Vanair AIR N ARC RELIANT 250 Series User manual

ALL-IN-ONE POWER SYSTEMS®
WELDER • GENERATOR • AIR COMPRESSOR • BATTERY BOOSTER
OPERATION MANUAL & PARTS LIST
©2013 Vanair Manufacturing, Inc.
All rights reserved
Addendum 090044_r0
to Manual 090019-OP_r0
Effective Date:
4-2013
Vanair Manufacturing, Inc.
10896 West 300 North
Michigan City, IN 46360
www.vanair.com
NOTE:
THIS EXCERPT IS THE AIR-N-ARC 250 ADDENDUM TO
THE AIR-N-ARC 200 MANUAL.
Vanair Manufacturing, Inc.
Phone: [phone]
[phone]
Service Fax: [phone]
Parts Fax: [phone]
Sales Fax: [phone]

Addendum 090044
PAGE II
ADDENDUM AIR N ARC®250 SERIES ALL-IN-ONE POWER SYSTEM®
Addendum 090044
THE FOLLOWING ARE CHANGES
IN SPECIFICATIONS THAT
AFFECT THE AIR-N-ARC 250:
1. RATED WELDER OUTPUT:
250A high Frequency DC/CC, DC/CV,
100% duty Cycle @ 250 Amps
2. OIL CAPACITY:
2 Quarts
3. WELDER MAX AMPERAGE:
250+/-5
4. VARIABLE POWER DIAL ADJUSTS
THE WELDER AMPERAGE
Range: from 30 to 255 AMPS
5. MACHINE COMES STANDARD WITH
A 30 GALLON AIR TANK.
6. OPTIONS NO LONGER AVAILABLE:
Welding Rod P/N M/A98018
Welding Rod P/N MA44890
Welding Rod P/N MA99727
CONTINUED ON NEXT PAGE

Addendum 090044
AIR N ARC®250 SERIES ALL-IN-ONE POWER SYSTEM®ADDENDUM
PAGE III
BLANK PAGE

Addendum 090044
PAGE IV
ADDENDUM AIR N ARC®250 SERIES ALL-IN-ONE POWER SYSTEM®
1
3
15
7
9
4
11
13
8
5
12
14
8
5
16 10
17
2
9.6 ENGINE AND DRIVE PARTS
PA6100021ID_r0

9.6 ENGINE AND DRIVE PARTS
ITEM DESCRIPTION PART NUMBER QTY
1 CAP, RAIN 1-1/4” EXHAUST 262706 1
2 CLAMP, EXHAUST 1-1/4 REV.0 262906 1
3 CLAMP, LOOM #010 5/8” 268503 1
4 KEY, SQUARE 1/4 x 1/4 x 3 821104-300 1
5 CAPSCREW, HEX GR5 1/4-20 x 1-1/4 829104-125 5
6 CAPSCREW, HEX GR5 3/8-16 x 1.50 829106-150 1
7 CAPSCREW, HEX GR5 3/8-16 x 1.75 829106-175 3
8 WASHER, LOCK 1/4 838504-062 5
9 WASHER, LOCK 3/8 838506-094 4
10 OIL, MOTOR 10W30, 2.5 QUART 844300-001 1
11 SHEAVE, SERPENTINE, 8 GROOVE A15891Z 1
12 SHEAVE, 2 GROOVE, 5.75 DOUBLE A, ZINC DR76765Z 1
13 BUSHING, SDS, QD, 1-1/8 DIA. DR85785Z 1
14 BUSHING, L, QD, 1-1/8 DIA., 2 BOLT DR92958Z 1
15 HOSE, DRAIN 3/8 x 12” LG 3/8NPT EN22698 1
16 ENGINE, GAS KOHLER 25HP EFI EN270958 1
17 TUBE, EXHAUST 1.25 DIA. TU270889 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

Printed in the U.S.A.
Specifications Subject to Change
Without Prior Notice
Vanair Manufacturing, Inc.
10896 West 300 North
Michigan City, IN 46360
Phone: [phone]
[phone]
Service Fax: [phone]
Parts Fax: [phone]
Sales Fax: [phone]
www.vanair.com

ALL-IN-ONE POWER SYSTEMS®
WELDER • GENERATOR • AIR COMPRESSOR • BATTERY BOOSTER
OPERATION MANUAL & PARTS LIST
©2011 Vanair Manufacturing, Inc.
All rights reserved
090019-OP_r0
Effective Date:
05-11
NOTE
Read this manual before installing,
operating or servicing this
equipment. Failure to comply with
the operation and maintenance
instructions in this manual WILL
VOID THE EQUIPMENT WARRANTY.
NOTE
Use only Genuine Vanair Parts.
Inspect and replace damaged
components before operation.
Substituting non-Vanair
components WILL VOID THE
COMPRESSOR WARRANTY!
Vanair Manufacturing, Inc.
10896 West 300 North
Michigan City, IN 46360
Phone: [phone]
[phone]
Service Fax: [phone]
Parts Fax: [phone]
Sales Fax: [phone]
www.vanair.com
NOTE
Making unauthorized modifications to
the system components WILL VOID THE
WARRANTY!
Always inform Vanair Manufacturing,
Inc., before beginning any changes to
the Air N Arc system.
KEEP THE MANUAL
WITH THE VEHICLE

This limited warranty supersedes all previous Vanair warranties
and is exclusive with no other guarantees or warranties
expressed or implied.
LIMITED WARRANTY—Subject to the expressed terms and
conditions set forth below, Vanair Mfg., Inc. (“Vanair”), of
Michigan City, Indiana (USA), warrants to the original retail
purchaser of new Vanair equipment that such equipment is free
from defects in materials and workmanship when shipped by
Vanair.
For warranty claims received by Vanair within the applicable
warranty periods described below, Vanair will repair or replace
any warranted equipment, parts or components that fail due to
defects in material or workmanship or refund the purchase price
for the equipment, at Vanair’s discretion. Vanair is not
responsible for time or labor to gain access to the machine to
preform work. WARRANTY WILL BE VOID IF GENUINE VANAIR
PARTS AND FLUIDS ARE NOT USED.
Vanair must be notied in writing within thirty (30) days of any
such defect or failure. No warranty work or returns without prior
authorization is allowed. Vanair will provide instructions on the
warranty claim procedures to be followed.
Warranty will commence upon receipt of the Warranty
Registration Card. If the Warranty Registration Card is not
received within six (6) months of shipment from Vanair, the
warranty commencement date shall be thirty (30) days from the
date of shipment from Vanair. Records of warranty adherence
are the responsibility of the end user.
1. Lifetime Warranty Parts – 3 Years Labor
• Rotary Screw Air Compressor Air End
2. 6 Years Parts – 3 Years Labor
• Vanair Super Capacitor (VSC)
3. 3 Years Parts – 1 Year Labor
• Reciprocating Compressor Air End
• Generators
• Welders
4. 2 Years Parts – 1 Year Labor
• Hydraulic Motors
• Hydraulic Pumps
5. 1 Year Parts – 1 Year Labor
• All electronics including, but not limited to:
(i) I/O Boards
(ii) Modules
(iii) Panel Boxes
(iv) Instrumentation
(v) Clutches
(vi) Solenoids
(vii) Running Gear/Trailers
(viii) Compressor/Hydraulic Coolers, including Fan
and Radiator Core
This Limited Warranty shall not apply to:
1. Consumable components, such as shaft seals,
valves, belts, lters, capacitors, contactors, relays,
brushes or parts that fail due to normal wear and use.
2. Items furnished by Vanair, but manufactured by
others, such as engines and trade accessories (these items
are covered by the manufacturer’s warranty, if any).
3. Equipment that has been modied by any party other
than Vanair or equipment which has not been used and
maintained in accordance with Vanair’s specications.
4. Equipment which has been improperly installed
and/or improperly operated, based upon Vanair’s
specications for the equipment or industry standards.
5. Equipment installed by non-authorized or third party
personnel.
Vanair products are intended for purchase and use by
commercial/industrial users and persons trained and
experienced in the use and maintenance of industrial
equipment.
In the event of a warranty claim covered by this Limited
Warranty, the exclusive remedies shall be, at Vanair’s sole
discretion: (i) repair; or (ii) replacement; (iii) where authorized in
writing by Vanair in appropriate cases, the reasonable cost of
repair or replacement at an authorized Vanair service facility ; or
(iv) payment of (or credit for) the purchase price (less reasonable
depreciation based upon actual use) upon return of the
equipment at the warranty claimant’s risk and expense. Vanair
will pay standard ground freight for any warranty item shipped
to and from Vanair or (Vanair designated facility) within the rst
year of the applicable warranty period. Any additional expedited
freight cost is the responsibility of the purchaser.
TO THE GREAT EXTENT PERMITTED BY APPLICABLE LAW, THE
REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES APPLICABLE TO THE VANAIR EQUIPMENT. IN NO
EVENT SHALL VANAIR BECOME LIABLE FOR DIRECT, INDIRECT,
SPECIAL, PUNITIVE, INCIDENTAL OR CONSEQUENTIAL DAMAGES
(INCLUDING LOSS OF PROFIT OR LOST BUSINESS
OPPORTUNITY), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY. IN NO EVENT SHALL VANAIR BECOME
OBLIGATED TO PAY MORE ON ANY WARRANTY CLAIM THAN THE
PURCHASE PRICE ACTUALLY PAID BY THE ORIGINAL RETAIL
PURCHASER.
THIS LIMITED WARRANTY IS MADE IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A
PARTICULAR PURPOSE, OR ANY OTHER WARRANTY OR
GUARANTY ARISING BY OPERATION OF LAW. ANY WARRANTY
NOT EXPRESSLY PROVIDED HEREIN, IMPLIED WARRANTY,
GUARANTY AND ANY REPRESENTATION REGARDING THE
PERFORMANCE OF THE EQUIPMENT, AND ANY REMEDY FOR
BREACH OF CONTRACT, IN TORT, OR ANY OTHER LEGAL THEORY
WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY
IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE, OR
COURSE OF DEALING ARE EXCLUDED AND DISCLAIMED BY
VANAIR.
Some states in the United States of America do not allow
limitations of how long an implied warranty lasts, or the
exclusion of incidental, indirect, special or consequential
damages, and as such, the above limitations and exclusions may
not apply to you. This warranty provides specic legal rights.
Other rights may be available to you, but may vary from state to
state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be saved, the limitations and
exclusions set out forth above may not apply. This Limited
Warranty provides specic legal rights, and other rights may be
available, but may vary from province to province.
AIR N ARC®
ALL-IN-ONE POWER-SYSTEMS®
RELIANT™ SERIES
POWERFLEX™ SERIES
PRO SERIES
CONTRACTOR SERIES
VIPER™ SERIES
FST™ SERIES
10896 W. 300 N.
MICHIGAN CITY, IN 46360
[phone]
VANAIR.COM
EFFECTIVE: JAN 8, 2016
(844) VAN - SERV
[e-mail]
[e-mail]
090088_r1 MOBILE POWER SOLUTIONS

AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®TABLE OF CONTENTS
090019-OP_r0 PAGE - I
TABLE OF CONTENTS
WARRANTY ............................................... BEHIND COVER
TABLE OF CONTENTS......................................................I
GLOSSARY........................................................................VII
G.1 GENERAL TERMS AND DEFINITIONS ........................................................................................VII
G.2 WELDING TERMS AND DEFINITIONS.........................................................................................VII
G.3 AIR COMPRESSOR TERMS AND DEFINITIONS ........................................................................VIII
WARRANTY CLAIMS PROCEDURE .............................. XI
CLAIMS PROCESS FOR WARRANTED PARTS....................................................................................XI
PROCEDURE..........................................................................................................................................XI
INTRODUCTION.................................................................1
EXPERIENCE THE VANAIR ADVANTAGE.............................................................................................1
A NOTE ON MANUAL NAVIGATION......................................................................................................2
SECTION 1: SAFETY ........................................................3
1.1 GENERAL INFORMATION ............................................................................................................3
1.2 DANGERS, WARNINGS, CAUTIONS, AND NOTES ....................................................................3
1.3 INTERNATIONAL SAFETY SYMBOL............................................................................................4
1.4 ARC WELDING HAZARDS............................................................................................................4
1.4.1 ELECTRICAL SHOCK CAN KILL........................................................................................................................ 4
1.4.2 FUMES AND GASES CAN BE HAZARDSOUS.................................................................................................. 6
1.4.3 BUILD UP OF GAS CAN INJURE OR KILL........................................................................................................ 6
1.4.4 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING...................... 7
1.4.5 ARC RAYS CAN BURN EYES AND SKIN.......................................................................................................... 7
1.4.6 WELDING CAN CAUSE FIRE AND EXPLOSION.............................................................................................. 7
1.4.7 FLYING METAL CAN INJURE EYES.................................................................................................................. 8
1.4.8 HOT PARTS CAN CAUSE SEVERE BURNS..................................................................................................... 9
1.4.9 NOISE CAN DAMAGE HEARING....................................................................................................................... 9
1.4.10 MAGNETIC FIELDS CAN AFFECT PACEMAKERS........................................................................................... 9
Continued on next page...

TABLE OF CONTENTS AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - II 090019-OP_r0
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 HOT PARTS CAN CAUSE SEVERE BURNS......................................................................................................11
1.5.5 ENGINE EXHAUST GASES CAN KILL ...............................................................................................................11
1.5.6 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING.......................11
1.5.7 BATTERY ACID CAN BURN SKIN AND EYES ...................................................................................................12
1.5.8 ENGINE HEAT CAN CAUSE FIRE......................................................................................................................12
1.5.9 EXHAUST SPARKS CAN CAUSE FIRE..............................................................................................................12
1.6 COMPRESSED AIR HAZARDS.................................................................................................... 12
1.6.1 BREATHING CCOMPRESSED AIR CAN CAUSE SERIOUIS INJURY OR DEATH ...........................................12
1.6.2 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING.......................12
1.6.3 COMPRESSED AIR CAN CAUSE INJURY.........................................................................................................13
1.6.4 TRAPPED AIR PRESSURE AND WHIPPING HOSES CAN CAUSE INJURY....................................................13
1.6.5 HOT METAL FROM AIR ARC CUTTING AND GOUGING CAN CAUSE FIRE OR EXPLOSION.......................13
1.6.6 HOT PARTS CAN CAUSE SEVERE BURNS......................................................................................................13
1.6.7 READ INSTRUCTIONS........................................................................................................................................13
1.7 ADDITIONAL SYMBOLS FOR INSTALLATION, OPERATION AND MAINTENANCE.................. 14
1.7.1 FALLING UNIT CAN CAUSE INJURY..................................................................................................................14
1.7.2 OVERHEATING CAN DAMAGE MOTORS..........................................................................................................14
1.7.3 FLYING SPARKS CAN CAUSE INJURY..............................................................................................................14
1.7.4 OVERUSE CAN CAUSE OVERHEATING...........................................................................................................14
1.7.5 ENCLOSED SPACES CAN CAUSE A BUILD-UP OF NOXIOUS FUMES AND OVERHEATING.......................15
1.7.6 TILTING OF TRAILER CAN CAUSE INJURY......................................................................................................15
1.7.7 READ INSTRUCTIONS........................................................................................................................................15
1.7.8 H.F. RADIATION CAN CAUSE INTERFERENCE................................................................................................15
1.7.9 ARC WELDING CAN CAUSE INTERFERENCE.................................................................................................16
1.8. CALIFORNIA PROPOSITION 65 WARNINGS.............................................................................. 16
1.9 PRINCIPAL SAFETY STANDARDS .............................................................................................. 17
1.10 EMF INFORMATION ..................................................................................................................... 18
1.11 SAFETY DECALS ......................................................................................................................... 18
1.12 DISPOSING OF MACHINE FLUIDS.............................................................................................. 19
Continued on next page...

AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®TABLE OF CONTENTS
090019-OP_r0 PAGE - III
SECTION 2: DESCRIPTION ..............................................22
FIGURE 2-1: MAJOR MACHINE COMPONENTS LOCATIONS.............................................................20
2.1 GENERAL DESCRIPTION ................................................................................................................22
2.2 COMPRESSED AIR SYSTEM...........................................................................................................22
2.2.1 COMPRESSOR UNIT............................................................................................................................................... 22
2.2.2 AIR INTAKE / AIR FILTER.................................................................................................................................. 23
2.2.3 PRESSURE RELIEF VALVE............................................................................................................................... 24
2.2.4 PILOT VALVE...................................................................................................................................................... 24
2.3 ENGINE..........................................................................................................................................25
2.4 AC GENERATOR...........................................................................................................................26
2.5 INSTRUMENTATION .....................................................................................................................27
2.5.1 VOLTS/AMPS DISPLAY...................................................................................................................................... 29
2.5.2 WELDER FUNCTION SWITCHES...................................................................................................................... 29
2.5.3 FUEL GAUGE/HOUR METER ............................................................................................................................ 29
2.5.4 ENGINE CONTROL (ON/OFF/START) SWITCH................................................................................................ 29
2.5.5 CIRCUIT BREAKER OVERLOAD TRIP/RESET BUTTONS............................................................................... 29
2.5.6 AC VOLTAGE OUTLETS..................................................................................................................................... 30
2.5.7 GENERATOR CONTROL ON/OFF TOGGLE SWITCH...................................................................................... 30
2.5.8 DC CHARGER MODE TOGGLE SWITCH ......................................................................................................... 30
2.5.9 VOLTS/AMPS MANUAL ADJUSTMENT DIAL ................................................................................................... 30
2.5.10 COMPRESSOR AIR GAUGE.............................................................................................................................. 30
2.5.11 BATTERY CABLE RECEPTACLE....................................................................................................................... 30
2.5.12 WELDER LEAD CONNECTION.......................................................................................................................... 30
SECTION 3: SPECIFICATIONS.........................................31
TABLE 3A: WELDER, GENERATOR, AND ENGINE SPECIFICATIONS................................................31
TABLE 3B: AIR COMPRESSOR SPECIFICATIONS...............................................................................31
TABLE 3C: UNIT WEIGHT AND DIMENSIONS SPECIFICATIONS .......................................................32
TABLE 3D: BOLT AND TORQUE SPECIFICATIONS.............................................................................32
TABLE 3E: VARIOUS FUNCTION ACCEPTABLE TESTING OUTPUT RANGES .................................33
SECTION 4: INSTALLATION.............................................35
4.1 MACHINE PACKAGE RECEIPT/INSPECTION.............................................................................35
4.2 MACHINE PACKAGE PREP..........................................................................................................35
4.3 SERVICE BODY PREP..................................................................................................................35
4.4 MACHINE PACKAGE MOUNTING................................................................................................36
Continued on next page...

TABLE OF CONTENTS AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - IV 090019-OP_r0
SECTION 4: INSTALLATION (CONTINUED)
4.5 INSTALLATION AND DIMENSIONS DIAGRAM (PART 1 OF 2)................................................... 39
4.5 INSTALLATION AND DIMENSIONS DIAGRAM (PART 2 OF 2)................................................... 40
SECTION 5: OPERATION.................................................41
5.1 GENERAL INFORMATION ........................................................................................................... 41
5.2 ENGINE START-UP AND SHUTDOWN PROCEDURE ............................................................... 43
5.2.1 ENGINE START-UP.............................................................................................................................................43
5.2.2 ENGINE SHUTDOWN..........................................................................................................................................44
5.3 ENGINE THROTTLE CONTROL FUNCTIONS............................................................................. 45
5.4 OPERATING THE WELDER.........................................................................................................45
5.4.1 WELDING OPERATOR PROCEDURE................................................................................................................46
5.4.1.1 CC (CONSTANT CURRENT) MODE......................................................................................46
5.4.1.2 CV (CONSTANT VOLTAGE) MODE - USING AVOLTAGE SENSING SUITCASE FEEDER.............47
5.4.1.3 CV (CONSTANT VOLTAGE) MODE - USING ASPOOL GUN....................................................48
5.5 OPERATING THE GENERATOR.................................................................................................. 49
5.6 OPERATING THE AIR COMPRESSOR....................................................................................... 49
5.7 OPERATING THE BATTER BOOSTER/CHARGER..................................................................... 51
5.7.1 CONNECTION - DISCONNECTION SEQUENCE AND OPERATION................................................................51
5.8 EXTREME CONDITION OPERATION.......................................................................................... 52
5.8.1 COLD WEATHER OPERATION ..........................................................................................................................53
5.8.1.1 ENGINE OPERATION .......................................................................................................53
5.8.2 HIGH TEMPERATURE OPERATION..................................................................................................................53
5.8.3 HIGH ALTITUDE OPERATION............................................................................................................................53
SECTION 6: MAINTENANCE............................................55
6.1 GENERAL INFORMATION ........................................................................................................... 55
6.2 ROUTINE MAINTENANCE SCHEDULE....................................................................................... 55
6.3 MAINTENANCE SCHEDULE TABLE............................................................................................ 57
6.4 REPLACEMENT PARTS............................................................................................................... 61
6.5 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES................................................... 61
6.5.1 COMPRESSOR AIR FILTER...............................................................................................................................63
6.5.1.1 COMPRESSOR AIR FILTER REPLACEMENT .......................................................................63
6.5.2 COMPRESSOR OIL MAINTENANCE..................................................................................................................65
6.5.2.1 COMPRESSOR OIL CHANGE............................................................................................66
6.5.3 UNLOADER VALVE MAINTENANCE..................................................................................................................66
6.5.3.1 LOW PRESSURE VALVE MAINTENANCE............................................................................67
Continued on next page...

AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®TABLE OF CONTENTS
090019-OP_r0 PAGE - V
SECTION 6: MAINTENANCE (CONTINUED)
6.5.3.2 LOW PRESSURE VALVE REPLACEMENT...........................................................................69
6.5.3.3 HIGH PRESSURE VALVE MAINTENANCE...........................................................................70
6.5.3.4 HIGH PRESSURE VALVE REPLACEMENT ..........................................................................71
6.5.4 COMPRESSOR HEAD VALVE ASSEMBLY INSPECTION AND MAINTENANCE............................................. 72
6.5.4.1 REMOVE VALVE PACKAGE..............................................................................................74
6.5.4.2 ASSEMBLE VALVE ASSEMBLY PACKAGE..........................................................................75
6.5.4.3 ASSEMBLE VALVE ASSEMBLY PACKAGE INTO COMPRESSOR ...........................................76
6.5.5 ADJUSTING COMPRESSOR CUT-IN/CUT-OUT PRESSURE........................................................................... 76
6.5.6 ADJUSTING THE ENGINE SPEED.................................................................................................................... 77
6.5.7 REPLACING OR RE-TENSIONING THE COMPRESSOR AND/OR GENERATOR DRIVE BELTS.................. 78
6.5.7.1 ACCESSING THE DRIVE BELTS - REMOVING THE BELT GUARD SHIELD.............................79
6.5.7.2 REPLACING THE BELT GUARD SHIELD ............................................................................80
6.5.7.3 RE-TENSIONING THE AIR COMPRESSOR DRIVE BELT(S) ..................................................80
6.5.7.4 COMPRESSOR BELT SIZING............................................................................................81
6.5.7.5 COMPRESSOR BELT LINK DISENGAGEMENT ....................................................................82
6.5.7.6 COMPRESSOR BELT ASSEMBLY......................................................................................83
6.5.7.7 ROUTING COMPRESSOR BELTS ONTO PULLEY GROOVES................................................84
6.5.7.8 RE-TENSIONING OR REPLACING THE GENERATOR SERPENTINE BELT ..............................85
6.5.7.9 RE-TENSIONING THE GENERATOR SERPENTINE BELT......................................................85
6.5.7.10 REPLACING THE GENERATOR SERPENTINE DRIVE BELT ..................................................87
6.5.8 DRAINING THE AIR TANK.................................................................................................................................. 89
6.5.9 ENGINE MAINTENANCE.................................................................................................................................... 89
6.5.9.1 ENGINE AIR FILTER MAINTENANCE.................................................................................90
6.5.9.2 CHECKING THE ENGINE OIL............................................................................................91
6.5.9.3 REPLACING THE ENGINE OIL ..........................................................................................93
6.5.9.4 REPLACING THE IN-LINE FUEL FILTERS...........................................................................94
6.5.9.5 ENGINE COOLER MAINTENANCE.....................................................................................95
6.6 SERVICING THE SYSTEM FUSES AND CIRCUIT BREAKERS..................................................96
6.7 STORAGE AND INTERMITTENT USE.............................................................................................98
6.7.1 INTERMITTENT USE.......................................................................................................................................... 98
6.7.2 LONG TERM STORAGE..................................................................................................................................... 98
SECTION 7: TROUBLESHOOTING ................................99
7.1. GENERAL INFORMATION.........................................................................................................99
Continued on next page...

TABLE OF CONTENTS AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - VI 090019-OP_r0
SECTION 7: TROUBLESHOOTING (CONTINUED)
7.2 A NOTE ON CONDENSATION DUE TO COMPRESSION.........................................................100
7.3 TROUBLESHOOTING GUIDE ....................................................................................................100
SECTION 8: DIAGRAMS.................................................111
8.1 GENERAL INFORMATION ........................................................................................................... 111
8.2 WIRING DIAGRAM - AIR N ARC 200 SERIES............................................................................. 112
8.3 WIRING DIAGRAM - SWITCHES & LIGHTS................................................................................ 113
8.4 COMPRESSOR FLOW SCHEMATIC DIAGRAM.......................................................................... 114
SECTION 9: ILLUSTRATED PARTS LIST......................115
9.1 PARTS ORDERING PROCEDURE............................................................................................... 115
TABLE 9A: RECOMMENDED SPARE PARTS LIST.............................................................................. 116
9.2 AIR N ARC 200 SYSTEMS ASSEMBLIES.................................................................................... 118
9.3 COMPRESSOR AND PARTS ASSEMBLY................................................................................... 120
9.4 FRAME .......................................................................................................................................... 122
9.5 INSTRUMENT PANEL................................................................................................................... 124
9.6 ENGINE AND DRIVE PARTS........................................................................................................ 128
9.7 BELT GUARD ASSEMBLY............................................................................................................ 130
9.8 ELECTRICAL SYSTEM................................................................................................................. 132
9.9 FUEL TANK ASSEMBLY............................................................................................................... 136
9.10 CONTROL ASSEMBLY................................................................................................................. 138
9.11 DECAL AND PLATE LOCATIONS (1 OF 3).................................................................................. 140
9.11 DECAL AND PLATE LOCATIONS (2 OF 3).................................................................................. 142
9.11 DECAL AND PLATE LOCATIONS (3 OF 3).................................................................................. 144
APPENDIX A: ADDITIONAL INFORMATION .................147
A.1 ELECTRIC MOTOR CHART - STARTING WATTS....................................................................... 147
A.2 EXTENSION CORD CHART.........................................................................................................148
A.3 WATTAGE REQUIREMENTS FOR COMMON RECEPTACLE UNITS......................................... 149
A.4 AIR TOOL AIR CONSUMPTION CHART...................................................................................... 150
A.5 AIR N ARC 200 SERIES ALL-IN-ONE POWER SYSTEM AVAILABLE OPTIONS LIST .............. 151
A.6 HOSE INSTALLATION GUIDE......................................................................................................153
A.7 ELECTRODE IGNITION PROCEDURE........................................................................................ 154
A.8 PRESSURE SYSTEM CONTROL - FUNCTIONAL SEQUENCES............................................... 155
APPENDIX B: MAINTENANCE AND SERVICE LOG.....157
B.1 GENERAL DESCRIPTION............................................................................................................ 157
B.2 MAINTENANCE AND SERVICE LOG........................................................................................... 158

AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®GLOSSARY
090019-OP_r0 PAGE - VII
G.1 GENERAL TERMS AND
DEFINITIONS
Air/Oil Separator - Coalescer element.
CFM - Cubic Feet per Minute.
ft-lb - Foot Pound (torque measurement).
N.C. - Normally closed.
N.O. - Normally open.
RMA - Return Material Authorization
(number). This number is assigned by a
service technician, and is needed for
warranty claims.
RPM - Revolutions Per Minute.
Speed Control - Governor.
G.2 WELDING TERMS AND
DEFINITIONS
Air Carbon Arc Cutting (CAC-A) - A cutting
process by which metals are melted by the
heat of an arc using a carbon electrode.
Molten metal is forced away from the cut by
a blast of forced air.
Alternating Current (AC) - An electrical
current that reverses its direction at regular
intervals, such as 60 cycles alternating
current (AC), or 60 hertz.
Amperage - The measurement of the
amount of electricity flowing past a given
point in a conductor per second. Current is
another name for amperage.
Arc - The physical gap between the end of
the electrode and the base metal. The
physical gap causes heat due to resistance
of current flow and arc rays.
Constant Current (CC) Welding Machine -
These welding machines have limited
maximum short circuit current, with
consistent amperage regardless of the
voltage output.
Constant Voltage (CV) Welding Machine -
This type of welding machine output
maintains a relatively stable, consistent
voltage regardless of the amperage output. It
results in a relatively flat volt-amp curve.
Current - Another name for amperage. The
amount of electricity flowing past a point in a
conductor every second.
Direct Current (DC) - Flows in one direction
and does not reverse its direction of flow as
alternating current does.
Direct Current Electrode Negative (DCEN)
- The direction of current flow through a
welding circuit when the electrode lead is
connected to the negative terminal and the
work lead is connected to the positive
terminal of a DC welding machine. Also
called direct current, straight polarity
(DCSP).
Direct Current Electrode Positive (DCEP)
- The direction of current flow through a
welding circuit when the electrode lead is
connected to a positive terminal and the
work lead is connected to a negative
terminal to a DC welding machine. Also
called direct current, reverse polarity
(DCRP).
Duty Cycle - The number of minutes out of a
10-minute time period an arc welding
machine can be operated at maximum rated
output. An example would be 60% duty cycle
at 250 amps. This would mean that at 250
amps the welding machine can be used for 6
GLOSSARY:
TERMS AND DEFINITIONS

GLOSSARY AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - VIII 090019-OP_r0
minutes and then must be allowed to cool
with the fan motor running for 4 minutes.
Flux Cored Arc Welding (FCAW) - An arc
welding process which melts and joins
metals by heating them with an arc between
a continuous, consumable electrode wire
and the work. Shielding is obtained from a
flux contained within the electrode core.
Added shielding may or may not be provided
from externally supplied gas or gas mixture.
Hertz - Hertz is often referred to as "cycles
per second". In the United States, the
frequency or directional change of
alternating current is usually 60 hertz.
KVA (Kilovolt-amperes) - Kilovolt-amperes.
The total volts times amps divided by 1,000,
demanded by a welding power source from
the primary power furnished by the utility
company.
KW (Kilowatts) - Primary KW is the actual
power used by the power source when it is
producing its rated output. Secondary KW is
the actual power output of the welding power
source. Kilowatts are found by multiplying
volts and amps and dividing by 1,000 and
taking into account any power factor.
Microprocessor - One or more integrated
circuits that can be programmed with stored
instructions to perform a variety of functions.
MIG Welding (GMAW or Gas Metal Arc
Welding) - Also referred to as solid wire
welding. An arc welding process which joins
metals by heating them with an arc. The arc
is between a continuously fed filler metal
(consumable) electrode and the work piece.
Externally supplied gas or gas mixtures
provide shielding.
Open-Circuit Voltage (OCV) - As the name
implies, no current is flowing in the circuit
because the circuit is open. The voltage is
impressed upon the circuit, however, so that
when the circuit is completed, the current will
flow immediately.
Plasma Arc Cutting - An arc cutting
process which severs metal by using a
constricted arc to melt a small area of the
work. This process can cut all metals that
conduct electricity.
Pounds Per Square Inch (psi) - A
measurement equal to a mass or weight
applied to one square inch of surface area.
Rated Load - The amperage and voltage the
power source is designed to produce for a
given specific duty cycle period. For
example, 275 amps, 25 load volts, at 60%
duty cycle.
Stick Welding (SMAW or Shielded Metal
Arc) - An arc welding process which melts
and joins metals by heating them with an arc,
between a covered metal electrode and the
work. Shielding gas is obtained from the
electrode outer coating, often called flux.
Filler metal is primarily obtained from the
electrode core.
TIG Welding (GTAW or Gas Tungsten Arc)
- Often called TIG welding (Tungsten Inert
Gas), this welding process joins metals by
heating them with a tungsten electrode
which should not become part of the
completed weld. Filler metal is sometimes
used and argon inert gas or inert gas
mixtures are used for shielding.
Voltage - The pressure or force that pushes
the electrons through a conductor. Voltage
does not flow, but causes amperage or
current to flow. Voltage is sometimes termed
electromotive force (EMF) or difference in
potential.
Voltage-Sensing Wire Feeder - Feeder
operates from arc voltage generated by
welding power source.
Wire Feed Speed - Expressed in in/min or
mm/s, and refers to the speed and amount of
filler metal fed into a weld. Generally
speaking the higher the wire feed speed, the
higher the amperage.
G.3 AIR COMPRESSOR
TERMS AND
DEFINITIONS
Aftercoolers - devices for removing the heat
of compression of the air or gas after

AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®GLOSSARY
090019-OP_r0 PAGE - IX
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. Receivers help to eliminate
pulsations in the discharge line and also act
as storage capacity during intervals when the
dean
Air Regulator - Used to control the amount
of pressure received from the tank.
Check Valve - Ensures the air flows in one
direction.
Discharge Pressure - This is the absolute
pressure of the air at outlet (delivery) of a
compressor.
Free Air Delivery (FAD) - Free air delivery is
the volume of air delivered under the
conditions of temperature and pressure
existing at the compressor intake. This
generally taken as 1.0332 kg/cm square abs
& 15 degree Centigrade.
Inlet Pressure - This is the absolute
pressure of the air at inlet (suction) to a
compressor.
Intercoolers - devices for removing the heat
of compression of the air or between
consecutive stages of multistage air
compressors.
Line Pressure Gauge - Reads amount of
pressure in the air hose, which supplies the
tool with air.
Moisture Separators - devices for collecting
and removing moisture precipitated from the
air or gas during the process of cooling.
Piston - Compresses the air by pulling air
into the cylinder of the pump when it moves
downward and the pushes the air out when it
moves upward.
Pressure Switch - Stops the motor when the
tank is full (cut out pressure) and starts the
motor when the pressure falls to a specific
setting (cut in pressure).
PSIG - pounds per square inch gauge
Pump - Part that compresses the air and
pushes it into the tank.
Reciprocating Air Compressors - those in
which each compressing element consists of
a piston moving back and forth in a cylinder.
Rotary Air Compressors - those which
utilize two inter-meshing helical rotors to trap
a volume of air, then compress it to a higher
pressure.
Single Stage Air Compressors - those in
which compression from initial to final
pressure is complete in a single step or
stage.
Tank - Holds the compressed air until used
by an air tool or for some other purpose.
Tank Pressure Gauge - Indicates amount of
pressure in tank.
Two Stage Air Compressors - those in
which compression from initial to final
pressure is completed in two distinct steps or
stages.

GLOSSARY AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - X 090019-OP_r0
BLANK PAGE

AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®WARRANTY PROCEDURE
090019-OP_r0 PAGE - XI
CLAIMS PROCESS FOR WARRANTED
VANAIR 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.
PROCEDURE:
When a customer needs assistance in troubleshooting a
system and/or returning parts, follow the steps below.
1. Locate the machine’s serial number:
The machine package serial number plate is located on
the base floor, near to the compressor mounting and the
generator tower canopy (see Figures W-1 and W-2).
2. Have a list of the symptoms/condition/malfunctions
along with any applicable temperature and pressure
readings, and also the number of operational hours
available:
3. Contact the Vanair Service Department by phone (1-
219-879-5100) to speak with a Service Technician.
4. Vanair Service will troubleshoot the problem based
on the information provided by the customer.
5. If the unit cannot be returned to service, and Vanair
determines this matter may be a warranty issue, the
Service Technician may assign an RMA (Return
Material Authorization) number that will provide for
the return of the item to Vanair®for analysis and a
final determination as to the item’s warranty status.
6. Vanair will need a P.O. or credit card number to cover
the cost of the part and shipping before sending a
part to a customer for warranty consideration.
7. If the returned item, which in Vanair’s judgment is
proven to be defective as warranted, than Vanair will
WARRANTY CLAIMS
PROCEDURE
NOTE
The unit’s serial number is important to
determine the proper configuration of the
machine.
IMPORTANT
Customers have 30 days after the RMA
number is issued to return the item. If the
part is not returned within this period, the
RMA is void and any claims will be
denied.

WARRANTY PROCEDURE AIR N ARC®200 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - XII 090019-OP_r0
Figure W-1: Machine Serial Number Location
800-526-8817
PSIG
260940
MODEL NUMBER
SERIAL NUMBER
MAXIMUM PRESSURE
COMPRESSOR INPUT RPM
www.vanai r.com
Figure W-2: Engine Serial Number Location