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 LAYOUT NAVIGATION..................1 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 HYDRAULIC SAFETY ........................10 1.5.1 AVOID HIGH PRESSURE FLUIDS........................10 1.5.2 MOVING PARTS CAN CAUSE INJURY ......................10 1.5.3 HOT PARTS CAN CAUSE SEVERE BURNS......................11 1.5.4...
Page 5 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM TABLE OF CONTENTS SECTION 2: DESCRIPTION (CONTINUED) COMPRESSED AIR SYSTEM .......................21 2.2.1 COMPRESSOR UNIT ............................21 2.2.2 ELECTRONIC INLET VALVE ..........................22 2.2.3 AIR INLET FILTER .............................. 23 2.2.4 SECONDARY SPIN-ON AIR/OIL COALESCER ....................23 2.2.5 MINIMUM PRESSURE/CHECK VALVE ......................
Page 6 ® ® TABLE OF CONTENTS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 2: DESCRIPTION (CONTINUED) 2.6.18 HOUR METER ..............................32 SECTION 3: SPECIFICATIONS......... 33 TABLE 3A: SPECIFICATIONS - WELDER AND GENERATOR.............. 33 TABLE 3B: SPECIFICATIONS - MOTOR....................33 TABLE 3C: SPECIFICATIONS — AIR COMPRESSOR ................. 33 TABLE 3D: SPECIFICATIONS —...
Page 7 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM TABLE OF CONTENTS SECTION 5: OPERATION (CONTINUED) 5.2.1 MACHINE START-UP ............................54 5.2.2 MACHINE SHUTDOWN............................55 MOTOR THROTTLE CONTROL FUNCTIONS................56 OPERATING THE WELDER......................56 5.4.1 WELDER OPERATING PROCEDURE ....................... 57 5.4.1.1 CC (CONSTANT CURRENT) MODE .................57 5.4.1.2 CV (CONSTANT VOLTAGE) MODE - USING A VOLTAGE SENSING SUITCASE FEEDER ................59 5.4.1.3 CV (CONSTANT VOLTAGE) MODE - USING A SPOOL GUN........59...
Page 8 ® ® TABLE OF CONTENTS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE (CONTINUED) 6.6.1.2 COMPRESSOR AIR FILTER INSPECTION ............. 75 6.6.1.3 COMPRESSOR AIR FILTER REPLACEMENT ............75 6.6.2 REPAIRING THE AIR INLET VALVE........................76 6.6.3 CHECKING THE COMPRESSOR OIL ........................78 6.6.4 REPLACING THE COMPRESSOR OIL FILTER ELEMENT ..................79 6.6.5 CHANGING THE COMPRESSOR OIL ........................80 6.6.6 REPLACING THE SPIN-ON AIR/OIL COALESCER ....................81...
Page 9 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM TABLE OF CONTENTS SECTION 8: DIAGRAMS ..........109 GENERAL INFORMATION ......................109 WIRING DIAGRAM - AIR N ARC 300 SERIES (HYDRAULIC) .............110 COMPRESSOR FLOW SCHEMATIC DIAGRAM ................111 SECTION 9: ILLUSTRATED PARTS LIST ..... 113 PARTS ORDERING PROCEDURE ....................113 TABLE 9A: RECOMMENDED SPARE PARTS LIST................114 AIR N ARC 300 SYSTEMS ASSEMBLIES ..................116...
Page 10 ® ® TABLE OF CONTENTS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - VIII 090034-OP_r0...
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 090034-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.vanair.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. SER No. R.P.M.
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
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM INTRODUCTION EXPERIENCE THE VANAIR ® AIR N ARC ALL-IN-ONE POWER SYSTEM ADVANTAGE! The Air N Arc All-In-One Power System is designed to provide compressed air, DC welding output, AC power, and battery boosting/charging in one easy to use interface.
Page 20: A Note On Manual Layout 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 motor 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: Hydraulic Safety
® ® 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: Hot Parts Can Cause Severe Burns
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY Have only qualified people remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. Disconnect negative (−) battery cable from battery to prevent accidental starting during servicing. Keep hands, hair, loose clothing, and tools away from moving parts.
Page 30: Enclosed Spaces Can Cause Abuild-Up Of Noxious Fumes And Overheating
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 1.6.2 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. 1.6.3 COMPRESSED AIR CAN CAUSE INJURY Wear approved safety goggles.
Page 31: Read Instructions
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY 1.6.7 READ INSTRUCTIONS Read Owner’s Manual before using or servicing unit. Stop motor and release air pressure before servicing. Use only genuine Air-N-Arc replacement parts. 1.7 ADDITIONAL SYMBOLS FOR INSTALLATION, OPERATION AND MAINTENANCE 1.7.1...
Page 32: Overuse Can Cause Overheating
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 1.7.4 OVERUSE CAN CAUSE OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. 1.7.5 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND...
Page 33: Arc Welding Can Cause Interference
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
Page 34: Principal Safety Standards
® ® SECTION 1: SAFETY AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Page 35: Emf Information
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, web site: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S.
Page 36: Machine Canopy Access Safety Switches
REAR DOOR SAFETY SWITCH Always dispose of machine fluids under the guidance of all applicable local, regional and/or federal law. Figure 1-1: Canopy Access Safety Switch ® Vanair encourages recycling when allowed. additional information, consult the container. 090034-OP_r0 PAGE - 18...
Page 37 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 1: SAFETY 090034-OP_r0 PAGE - 19...
Page 38: Section 2: Description
® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM Figure 2-1: MAJOR MACHINE COMPONENTS LOCATIONS DESCRIPTION DESCRIPTION AIR OUT AIR OUT PANEL COMPRESSOR FLUID FILL PORT A/C GENERATOR COMPRESSOR OIL FILTER HYDRAULIC MANIFOLD AIR TANK RESERVOIR (4 GAL.) HYDRAULIC MOTOR COMPRESSOR OIL COOLER FLOW CONTROLLER...
Page 39: General 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 PRESSURE SWITCH Figure 2-6: Pressure Switch Location DESCRIPTION HYDRAULIC FAN/ COOLER COMPRESSOR FAN/ COOLER Figure 2-7: Cooling System 090034-OP_r0 PAGE - 25...
Page 44: Compressor Temperature And Pressure Switches
® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM the hydraulic oil temperature switch. The compressor fan is turned on by the compressor oil temperature switch. compressor cooling system allows compressor lubricant temperature to be maintained to a minimum of approximately 160°F (71°C).
Page 45: Instrumentation
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 2: DESCRIPTION brushless style. These units should require maintenance since they do not have slip rings, nor slipping contacts. The end brackets are die-cast in a high resistance aluminum alloy, the shaft is C45 steel, and is fitted with a keyed fan.
Page 46: Volts/Amps Meter
® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM System Component or Manual Location Component Group Section Motor ON/RESET Switch 2.6.17 page 31 Hour Meter 2.6.18 page 32 See Figure 2-11. The standard instrument panel for the Air N Arc 300 Series contains a volts/amps meter, welder function switches, DC charger mode toggle switch, volts/ amps manual adjustment dial, compressor ON/OFF...
Page 47: Compressor Air Pressure Gauge
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 2: DESCRIPTION amperage or voltage, in variable increments, for the IMPORTANT desired weld heat. 2.6.5 COMPRESSOR AIR PRESSURE GAUGE DO NOT OPEN the instrument panel box. Opening the instrument panel box will The compressor air pressure switch/gauge indicates void the warranty.
Page 48 ® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION DESCRIPTION DC VOLTS/AMPS METER (2.6.1) AC GENERATOR CONTROL ON/OFF SWITCH (2.6.10) WELDER CC/CV TOGGLE SWITCH (2.6.2) AC VOLTAGE OUTLETS (2.6.11) DC CHARGER/WELDER TOGGLE SWITCH (2.6.2) AC CIRCUIT BREAKER TRIP/RESET BUTTONS (2.6.12) DC CHARGER MODE TOGGLE SWITCH (2.6.3) FRONT ACCESS PANEL OPEN LAMP (2.6.13) SHUT-...
Page 49: Generator Control On/Off Toggle Switch
If trouble persists, consult Section system problem. ® 7, Troubleshooting, or the Vanair Service Department. 2.6.13 FRONT ACCESS PANEL OPEN INDICATOR LAMP NOTE...
Page 50: Hydraulic Overtemp Indicator Lamp
® ® SECTION 2: DESCRIPTION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 2.6.16 HYDRAULIC OVERTEMP INDICATOR LAMP The hydraulic overtemp indicator lamp signifies that the machine has shut down due to excessive hydraulic oil temperature (180°+F). 2.6.17 MACHINE CONTROL (RESET) SWITCH The machine activation switch engages the phases of the motor, which is integral to all the functions of the 300 Series Power System.
Page 51: Section 3: Specifications
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 3: SPECIFICATIONS SECTION 3: SPECIFICATIONS TABLE 3A: SPECIFICATIONS - WELDER AND GENERATOR 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 3D: 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 3F: VARIOUS FUNCTION FACTORY SETTING RANGES FUNCTION FACTORY SETTING Motor No-Load Hi RPM 3100 Air Cut-in pressure Air Cut-out pressure AC generator Hz (no load) AC generator 240 plug (no load) AC generator 120 plug (no load) AC generator 120 plug (no load) Welder OCV Voltage...
Page 54 ® ® SECTION 3: SPECIFICATIONS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - 36 090034-OP_r0...
Page 55: Section 4: Installation
Machine Package Receipt/Inspection page 37 NOTE Air N Arc 300 Series All-In-One Machine page 38 Package Preparation ® Contact Vanair (219) 879-5100 / (800) 526-8817 General Overview of Installation page 38 Service Fax: (219) 879-5335 Preparing the Vehicle Service Body page 38 www.vanair.com...
Page 56: Ana 300 Series All-In-One Machine Package Preparation
® ® SECTION 4: INSTALLATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM ® 4.2 AIR N ARC 300 SERIES ALL-IN- ® NOTE MACHINE PACKAGE PREPARATION Refer to Section 4.10 for the proper installation and dimensions diagram (note that the section contains two parts/diagrams), and the following instructions.
Page 57 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 4: INSTALLATION System Component or Manual Location Part Group Task Section Machine Clearance Allowance 4.4.1 page 40 Determining Proper Ventilation 4.4.2 page 40 Requirements Roof Requirements (If Applicable) 4.4.3 page 40 When determining the best location to mount the Air N CAUTION...
Page 58: Machine Clearance Allowance
® ® SECTION 4: INSTALLATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM needed to assure stabiltity of the machine once it is mounted. CAUTION Note that improperly-mounted equipment may have the potentional to cause harm, and possibly cause damage or undo stress on the equipment.
Page 59 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 4: INSTALLATION NOTE If one side of machine is restricted to the minimum 6” clearance, then the other side should be left open to fresh air. DESCRIPTION DESCRIPTION WIDTH SIDES: Six (6) inches clearance HEIGHT ABOVE MACHINE: 16.19 inches of clear- space allowance ance space allowance for opening hood.
Page 60: Mounting The Machine
® ® SECTION 4: INSTALLATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 4.5 MOUNTING THE MACHINE Refer to Figure 4-1. Once all of the factors listed in Section 4.3 have been considered, and the machine placement location has been resolved, the machine must be fully unpackaged from its crate mounting.
Page 61: Separating The Machine From The Crate Mounting
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 4: INSTALLATION 4.5.1 SEPARATING THE MACHINE FROM THE CRATE MOUNTING Refer to Figure 4-2 and the following instructions. 1. Remove the nuts, lock washers, washers and mounting bolts used to fasten the machine to the shipping crate skid platform.
Page 62: Stabilizing Precautions For Machine Mounting
® ® SECTION 4: INSTALLATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION MOUNTING HOLE LOCATIONS Figure 4-5: Drill Point Locations 2. Refer to Figure 4-5 . Using a scribing tool or IMPORTANT pen, place a mark through all of both mounting holes [ A ] on the service body’s Vehicle mounting surface must be level, mounting surface.
Page 63: Grounding The Machine
A minimum of four (4) vibration isolators are location on the service body and route the control trunk required (Vanair no. PR271935). line to the location where the unit will mount. Ensure that Some or all of the mounting hardware used...
Page 64: Post-Set Up Initial Test Function
Air system piping relation to the 300 Series Mounting brackets are available to space panel off from truck body (Figure 4-7). machine. Contact Vanair® for details. • Hindrance to any access, or operation of, other standard or mounted vehicle system(s), including any under deck, or accessible wiring, piping, etc.
Page 65 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 4: INSTALLATION 4.7 . Use the following check list to aid in determining that all functions are ready for a test run. PRE-TEST FUNCTION CHECK LIST TASK SECTION COMPLETED REFERENCE ...
Page 66: Compressor Flow Schematic Diagram
® ® SECTION 4: INSTALLATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 4.11 COMPRESSOR FLOW SCHEMATIC DIAGRAM 271384_r1 PAGE - 48 090034-OP_r0...
Page 67: Installation And Dimensions Diagram (Part 1 Of 2)
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 4: INSTALLATION 4.12 INSTALLATION AND DIMENSIONS DIAGRAM (PART 1 OF 2) 050735ID_1of2_r0 090034-OP_r0 PAGE - 49...
Page 68: Installation And Dimensions Diagram (Part 2 Of 2)
® ® SECTION 4: INSTALLATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 4.12 INSTALLATION AND DIMENSIONS DIAGRAM (PART 2 OF 2) 050735ID_2of2_r0 PAGE - 50 090034-OP_r0...
Page 69 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 4: INSTALLATION BLANK PAGE 090034-OP_r0 PAGE - 51...
Page 70 ® ® SECTION 5: OPERATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION DESCRIPTION DC VOLTS/AMPS METER (2.6.1) AC GENERATOR CONTROL ON/OFF SWITCH (2.6.10) WELDER CC/CV TOGGLE SWITCH (2.6.2) AC VOLTAGE OUTLETS (2.6.11) DC CHARGER/WELDER TOGGLE SWITCH (2.6.2) AC CIRCUIT BREAKER TRIP/RESET BUTTONS (2.6.12) DC CHARGER MODE TOGGLE SWITCH (2.6.3) FRONT ACCESS PANEL OPEN LAMP (2.6.13) SHUT-...
Page 71: 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 72: Machine 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 62 Follow all applicable safety recommendations as outlined in Section Connection - Disconnection Sequence 5.7.1 page 62 1: Safety of this manual.
Page 73: Machine Shutdown
However, this method is best reserved for emergency additional information pertaining to the starting of the truck. ® shutdown situations only. Vanair recommends that the following procedure is used for routine shutdowns in order to keep the system in optimal condition, and...
Page 74: Motor Throttle Control Functions
® ® SECTION 5: OPERATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 1. Shut off any tools or other items that are drawing power from the generator, or compressed air from the air tank. 2. Close all service valves. 3.
Page 75: Welder Operating Procedure
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION while welding. NOTE System Operation Group Manual Location Section The amps/volts display will read the set Operating the Welder page 56 value for five (5) seconds when the dial is Welder Operating Procedure 5.4.1 page 57...
Page 76 If a longer welding lead is desired, 2. Select the appropriate electrode for the optional 25 and 50 ft. lead segments may material and process being performed. See be purchased from Vanair Table 5B: ELECTRODE SPECIFICATIONS Manufacturing, Inc. for a maximum lead for selecting an electrode.
Page 77: Cv (Constant Voltage) Mode - Using A Voltage Sensing Suitcase Feeder
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION 5.4.1.2 CV (CONSTANT VOLTAGE) MODE - USING A VOLTAGE SENSING SUITCASE FEEDER CV (Constant Voltage) Mode – commonly referred to as - Wire Welding, MIG welding, or Gas Metal Arc Welding (GMAW) 1.
Page 78: Operating The Generator
® ® SECTION 5: OPERATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM material being welded. At anytime during welding, the power dial may be adjusted to the desired voltage level. What the numbers mean that are used to identify a stick welding electrode: Using E6010 for an example...
Page 79: Operating The Air Compressor
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION To operate the generator: WARNING 1. See Section 5.2, Machine Start-Up Do not rely on the thermal overload Procedure. circuit breakers on the generator to 2. Turn the generator switch on the control panel protect personnel, power tools, or the to the ON position.
Page 80: Operating The Battery Booster/Charger
5.7 OPERATING THE BATTERY WARNING BOOSTER/CHARGER ® The Vanair state-of-the-art battery charging module and the optional battery charging cables add further versatility to the 300 Series Power System. The battery charging system operates off the DC generator, and not the main AC power generator.
Page 81: Extreme Condition Operation
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION positive terminal, BLACK to the negative IMPORTANT terminal ( Figure 5-6 ). 3. Plug the battery charge cables into the battery Never leave the machine unattended cable connection. while charging a battery.
Page 82: Cold Weather Operation
-40°F (-18°C to -40°C). Consult proper starting. Appendix Section A.5 (options list) and Vanair for details. COLD WEATHER SAFEGUARDS •Park the vehicle or equipment indoors when not in use. •Use a block heater or glow plugs.
Page 83: High Dust Content Operation
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 5: OPERATION the minimum, all coolers, including air passage ways around the coolers, should be free of debris and dirt. The operator should be aware that high temperatures can influence motor performance, which can directly effect some machine function capacity outputs.
Page 84 ® ® SECTION 5: OPERATION AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - 66 090034-OP_r0...
Page 85: Section 6: Maintenance
Section RED COMPRESSOR FILL CAP 1: Safety of this manual. FILL CAP BLEED VENT GROOVE ® Vanair Manufacturing, Inc. considers the maintenance Open/crack cap slightly to allow schedule given in Section 6.3, Maintenance Schedule bleed vent to relieve pressure Table, to be part of the warranty agreement with the customer.
Page 86: Maintenance Schedule Table
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM Vanair Manufacturing, Inc. especially requires that a NOTE consistent service regimen established compressor oil changes, and compressor air filter Operating the machine package in a servicing. when the motor and compressor air filters are severe environment may require more serviced, and the motor oil is changed.
Page 87 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 090034-OP_r0 PAGE - 69...
Page 88 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM PAGE - 70 090034-OP_r0...
Page 89 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 090034-OP_r0 PAGE - 71...
Page 90: Replacement Parts
300 SERIES ALL-IN-ONE POWER SYSTEM 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 91: Parts Replacement And Adjustment Procedures
Inspecting the System Coolers 6.6.11 page 91 Genuine Vanair Replacement Parts. Using replacement parts other than Adjusting The Motor Speed 6.6.12 page 92 Genuine Vanair Replacement Parts will Continued on next page void the warranty. 090034-OP_r0 PAGE - 73...
Page 92: Compressor Air Filter
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM Adjusting The Pressure Setting 6.6.13 page 92 WARNING Replacing and Re-tensioning the 6.6.14 page 94 Relieve pressure from the compressor Serpentine Drive Belts system before removing any Re-tensioning the Air Compressor components.
Page 93: Compressor Air Filter Inspection
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 6. Replace cover [B] and wing nuts [A]. 7. Close hood. 6.6.1.2 COMPRESSOR AIR FILTER INSPECTION Consult Figure 6-3 and the following procedure to inspect the compressor air filter REPLACEMENT TOOLS/ITEMS NEEDED PART(S)
Page 94: Repairing The Air Inlet Valve
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 4. Seat a new filter element [C] onto the filter mounting posts [D]. 5. Replace cover [B] and wing nuts [A]. 6. Close the hood. 7. Dispose of discarded filter within the guidelines of all applicable local, regional and/or federal laws.
Page 95 ® ® 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 96: 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 DANGER NEVER check the compressor oil level WARNING...
Page 97: Replacing The Compressor Oil Filter Element
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE Consult Figure 6-5 and the following procedure to check WARNING the compressor oil. Compressor oil can ignite if it comes in REPLACEMENT TOOLS/ITEMS NEEDED contact with very hot surfaces, like a PART(S) muffler or exhaust manifold on the motor.
Page 98: Changing The Compressor Oil
TOOLS NEEDED REPLACEMENT PART(S) pressure to the atmosphere. Clean Utility Hose ® Vanair Vanguard™ Refer to Figure 6-1. Open fill cap (18” in length) Premium Synthetic Oil SLOWLY (contents under pressure) to No. 264626-1GAL make sure all pressure has been relieved.
Page 99: 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 100: 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 101 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE M N P Q R B C D E DESCRIPTION DESCRIPTION - ASSEMBLY PART - KIT (REPLACEMENT) PART SERPENTINE BELT (COMPRESSOR) COMPRESSOR FRONT COVER CAPSCREW (10MM 1.5 x 30MM) O-RING WASHER SHAFT SEAL RING...
Page 102: Part Ii - Accessing The Compressor Unit Shaft Seal
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 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 103: Part Iii - Replacing The Compressor Serpentine Belt
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 15. Place the compressor cover [R] over its NOTE seating position on the compressor unit body. If present, scrape off any remnant pieces 16. Fasten compressor cover [R] to compressor of previous gasket from the compressor body using the four (4) pan head screws [Q].
Page 104 ® ® 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 105: 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 106: 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 107 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE DESCRIPTION DESCRIPTION HYDRAULIC SUPPLY MACHINE FRAME HYDRAULIC RETURN AIR STORAGE TANK AIR TANK MOISTURE DRAIN VALVE Figure 6-12: Air Tank Drain valve located at the lower right corner of the base frame on the back end of the machine.
Page 108: 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 109: 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 110: Adjusting The Motor Speed
Should any residue appear during inspection, clear with the use of air blown across the surface of the cooler fins. 6.6.12 ADJUSTING THE MOTOR SPEED ® Consult the Vanair Service Department for issues relating to adjustment of motor speed. NOTE WARNING...
Page 111 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE DESCRIPTION PRESSURE SWITCH COMPRESSOR CUT-IN PRESSURE ADJUSTMENT SCREW Figure 6-15: Pressure Switch Adjustment for Cut-in / Cut-out Pressure Settings The Cut-out pressure is defined as the pressure in which the compressor stops pumping.
Page 112: 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 113: Replacing The Air Compressor Serpentine Drive Belt
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 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 114: Re-Tensioning The Generator Serpentine Belt
® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION HYDRAULIC MOTOR AIR COMPRESSOR SERPENTINE BELT COMPRESSOR UNIT IDLER SHEAVE AIR COMPRESSOR DRIVE SHEAVE GENERATOR SERPENTINE BELT (ref) Figure 6-17: Compressor Serpentine Belt Positioning making sure that it goes on the outside of the double sheave track on the motor pulley.
Page 115: Replacing The Generator Serpentine Drive 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 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION DESCRIPTION DC GENERATOR SHEAVE COMPRESSOR SERPENTINE BELT AC GENERATOR SHEAVE GENERATOR BELT TENSIONER PLATE GENERATOR IDLER SHEAVE TENSIONER PLATE MOUNTING AND ADJUSTMENT BOLT GENERATOR SERPENTINE BELT Figure 6-19: Generator Serpentine Belt Positioning To replace the generator serpentine belt consult Figures 6-19, and the following procedure:...
Page 117: Servicing The System Fuses And Circuit Breakers
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 6: MAINTENANCE 5. At this point the belt will need to be checked NOTE for proper tension. Consult Section 6.6.15.3 on how to re-tension the generator Compressor belt goes on the outer track serpentine belt, and Section 6.6.15.1 to re- of the motor sheave;...
Page 118 ® ® SECTION 6: MAINTENANCE AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM DESCRIPTION DESCRIPTION R1 - A/C GENERATOR 15 AMP FUSE WELDER FIELD R2 - SWITCHED POWER 15 AMP FUSE COMPRESSOR FAN R3 - HYDRAULIC FAN 25 AMP FUSE HYDRAULIC FAN R4 - COMPRESSOR FAN 50 AMP CIRCUIT BREAKER - AUTO RESET...
Page 119: 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 120: 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 COMPRESSOR Compressor overheats Low compressor oil level Check oil level and refill to proper level if necessary (ensure machine is parked on a This condition will cause a level surface).
Page 121 Possible Cause Corrective Action COMPRESSOR (CONTINUED) Compressor shuts down with air Plugged or restricted cooler core Flush cooler. Consult the Vanair Service demand present (continued) 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 122 ® ® 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) Repair/replace inlet valve. Refer to Section Compressor will not build up Inlet valve fails to open or is frozen 6.6.2, Repairing the Air Inlet Valve.
Page 123 ® ® 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 gauge is malfunctioning Check gauge for proper operation; replace if pressures (continued) necessary and check controls. No service air output If equipped, OSHA valve/velocity fues, Reset or replace OSHA valve.
Page 124 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. Connections not making contact Correct connection at lug and clamp Belt slipping Re-tension or replace belt.
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 WELDER (CONTINUED) No welder output Fuse at welder field blown Replace the welder field fuse. Refer to Section 6.7, Servicing the System Fuses and Circuit Breakers Low battery voltage Check/replace battery...
Page 126 ® ® SECTION 7: TROUBLESHOOTING AIR IN ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - 108 090034-OP_r0...
Page 127: 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 128: Wiring Diagram - Air N Arc 300 Series (Hydraulic)
® ® SECTION 8: DIAGRAMS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 8.2 WIRING DIAGRAM - AIR N ARC 300 SERIES (HYDRAULIC) ID271382_r2 PAGE - 110 090034-OP_r0...
Page 129: Compressor Flow Schematic Diagram
® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 8: DIAGRAMS 8.3 COMPRESSOR FLOW SCHEMATIC DIAGRAM DESCRIPTION DESCRIPTION HYDRAULIC COOLER PRESSURE SWITCH HYDRAULIC MOTOR COMPRESSSOR 12V SOLENOID VALVE OIL FILTER FLOW CONTROL OIL FILL FLOW ADJUSTMENT COMPRESSOR COOLER PRESSURE RELIEF VALVE INSTRUMENT PANEL AIR FILTER...
Page 130 ® ® SECTION 8: DIAGRAMS AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - 112 090034-OP_r0...
Page 131: 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 132 Figure 6-4 ® 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! NOTE NOTE For a complete list of available...
Page 133 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST NOTES 090034-OP_r0 PAGE - 115...
Page 134: 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 PA6130044_r1 PAGE - 116 090034-OP_r0...
Page 135 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.2 AIR N ARC 300 SYSTEMS ASSEMBLIES ITEM DESCRIPTION PART NUMBER SCHEMATIC, FLOW ANA 300 HYDRAULIC 271384 HARNESS, MAIN MACHINE EP271411 AIR STORAGE ASSEMBLY PA6000027ID ID, COMPRESSOR &...
Page 136: 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) PA6010072ID_r1 PAGE - 118 090034-OP_r0...
Page 137 TUBING, 1/4 DIA., NYLON, 230 PSI X 3 FT 264480. OIL, VANGUARD 3.5 QUARTS 264626 ELBOW,1/2MPT x 1/2FJIC SWVL 90 268929-008 COMPR & PART VANAIR 31 EMC, 12VDC STD SHAFT 269761 SWITCH , TEMPERATURE (ELECTRIC) 270853 TEE, PIPE GALV 1/2 804415-020...
Page 138: Compressor And Parts Assembly (2 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.3 COMPRESSOR AND PARTS ASSEMBLY (2 OF 2) PA6010072ID_r1 PAGE - 120 090034-OP_r0...
Page 139 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.3 COMPRESSOR AND PARTS ASSEMBLY (2 OF 2) ITEM DESCRIPTION PART NUMBER CONNECTOR, 37FL/MPT #08 x 1/2 860108-050 TENSIONER, AIR END A1270372 BRACKET, COMPRESSOR MTG A1270373 WASHER, SHEAVE COMPRESSOR A1270884...
Page 140: Cooling System
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.4 COOLING SYSTEM PA6020033ID_r2 PAGE - 122 090034-OP_r0...
Page 141 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.4 COOLING SYSTEM ITEM DESCRIPTION PART NUMBER ELBOW, 90 DEG. #16 MJIC x #12 MSAE 260403-117 ELBOW, 90 DEG. SWIVEL #12 FJIC x #12 MJIC 261842-008 SEAL, RUBBER "D"...
Page 142: Cooling System - Compressor
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.5 COOLING SYSTEM - COMPRESSOR PA6020036ID_r1 PAGE - 124 090034-OP_r0...
Page 143 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.5 COOLING SYSTEM - COMPRESSOR ITEM DESCRIPTION PART NUMBER COOLER, OIL NK40 264121 SEAL, RUBBER "D" TRIM-LOK 1" x 1" 264138 1.3 FT FAN & MOTOR ASSY. 13" PUSH 12V 271446 NUT, HEX FLANGE 1/4-20 825304-236...
Page 144: Frame And Canopy
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.6 FRAME AND CANOPY ASSEMBLY PA6030031ID_r0 PAGE - 126 090034-OP_r0...
Page 145 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.6 FRAME AND CANOPY ASSEMBLY 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 LATCH, SENTRY PANEL...
Page 146: Instrument Panel (1 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.7 INSTRUMENT PANEL (1 OF 2) PA6040027ID_r1 PAGE - 128 090034-OP_r0...
Page 147 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.7 INSTRUMENT PANEL (1 OF 2) 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 TUBING, 1/4 DIA., NYLON, 230 PSI X 1.25 FT...
Page 148: Instrument Panel (2 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.7 INSTRUMENT PANEL (2 OF 2) PA6040027ID_r1 PAGE - 130 090034-OP_r0...
Page 149 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.7 INSTRUMENT PANEL (2 OF 2) ITEM DESCRIPTION PART NUMBER LAMP, INDICATOR, LED, RED CO89659 DECAL, FACEPLATE DL271380 DECAL, CONTROL PANEL, WELDER DL271380-002 RECEPTACLE, PANEL 350 AMP EL269932 RECEPTACLE, 240V/30A TURNLOC EL270148...
Page 150: Generators And Parts
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.8 GENERATOR AND PARTS PA6050012ID_r1 PAGE - 132 090034-OP_r0...
Page 151 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.8 GENERATOR AND PARTS ITEM DESCRIPTION PART NUMBER GENERATOR, AC, 6.8KW 269530 KEY, SQUARE 3/16 x 3/16 x 1.5 821103-150 NUT, HEX LOCKING 1/2-13 825508-262 CAPSCREW, HEX GR5 1/4-20 x 1 1/4 829104-125 CAPSCREW, HEX GR8 5/16-18 x 1.0 LG.
Page 152: Motor Assembly
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.9 MOTOR ASSEMBLY PA6100027ID_r2 PAGE - 134 090034-OP_r0...
Page 153 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.9 MOTOR ASSEMBLY ITEM DESCRIPTION PART NUMBER ELBOW, 90 DEG #10 MJIC x #10 MSAE 260403-106 ELBOW, 90 DEG #12 MJIC x #12 MSAE 260403-107 NUT, HEX LOCKING 3/8-16 825506-198 CAPSCREW, HEX GR5 1/2-13 x 1.5...
Page 154: Air Storage Tank
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.10 AIR STORAGE TANK PA6000027ID_r4 PAGE - 136 090034-OP_r0...
Page 155 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.10 AIR STORAGE TANK 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 TUBING, 1/4 DIA., NYLON, 230 PSI x 3.5 FT 264480...
Page 156: Assembly Flow Control (1 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.11 ASSEMBLY FLOW CONTROL (1 OF 2) PA6120097ID_r4 PAGE - 138 090034-OP_r0...
Page 157 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.11 ASSEMBLY FLOW CONTROL (1 OF 2) ITEM DESCRIPTION PART NUMBER CONNECTOR, O-RING 7/8 x 1-1/16JIC 260387-110 CONNECTOR, O-RING 3/4 x 3/4 JIC 260387-112 ELBOW, 90 DEG. #12 MJIC x #12 MSAE 260403-107 ELBOW, 90 DEG.
Page 158: Assembly Flow Control (2 Of 2)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.11 ASSEMBLY FLOW CONTROL (2 OF 2) PA6120097ID_r4 PAGE - 140 090034-OP_r0...
Page 159 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.11 ASSEMBLY FLOW CONTROL (2 OF 2) ITEM DESCRIPTION PART NUMBER DECAL, HYDRAULIC LABEL DL271919 THERMOSTAT, DISC CLOSE ON RISE 100 F EL270040 PIPE BRASS, BULKHEAD 1/4 NPT FI45068 HOSE, COOLER TO RETURN TU271455-007...
Page 160: Decal Locations (1 Of 3)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.12 DECAL LOCATIONS (1 OF 3) WARNING WARNING WARNING Rotating parts Accidental starts can cause severe can cause injury or death. severe injur y. Disconnect battery Stay away while and ground engine and...
Page 161 DL270120 DECAL, SULPHURIC ACID 264375 DECAL, HOT PARTS 264372 DECAL, CARBON MONOXIDE 264376 DECAL, CAP REMOVAL 049685 DECAL, VANAIR INFORMATION DECAL, HIGH PRESSURE HYDRAULIC SYSTEM 264380 DECAL, ROTATING PARTS 264374 DECAL, ACCIDENTAL STARTS 264373 DECAL, COMPRESSOR MAINTENANCE DECAL, FAN GUARD...
Page 162: Decal Locations (2 Of 3)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.12 DECAL LOCATIONS (2 OF 3) FRONT VIEW HYDRAULIC SUPPLY HYDRAULIC RETURN AIR TANK DRAIN Drain Daily REAR VIEW HYDRAULIC PAGE - 144 090034-OP_r0...
Page 163 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.12 DECAL LOCATIONS (2 OF 3) ITEM DESCRIPTION PART NUMBER DECAL, ANA 300 VANAIR LOGO 16.5” DL269707 DECAL, ANA BY VANAIR, WHT. 269706 DECAL, HYDRAULIC SUPPLY DECAL, HYDRAULIC RETURN DECAL, AIR TANK DRAIN...
Page 164: Decal Locations (3 Of 3)
® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM 9.12 DECAL LOCATIONS (3 OF 3) HYDRAULIC SUPPLY HYDRAULIC RETURN AIR TANK DRAIN Drain Daily PAGE - 146 090034-OP_r0...
Page 165 ® ® AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM SECTION 9: ILLUSTRATED PARTS LIST 9.12 DECAL LOCATIONS (3 OF 3) ITEM DESCRIPTION PART NUMBER DECAL, COMPRESSOR FLUID DRAIN DECAL, HYDRAULIC SUPPLY DECAL, HYDRAULIC RETURN DECAL, AIR TANK DRAIN This decal is included with decal sheet no. 263452. WARNING DO NOT REMOVE OR COVER ANY SAFETY DECAL.
Page 166 ® ® SECTION 9: ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM PAGE - 148 090034-OP_r0...
Page 167: 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 168: 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 169: 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 170: Air Tool Air Consumption Chart
® ® 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 4-6 CFM 5” High Speed Sanders 4-6 CFM Jitterbug Sanders 4 CFM Straight Line Sanders 4 CFM...
Page 171: 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 lb Pavement Breaker 48 CFM 90 lb Pavement Breaker 68-85 CFM 4” Piercing Tool 60 CFM 60 lb 1650 BPM Rock Drill 95 CFM...
Page 172 ® ® 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 WELD HELMET 2 x 4 auto-darkening lens, solid color (blue) MA269903 WELD HELMET LENSE Replacement lense for welding shield...
Page 173: 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 174 ® ® APPENDIX A: ADDITIONAL INFORMATION AIR N ARC 300 ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - 156 090034-OP_r0...
Page 175: 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 176: 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 177 ® ® 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 178 ® ® APPENDIX B: MAINTENANCE AND SERVICE LOG AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM BLANK PAGE PAGE - 160 090034-OP_r0...
Page 179 BLANK PAGE...
Page 180 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 2: Description

Section 2: Description (Continued)

Section 3: Specifications

Section 4: Installation

Section 5: Operation (Continued)

Section 5: Operation

Section 6: Maintenance

Parts Replacement and Adjustment Procedures Caution

Section 6: Maintenance (Continued)

Section 7: Troubleshooting

Section 8: Diagrams

Section 9: Illustrated Parts List

Appendix A: Additional Information

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