTLET A14883P SWITCH, HOOD SAFETY NO/NC 15A-125V. AC CO81774 TANK, 1 GAL RECOVERY, COOLANT EN45487...
Page 158: Frame And Canopy (2 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.7 FRAME AND CANOPY (2 OF 2) PA6030013ID_r2 PAGE - 140 090012-OP_r0...
Page 159 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.7 FRAME AND CANOPY (2 OF 2) ITEM DESCRIPTION PART NUMBER WASHER, NYLON FLAT 1/4 262704 WASHER, NYLON 5/16-18 262943 SCREW, TRUSS HD 5/16-18 x 3/4 SS 262945 SCREW, TRUSS HD 1/4-20 x 3/4 262953...
Page 160 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.7 FRAME AND CANOPY (2 OF 2) (CONTINUED) PA6030013ID_r2 PAGE - 142 090012-OP_r0...
Page 161 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.7 FRAME AND CANOPY ASSEMBLY (2 OF 2) (CONTINUED) ITEM DESCRIPTION PART NUMBER EXHAUST, OUTLET A14883P SWITCH, HOOD SAFETY NO/NC 15A-125V. AC CO81774 TANK, 1 GAL RECOVERY, COOLANT EN45487 CAPSCREW, S.H.FLAT #10-24 x 3/8 FA269805...
Page 162: Instrument Panel
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.8 INSTRUMENT PANEL PA6040015ID_r0 PAGE - 144 090012-OP_r0...
Page 163 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.8 INSTRUMENT PANEL ITEM DESCRIPTION PART NUMBER ELBOW, 1/4T x 1/8P PUSH-ON 261309 ELBOW, 90 DEG. PUSH ON 1/4T x 1/4P 261310 WASHER, NYLON 5/16-18 262943 WASHER, FLAT REDUCING 3/4 x 1 ELECT.
Page 164 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.8 INSTRUMENT PANEL (CONTINUED) PA6040015ID_r0 PAGE - 146 090012-OP_r0...
Page 165 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.8 INSTRUMENT PANEL (CONTINUED) ITEM DESCRIPTION PART NUMBER GAUGE, AIR, DRY, 0-200 PSI CO89649 LAMP, INDICATOR, LED, RED CO89659 DECAL, FACEPLATE DL270502 DECAL, CONTROL PANEL, WELDER DL270502-002 DECAL, CONTROL, ENG.
Page 166: Generators And Parts
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.9 GENERATORS AND PARTS PA6050007ID_r1 PAGE - 148 090012-OP_r0...
Page 167 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.9 GENERATORS AND PARTS ITEM DESCRIPTION PART NUMBER ELBOW, 90 DEG. PUSH ON 1/4T x 1/4P 261310 SWITCH, PRESSURE ADJUSTABLE 263850 BRACKET, ADJ. PRESSURE SWITCH 269299 GENERATOR, AC, 6.8KW 269530...
Page 168: Engine And Drive Parts (1 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.10 ENGINE AND DRIVE PARTS (1 OF 2) PA6100012ID_r2 PAGE - 150 090012-OP_r0...
Page 169 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.10 ENGINE AND DRIVE PARTS (1 OF 2) ITEM DESCRIPTION PART NUMBER CLAMP, HOSE 3/16 - 5/16 HOSE 260864 WASHER, NYLON FLAT 1/4 262704 HOSE, FLEX 2" I.D. X 21" LG. 262705 CLAMP, EXHAUST 1 1/2 262906-150...
Page 170 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.10 ENGINE AND DRIVE PARTS (1 OF 2) (CONTINUED) PA6100012ID_r2 PAGE - 152 090012-OP_r0...
Page 171 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.10 ENGINE AND DRIVE PARTS (1 OF 2) (CONTINUED) DESCRIPTION PART NUMBER CAPSCREW, HEX GR8 7/16-20UNF x 2.5 829807-250 SCREW, MACH SHOULDER 1/2X 3 LG 830508-300 SCREW, ROUND HD #8-32 X 1/2 831601-050...
Page 172 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.10 ENGINE AND DRIVE PARTS (1 OF 2) (CONTINUED) PA6100012ID_r2 PAGE - 154 090012-OP_r0...
Page 173 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.10 ENGINE AND DRIVE PARTS (1 OF 2) (CONTINUED) ITEM DESCRIPTION PART NUMBER RELAY, SOLENOID CONTROL, SD85 CO72121 SENDER, TEMPERATURE, DIESEL CO74454 CLUTCH, CMS 5.8 P.D. 8 GRV "K" STYLE SHEAVE DR269574 SHEAVE, STUB SHAFT 8 GROOVE DR270365...
Page 174: Engine And Drive Parts (2 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.11 ENGINE AND DRIVE PARTS (2 OF 2) PA6100012ID_r2 PAGE - 156 090012-OP_r0...
Page 175 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.11 ENGINE AND DRIVE PARTS (2 OF 2) ITEM DESCRIPTION PART NUMBER CLAMP, HOSE 3/16 - 5/16 HOSE 260864 WASHER, NYLON FLAT 1/4 262704 HOSE, FLEX 2" I.D. X 21" LG. 262705 CLAMP, EXHAUST 1 1/2 262906-150...
Page 176 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.11 ENGINE AND DRIVE PARTS (2 OF 2) (CONTINUED) PA6100012ID_r2 PAGE - 158 090012-OP_r0...
Page 177 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.11 ENGINE AND DRIVE PARTS (2 OF 2) (CONTINUED) DESCRIPTION PART NUMBER CAPSCREW, HEX GR8 7/16-20UNF x 2.5 829807-250 SCREW, MACH SHOULDER 1/2X 3 LG 830508-300 SCREW, ROUND HD #8-32 X 1/2 831601-050...
Page 178 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.11 ENGINE AND DRIVE PARTS (2 OF 2) (CONTINUED) PA6100012ID_r2 PAGE - 160 090012-OP_r0...
Page 179 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.11 ENGINE AND DRIVE PARTS (2 OF 2) (CONTINUED) ITEM DESCRIPTION PART NUMBER RELAY, SOLENOID CONTROL, SD85 CO72121 SENDER, TEMPERATURE, DIESEL CO74454 CLUTCH, CMS 5.8 P.D. 8 GRV "K" STYLE SHEAVE DR269574 SHEAVE, STUB SHAFT 8 GROOVE DR270365...
Page 180: Electrical System
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.12 ELECTRICAL SYSTEM PA6120048ID_r1 PAGE - 162 090012-OP_r0...
Page 181 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.12 ELECTRICAL SYSTEM ITEM DESCRIPTION PART NUMBER CAPSCREW, HEX GR5 1/4-20 x 3/4 829104-075 WASHER, LOCK 1/4 838504-062 BRACKET, BATTERY A1270389 CIRCUIT BREAKER, 30 AMP CO71774 BOX, BATTERY EL269924...
Page 182: Fuel Tank Assembly
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.13 FUEL TANK ASSEMBLY PA6140005ID_r0 PAGE - 164 090012-OP_r0...
Page 183 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.13 FUEL TANK ASSEMBLY ITEM DESCRIPTION PART NUMBER RIVET, 3/16" DIA, S.S. 263194 CLAMP, HOSE, #6, 5/16" - 7/8" 264787 CLAMP, HOSE, #24, 1"-2" DIA. 270493 NUT, HEX LOCKING #10-24 825502-083...
Page 184: Air Storage Assembly
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.14 AIR STORAGE ASSEMBLY WASHER WASHER PA6000040ID_r1 PAGE - 166 090012-OP_r0...
Page 185 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.14 AIR STORAGE ASSEMBLY ITEM DESCRIPTION PART NUMBER ELBOW, 90 DEG. PUSH ON 1/4T x 1/4P 261310 CONNECTOR, 1/8P x 1/4T PUSH ON 261316 VALVE, RELIEF 200 PSI 1/4 NPT MALE 264232 CAP, FEMALE JIC 3/4-16 #8 264322-003...
Page 186: Fuel Assembly - Without Fuel Tank
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.15 FUEL ASSEMBLY - WITHOUT FUEL TANK PA6140007ID_r0 PAGE - 168 090012-OP_r0...
Page 187 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.15 FUEL ASSEMBLY - WITHOUT FUEL TANK ITEM DESCRIPTION PART NUMBER CLAMP, HOSE, #6, 5/16" -7/8" 264787 ELBOW, 1/4 NPT x 3/16 HOSE BARB 270612 ELBOW, 1/4 NPT x 5/16 HOSE BARB 270651 HOSE, FUEL LINE 5/16"...
Page 188: Decal And Plate Locations (1 Of 4)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.16 DECAL AND PLATE LOCATIONS (1 OF 4) Inside view of hood panel ends Inside view of hood panel COMPRESSOR MAINTENANCE DAILY OPERATION: (BEFORE STARTING) 1) CHECK COMPRESSOR FLUID LEVE L WITH MACHINE LEVEL.
Page 189 SECTION 9: ILLUSTRATED PARTS LIST 9.16 DECAL AND PLATE LOCATIONS (1 OF 4) ITEM DESCRIPTION PART NUMBER DECAL, EXPLOSIVE FUEL 264377 DECAL, CAUTION DL270120 DECAL, VANAIR 265605 DECAL, READ MANUAL 49117 DECAL, SULFURIC ACID 264375 DECAL, HOT PARTS 264372 DECAL, CARBON MONOXIDE...
Page 190: Decal And Plate Locations (2 Of 4)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.17 DECAL AND PLATE LOCATIONS (2 OF 4) PAGE - 172 090012-OP_r0...
Page 191 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.17 DECAL AND PLATE LOCATIONS (2 OF 4) ITEM DESCRIPTION PART NUMBER 264374 DECAL, ROTATING PARTS DECAL, ACCIDENTAL STARTS 264373 DECAL, BREATHING AIR 361886 DECAL, AIR HOSE 261885 This decal is included with decal sheet no.
Page 192: Decal And Plate Locations (3 Of 4)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.18 DECAL AND PLATE LOCATIONS (3 OF 4) PAGE - 174 090012-OP_r0...
Page 193 SECTION 9: ILLUSTRATED PARTS LIST 9.18 DECAL AND PLATE LOCATIONS (3 OF 4) ITEM DESCRIPTION PART NUMBER DECAL, COMPRESSOR FLUID DRAIN — DECAL, ANA BY VANAIR, WHT, DIESEL DL270487 DECAL, AIR TANK DRAIN ANA27 DECAL, ENGINE OIL DRAIN ANA82 DECAL , LOW SULFUR FUEL 270802 This decal is included with decal sheet no.
Page 194: Decal And Plate Locations (4 Of 4)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.19 DECAL AND PLATE LOCATIONS (4 OF 4) Front View Rear View PAGE - 176 090012-OP_r0...
Page 195 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.19 DECAL AND PLATE LOCATIONS (4 OF 4) ITEM DESCRIPTION PART NUMBER DECAL, ANA BY VANAIR WHT. DL269706 DECAL, VANAIR LOGO DL270724 DECAL, ANA 300 PERF BADGE WHT. DL269704 DECAL, ANA 300 PERF BADGE WHT.
Page 196 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE page - 178 090012-OP_r0...
Page 197: Appendix A: Additional Information
® ® AIR N ARC 300 ALL-IN-ONE POWER SYSTEM APPENDIX A: ADDITIONAL INFORMATION APPENDIX A: ADDITIONAL INFORMATION A.1 ELECTRIC MOTOR CHART - STARTING WATTS NOTE For pumps, air compressors, air conditioners, inverters add at least 25% to starting current. HORSEPOWER RUNNING UNIVERSAL SPLIT...
Page 198: Extension Cord Chart
® ® APPENDIX A: ADDITIONAL INFORMATION AIR N ARC 300 ALL-IN-ONE POWER SYSTEM A.2 EXTENSION CORD CHART CONTINUOUS LOAD MINIMUM GAUGE (AWG) (use either Amps or Watts below) AMPS @120 volts @240 volts 0-50 feet 50-100 feet 100-150 f 1200 1440 1920 1200...
Page 199: Wattage Requirements For Common Receptacle Units
® ® AIR N ARC 300 ALL-IN-ONE POWER SYSTEM APPENDIX A: ADDITIONAL INFORMATION A.3 WATTAGE REQUIREMENTS FOR COMMON RECEPTACLE UNITS COMMON RECEPTICAL UNIT WATTAGE STARTING RUNNING Battery charger, 10 amps - 1/4” - 3/8” Drill - 1/2” - 1” 1250 1000 Welder 100 amps DC 3600...
Page 200: Appendix A: Additional Information (Cont.)
® ® APPENDIX A: ADDITIONAL INFORMATION AIR N ARC 300 ALL-IN-ONE POWER SYSTEM A.4 AIR TOOL AIR CONSUMPTION CHART TOOL AIR REQUIRED CFM @ 90 PSI Dual Action (DA) Sanders 28.8 -43.2 SCFM 5" High Speed Sanders 28.8 -43.2 SCFM Jitterbug Sanders 28.8 SCFM Straight Line Sanders...
Page 201: Air N Arc 300 Series All-In-One Power System Available Options List
® ® AIR N ARC 300 ALL-IN-ONE POWER SYSTEM APPENDIX A: ADDITIONAL INFORMATION A.4 AIR TOOL AIR CONSUMPTION CHART (CONTINUED) TOOL AIR REQUIRED CFM @ 90 PSI 60 Ib Pavement Breaker 48 SCFM 90 Ib Pavement Breaker 68 -85 SCFM 4"...
Page 202 ® ® APPENDIX A: ADDITIONAL INFORMATION AIR N ARC 300 ALL-IN-ONE POWER SYSTEM A.5 AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM AVAILABLE OPTIONS LIST (CONTINUED) OPTION ITEM DESCRIPTION PART ORDER NUMBER BATTERY 12 volt, 35 amp, sealed lead acid MA31821 BATTERY LTV, dry cell 100 KSI...
Page 203: Hose Installation Guide
® ® AIR N ARC 300 ALL-IN-ONE POWER SYSTEM APPENDIX A: ADDITIONAL INFORMATION A.6 HOSE INSTALLATION GUIDE 1. Hose is weakened when installed in twisted position. Pressure in twisted hose tends to loosen fitting connections. Design so that 2. Ample bend radius should be provided to machine motion produces bending rather than avoid collapsing of line and restriction of flow.
Page 204: Electrode Ignition Procedure
® ® APPENDIX A: ADDITIONAL INFORMATION AIR N ARC 300 ALL-IN-ONE POWER SYSTEM A.7 ELECTRODE IGNITION PROCEDURE CLOSE-UP PROFILE OF ELECTRODE IGNITION DESCRIPTION ACTION ELECTRODE Direction of striking: electrode is dragged across the work piece in a similar manner to striking a match WORK PIECE SURFACE Electrode is lifted slightly when it touches the work piece, but continues on with the striking motion...
Page 205: Appendix B: Maintenance And Service Log
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM APPENDIX B: MAINTENANCE AND SERVICE LOG APPENDIX B: MAINTENANCE AND SERVICE LOG B.1 GENERAL DESCRIPTION The maintenance and service log given in this appendix can be used to track and keep a record of the mainte- nance intervals of the machine, as well an any non-rou- tine repairs or changes made, throughout the productive life of the machine package.
Page 206: Maintenance And Service Log
® ® APPENDIX B: MAINTENANCE AND SERVICE LOG AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM B.2 MAINTENANCE AND SERVICE LOG 200 HOURS OR EIGHT MONTHS SERVICE POINTS Date of Purchase: Dates Completed & Parts Replaced: BREAK-IN PERIOD SERVICE POINTS Date Completed: 50 HOURS OR TWO MONTHS SERVICE POINTS Dates Completed:...
Page 207 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM APPENDIX B: MAINTENANCE AND SERVICE LOG B.2 MAINTENANCE AND SERVICE LOG 200 HOURS OR EIGHT MONTHS SERVICE POINTS Date of Purchase: Dates Completed & Parts Replaced: BREAK-IN PERIOD SERVICE POINTS Date Completed: 50 HOURS OR TWO MONTHS SERVICE POINTS Dates Completed:...
Page 208 ® ® APPENDIX B: MAINTENANCE AND SERVICE LOG AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - 190 090012-OP_r0...
Page 209 BLANK PAGE...
Page 210 Vanair Manufacturing, Inc. 10896 West 300 North Michigan City, IN 46360 Phone: (219) 879-5100 (800) 526-8817 Service Fax: (219) 879-5335 Parts Fax: (219) 879-5340 Sales Fax: (219) 879-5800 www.vanair.com Printed in the U.S.A. Specifications Subject to Change Without Prior Notice...

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Vanair AIR N ARC RELIANT 300 Series Operations Manual & Parts List

Table of Contents

Glossary

Warranty Claims Procedure

Introduction

Section 1: Safety

Section 1: Safety (Continued)

Section 1: Safety (Continued)

Section 2: Description

Section 2: Description (Continued)

Section 3: Specifications

Section 4: Installation

Section 5: Operation

Section 6: Maintenance

Caution

Section 6: Maintenance (Continued)

Section 7: Troubleshooting

Section 8: Diagrams

Section 9: Illustrated Parts List

Appendix A: Additional Information

Appendix A: Additional Information (Cont.)

Appendix B: Maintenance and Service Log

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Vanair AIR N ARC RELIANT 300 Series

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Table of Contents