Vanair AIR N ARC RELIANT 300 Series User manual

ALL-IN-ONE POWER SYSTEMS®
WELDER • GENERATOR • AIR COMPRESSOR • BATTERY BOOSTER
OPERATION MANUAL & PARTS LIST
©2012 Vanair Manufacturing, Inc.
All rights reserved
090012-OP_r0
Effective Date:
04-12
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
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.
NOTE
Use only Vanair Vanguard™
Premium Synthetic Oil and Genuine
Vanair Parts. Inspect and replace
damaged components before
operation. Substituting non-
Vanguard™ Oil or non-genuine
Vanair filter 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

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®300 SERIES ALL-IN-ONE POWER SYSTEM®TABLE OF CONTENTS
090012-OP_r0 PAGE - I
TABLE OF CONTENTS
WARRANTY ............................................... BEHIND COVER
TABLE OF CONTENTS......................................................I
GLOSSARY........................................................................IX
G.1 GENERAL TERMS AND DEFINITIONS ........................................................................................IX
G.2 WELDING TERMS AND DEFINITIONS.........................................................................................IX
G.3 AIR COMPRESSOR TERMS AND DEFINITIONS ........................................................................X
WARRANTY CLAIMS PROCEDURE ..............................XIII
CLAIMS PROCESS FOR WARRANTED PARTS....................................................................................XIII
PROCEDURE..........................................................................................................................................XIII
RETURN MATERIAL AUTHORIZATION FORM......................................................................................XVI
INTRODUCTION.................................................................1
EXPERIENCE THE VANAIR ADVANTAGE.............................................................................................1
A NOTE ON MANUAL NAVIGATION......................................................................................................2
SECTION 1: SAFETY ........................................................3
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 GASSES 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®300 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - II 090012-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 COMPRESSED 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 MACHINE CANOPY ACCESS SAFETY SWITCHES ................................................................... 18
Continued on next page...

AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®TABLE OF CONTENTS
090012-OP_r0 PAGE - III
SECTION 1: SAFETY (CONTINUED)
1.12 DISPOSING OF MACHINE FLUIDS..............................................................................................19
SECTION 2: DESCRIPTION ..............................................21
FIGURE 2-1: MAJOR MACHINE COMPONENTS LOCATIONS.............................................................20
2.1 GENERAL DESCRIPTION.............................................................................................................21
2.2 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.............................................................................................................. 23
2.2.6 PRESSURE RELIEF VALVE ............................................................................................................................... 23
2.2.7 ADJUSTABLE PRESSURE SWITCH.................................................................................................................. 24
2.2.8 OIL RESERVOIR AND PRIMARY AIR/OIL SEPARATOR................................................................................... 24
2.3 OIL COOLING SYSTEM ................................................................................................................24
2.3.1 COMPRESSOR TEMPERATURE AND PRESSURE SWITCHES ..................................................................... 26
2.3.2 COMPRESSOR SPIN-ON OIL FILTER............................................................................................................... 26
2.4 ENGINE..........................................................................................................................................26
2.5 AC GENERATOR...........................................................................................................................28
2.6 INSTRUMENTATION .....................................................................................................................28
2.6.1 VOLTS/AMPS METER ........................................................................................................................................ 29
2.6.2 WELDER FUNCTION SWITCHES...................................................................................................................... 29
2.6.3 DC CHARGER MODE TOGGLE SWITCH.......................................................................................................... 31
2.6.4 VOLTS/AMPS MANUAL ADJUSTMENT DIAL.................................................................................................... 31
2.6.5 COMPRESSOR ON/OFF TOGGLE SWITCH..................................................................................................... 31
2.6.6 COMPRESSOR AIR PRESSURE GAUGE......................................................................................................... 31
2.6.7 WELDER LEAD JUNCTION................................................................................................................................ 31
2.6.8 BATTERY CABLE RECEPTACLE....................................................................................................................... 31
2.6.9 GENERATOR CONTROL ON/OFF TOGGLE SWITCH...................................................................................... 31
2.6.10 AC VOLTAGE OUTLETS..................................................................................................................................... 31
2.6.11 CIRCUIT BREAKER OVERLOAD TRIP/RESET BUTTONS...............................................................................31
2.6.12 DOOR OPEN INDICATOR LAMP ....................................................................................................................... 32
2.6.13 ALTERNATOR FAIL INDICATOR LAMP.............................................................................................................. 32
Continued on next page...

TABLE OF CONTENTS AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - IV 090012-OP_r0
SECTION 2: DESCRIPTION (CONTINUED)
2.6.14 ENGINE CONTROL (ON/OFF/START) SWITCH.................................................................................................32
2.6.15 HIGH TEMPERATURE INDICATOR LAMP..........................................................................................................32
2.6.16 LOW OIL PRESSURE INDICATOR LAMP...........................................................................................................32
2.6.17 PREHEAT/START CONDITION INDICATOR LAMP............................................................................................32
2.6.18 FUEL GAUGE/HOUR METER.............................................................................................................................32
SECTION 3: SPECIFICATIONS.........................................33
TABLE 3A: WELDER, GENERATOR, AND ENGINE SPECIFICATIONS............................................... 33
TABLE 3B: SPECIFICATIONS — AIR COMPRESSOR.......................................................................... 33
TABLE 3C: SPECIFICATIONS — UNIT WEIGHT AND DIMENSIONS.................................................. 34
TABLE 3D: BOLT AND TORQUE SPECIFICATIONS ............................................................................ 34
TABLE 3E: VARIOUS FUNCTION FACTORY SETTING RANGES........................................................ 35
TABLE 3F: GENUINE VANGUARD™ OIL CHARACTERISTICS........................................................... 35
TABLE 3G: MACHINE PACKAGE DIMENSIONS................................................................................... 35
SECTION 4: INSTALLATION............................................37
4.1 MACHINE PACKAGE RECEIPT/INSPECTION ............................................................................ 37
4.2 MACHINE PACKAGE PREP.........................................................................................................37
4.3 SERVICE BODY PREP................................................................................................................. 37
4.4 MACHINE PACKAGE MOUNTING ............................................................................................... 39
4.5 INSTALLATION AND DIMENSIONS DIAGRAM (PART 1 OF 2)................................................... 42
4.6 INSTALLATION AND DIMENSIONS DIAGRAM (PART 2 OF 2)................................................... 43
SECTION 5: OPERATION.................................................45
5.1 GENERAL INFORMATION ............................................................................................................... 45
5.2 ENGINE START-UP AND SHUTDOWN PROCEDURE ............................................................... 46
5.2.1 ENGINE START-UP.............................................................................................................................................46
5.2.2 ENGINE SHUTDOWN..........................................................................................................................................47
5.3 ENGINE THROTTLE CONTROL FUNCTIONS............................................................................. 48
5.4 OPERATING THE WELDER.........................................................................................................48
5.4.1 WELDER OPERATING PROCEDURE................................................................................................................49
5.4.1.1 CC (CONSTANT CURRENT) MODE ........................................................................ 49
5.4.1.2 CV (CONSTANT VOLTAGE) MODE - USING A VOLTAGE
SENSING SUITCASE FEEDER.............................................................................. 51
Continued on next page...

AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®TABLE OF CONTENTS
090012-OP_r0 PAGE - V
SECTION 5: OPERATION (CONTINUED)
5.4.1.3 CV (CONSTANT VOLTAGE) MODE - USING A SPOOL GUN..................................51
5.5 OPERATING THE GENERATOR ..................................................................................................53
5.6 OPERATING THE AIR COMPRESSOR........................................................................................53
5.7 OPERATING THE BATTERY BOOSTER/CHARGER...................................................................54
5.7.1 CONNECTION - DISCONNECTION SEQUENCE AND OPERATION............................................................... 55
5.8 EXTREME CONDITION OPERATION...........................................................................................55
5.8.1 COLD WEATHER OPERATION............................................................................................................................... 56
5.8.1.1 ENGINE OPERATION...............................................................................................56
5.8.1.2 MACHINE OPERATION..........................................................................................58
5.8.2 HIGH TEMPERATURE OPERATION...................................................................................................................... 58
5.8.2.1 ENGINE OPERATION...............................................................................................58
5.8.2.2 MACHINE OPERATION............................................................................................59
5.8.3 HIGH DUST CONTENT OPERATION ..................................................................................................................... 59
5.8.3.1 ENGINE OPERATION...............................................................................................59
5.8.3.2 MACHINE OPERATION............................................................................................60
5.8.4 HIGH ALTITUDE OPERATION................................................................................................................................. 60
SECTION 6: MAINTENANCE ............................................61
6.1 GENERAL INFORMATION............................................................................................................61
6.2 ROUTINE MAINTENANCE SCHEDULE .......................................................................................61
6.3 MAINTENANCE SCHEDULE TABLE ............................................................................................63
6.4 REPLACEMENT PARTS................................................................................................................66
6.5 MAINTENANCE ACCESS .............................................................................................................66
6.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES ...................................................70
6.6.1 COMPRESSOR AIR FILTER................................................................................................................................... 72
6.6.1.1 COMPRESSOR AIR FILTER CHECK ......................................................................72
6.6.1.2 COMPRESSOR AIR FILTER INSPECTION..............................................................73
6.6.1.3 COMPRESSOR AIR FILTER REPLACEMENT.........................................................73
6.6.2 REPAIRING THE AIR INLET VALVE...................................................................................................................... 74
6.6.3 CHECKING THE COMPRESSOR OIL .................................................................................................................... 76
6.6.4 REPLACING THE COMPRESSOR OIL FILTER ELEMENT................................................................................... 77
Continued on next page...

TABLE OF CONTENTS AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - VI 090012-OP_r0
SECTION 6: MAINTENANCE (CONTINUED)
6.6.5 CHANGING THE COMPRESSOR OIL.....................................................................................................................78
6.6.6 REPLACING THE SPIN-ON AIR/OIL COALESCER ................................................................................................79
6.6.7 REPAIRING THE COMPRESSOR SHAFT SEAL ....................................................................................................80
6.6.7.1 PART I - REMOVING THE COMPRESSOR SERPENTINE BELT .......................... 80
6.6.7.2 PART II - ACCESSING THE COMPRESSOR UNIT SHAFT SEAL ......................... 82
6.6.7.3 PART III - REPLACING THE COMPRESSOR SERPENTINE BELT...................... 83
6.6.8 REPLACING THE AIR INLET SOLENOID VALVE...................................................................................................83
6.6.8.1 SOLENOID VALVE - PREPARATION BEFORE MOUNTING .................................. 85
6.6.8.2 CONNECTING THE NEW SOLENOID VALVE......................................................... 85
6.6.9 DRAINING THE AIR TANK.......................................................................................................................................86
6.6.10 REBUILDING THE MINIMUM PRESSURE/CHECK VALVE..................................................................................88
6.6.10.1 SETTING THE MINIMUM PRESSURE VALVE ...................................................... 88
6.6.11 INSPECTING THE SYSTEM COOLERS.................................................................................................................89
6.6.12 CHECKING THE ENGINE OIL.................................................................................................................................90
6.6.13 ADJUSTING THE ENGINE SPEED........................................................................................................................92
6.6.14 ADJUSTING THE PRESSURE SETTING ..............................................................................................................92
6.6.15 REPLACING AND RE-TENSIONING THE SERPENTINE DRIVE BELTS.............................................................93
6.6.15.1 RE-TENSIONING THE AIR COMPRESSOR SERPENTINE BELT........................ 93
6.6.15.2 REPLACING THE AIR COMPRESSOR SERPENTINE BELT................................ 95
6.6.15.3 RE-TENSIONING THE GENERATOR SERPENTINE BELT .................................. 97
6.6.15.4 REPLACING THE GENERATOR SERPENTINE BELT.......................................... 98
6.6.15.5 RE-TENSIONING THE ENGINE HYDRAULIC PUMP DRIVE BELT...................... 100
6.6.15.6 REPLACING THE ENGINE HYDRAULIC PUMP DRIVE BELT............................. 101
6.7 SERVICING THE SYSTEM FUSES AND CIRCUIT BREAKERS ................................................. 102
6.8 STORAGE AND INTERMITTENT USE......................................................................................... 102
6.8.1 INTERMITTENT USE................................................................................................................................................102
6.8.2 LONG TERM STORAGE ..........................................................................................................................................102
SECTION 7: TROUBLESHOOTING................................105
7.1. GENERAL INFORMATION ........................................................................................................... 105
7.2 TROUBLESHOOTING GUIDE ...................................................................................................... 106
Continued on next page...

AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®TABLE OF CONTENTS
090012-OP_r0 PAGE - VII
SECTION 8: DIAGRAMS .................................................115
8.1 GENERAL INFORMATION............................................................................................................115
8.2 WIRING DIAGRAM - AIR N ARC 300 SERIES (DIESEL) .............................................................116
8.3 WIRING DIAGRAM - SWITCHES & LIGHTS.................................................................................117
8.4 TRUNK LINE ASSEMBLY HARNESS...........................................................................................118
8.5 COMPRESSOR FLOW SCHEMATIC DIAGRAM..........................................................................119
SECTION 9: ILLUSTRATED PARTS LIST.....................121
9.1 PARTS ORDERING PROCEDURE...............................................................................................121
TABLE 9A: RECOMMENDED SPARE PARTS LIST...............................................................................122
9.2 AIR N ARC 300 SYSTEMS ASSEMBLIES ....................................................................................124
9.3 COMPRESSOR AND PARTS ASSEMBLY (1 OF 2).....................................................................126
9.4 COMPRESSOR AND PARTS ASSEMBLY (2 OF 2).....................................................................130
9.5 COOLING SYSTEM.......................................................................................................................132
9.6 FRAME AND CANOPY (1 OF 2)....................................................................................................136
9.7 FRAME AND CANOPY (2 OF 2)....................................................................................................140
9.8 INSTRUMENT PANEL...................................................................................................................144
9.9 GENERATORS AND PARTS.........................................................................................................148
9.10 ENGINE AND DRIVE PARTS (1 OF 2)..........................................................................................150
9.11 ENGINE AND DRIVE PARTS (2 OF 2)..........................................................................................156
9.12 ELECTRICAL SYSTEM .................................................................................................................162
9.13 FUEL TANK ASSEMBLY ...............................................................................................................164
9.14 AIR STORAGE ASSEMBLY ..........................................................................................................166
9.15 FUEL ASSEMBLY - WITHOUT FUEL TANK.................................................................................168
9.16 DECAL AND PLATE LOCATIONS (1 OF 4) ..................................................................................170
9.17 DECAL AND PLATE LOCATIONS (2 OF 4) ..................................................................................172
9.18 DECAL AND PLATE LOCATIONS (3 OF 4) ..................................................................................174
9.19 DECAL AND PLATE LOCATIONS (4 OF 4) ..................................................................................176
APPENDIX A: ADDITIONAL INFORMATION.................179
A.1 ELECTRIC MOTOR CHART - STARTING WATTS........................................................................179
A.2 EXTENSION CORD CHART..........................................................................................................180
A.3 WATTAGE REQUIREMENTS FOR COMMON RECEPTACLE UNITS .........................................181
Continued on next page...

TABLE OF CONTENTS AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - VIII 090012-OP_r0
APPENDIX A: ADDITIONAL INFORMATION (CONT.)
A.4 AIR TOOL AIR CONSUMPTION CHART...................................................................................... 182
A.5 AIR N ARC 300 SERIES ALL-IN-ONE POWER SYSTEM AVAILABLE OPTIONS LIST .............. 183
A.6 HOSE INSTALLATION GUIDE ......................................................................................................185
A.7 ELECTRODE IGNITION PROCEDURE........................................................................................ 186
APPENDIX B: MAINTENANCE AND SERVICE LOG.....187
B.1 GENERAL DESCRIPTION............................................................................................................ 187
B.2 MAINTENANCE AND SERVICE LOG........................................................................................... 188

AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®GLOSSARY
090012-OP_r0 PAGE - IX
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®300 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - X 090012-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®300 SERIES ALL-IN-ONE POWER SYSTEM®GLOSSARY
090012-OP_r0 PAGE - XI
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
demand increases.
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 is
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.
Line Pressure Gauge - Reads amount of
pressure in the air hose, which supplies the
tool with air.
PSIG - pounds per square inch gauge
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.

GLOSSARY AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - XII 090012-OP_r0
BLANK PAGE

AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®WARRANTY PROCEDURE
090012-OP_r0 PAGE - XIII
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
inside the machine compartment on the floor near to the
generator mounting location (see Figure W-1).
The engine and the compressor also have individual
serial numbers respectively (see Figure W-2). For
engine warranty issues, consult the Engine Operator’s
Manual for the engine’s limited warranty details. For
particular compressor unit issues, the compressor serial
number may be needed. In any case, engine and/or
compressor issues can be confirmed using the machine
serial number as found in Figure W-1.
2. Fill out the Return Material Authorization (RMA)
Form’s required information:
Locate the form on page XVI of this Section. Follow the
instructions given on the form to fill in the information
needed. This form is used for the purpose of soliciting a
warranty case. All of the field information except for the
bottom section block fields, which include Disposition of
Goods, Notifications and Additional Notes, will be
required.
3. Have a list of the symptoms/condition/malfunctions
along with any applicable temperature and pressure
readings, and also the number of operational hours
available:
WARRANTY CLAIMS
PROCEDURE
NOTE
The RMA number must be placed on the
outside of the package being returned.
NOTE
All labor claims or invoices must be
approved by the Vanair Warranty
Administrator prior to starting repair work
along with the cost of the repair. All paper
work associated with the returned item
and warranty repair cost must reference
the RMA number issued against the part,
and be forwarded to Vanair within 30 days
of the completion of work.

WARRANTY PROCEDURE AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - XIV 090012-OP_r0
Figure W-1: Machine Serial Number Location
800-526-8817
PSIG
260940
MODEL NUMBER
SERIAL NUMBER
MAXIMUM PRESSURE
COMPRESSOR INPUT RPM
www.vanair.com
KEY DESCRIPTION
AENGINE SERIAL TAG / SERIAL NUMBER LOCATION
BCOMPRESSOR SERIAL TAG / SERIAL NUMBER: TWO POSSIBLE LOCATIONS
Figure W-2: Engine and Compressor Serial Number Locations
Serial No.
D902
CodeNo.
Part No.
MOD No.
SERNo.
Rev. Lev.
PSmax.
Tmax. PSmax.
R.P.M.
max.
Tmax.
AB

AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®WARRANTY PROCEDURE
090012-OP_r0 PAGE - XV
The above information is needed in addition to the
information from Step #2.
4. Contact the Vanair®Service Department by phone (1-
219-879-5100) to speak with a Service Technician.
5. Vanair Service will troubleshoot the problem based
on the information provided by the customer, and
attempt to return the unit to service as quickly as
possible.
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
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.
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.
Before sending a warranty part to a customer, Vanair®will need a
P.O. or credit card number to cover the cost of the part and
shipping. After the part is analyzed and deemed to be covered
under warranty, Vanair will issue credit to the customer. All parts
eligible for warranty must have the RMA number on the invoice at
the time of purchase.
No items can be returned “freight collect”. Freight costs will be
addressed at the time the claim is closed. The customer pays any
additional costs for warranty parts delivered through expedited
services (i.e., Next Day, Second Day).
VANAIR WILL NEVER ACCEPT ANY INVOICES FOR PARTS
RETURNED: ANY PARTS RETURNED VIA INVOICE WILL BE
RETURNED FREIGHT COLLECT: NO PARTS ARE TO BE
RETURNED FREIGHT COLLECT!
Vanair Mfg., Inc. strives to continuously improve its customer
service. Please forward any questions, comments, or
suggestions to Vanair Service (219-879-5100) or e-mail us
([e-mail]).

RETURN MATERIAL AUTHORIZATION FORM
Ph. 219-879-5100
Fax. [phone]
[e-mail]
Return
Material
Authorization
10896 W. 300 N.
Michigan City, IN 46360
S / N: 30 _____________________ Customer: ____________________________ Date:____________________________
AnA S/N:_____________________ RMA#: ____________________________ Contact:____________________________
Email:_____________________________________________________________ Phone: ___________________________
Fax: ________________________ Address: __________________________________________________________________
Tech: _______________________ Dealer: ________________ PO#: ___________________________________________
GENERAL INFORMATION
All returns are sent back for warranty consideration and are subject to factory inspection and analysis. Vanair® is not
responsible for shipping damage due to insufficient or improper packaging methods. Failure to identify returned goods
with the assigned RMA number on the outside of the shipping package will delay processing or result in the shipment
being returned, freight collect. To receive warranty parts, a credit card or Purchase Order must be given to the service
technician. Once the disposition of the part is determined, (I.E. manufacturing defect or other) Vanair will credit your
account if covered by warranty. You can also contact the Service Department by email at [e-mail] if you
have any questions. Return parts to the address listed above.
INSTRUCTIONS TO CUSTOMERS
1Product must be returned within 30 days from the day the RMA is issued. The RMA is void thereafter and any parts received
after this time frame will be returned freight collect or not accepted.
2The RMA number must be placed on the outside of the shipping package. Do not write the RMA number on the component
with permanent marker, this damages the component. Please use a tag.
3 Components (including generators) must be returned completely assembled with no loose parts or they will not be accepted.
4 A copy of the form must be included with all paperwork.
5 No product will be accepted freight collect.
6 We will not accept any parts returned on an invoice. They will be returned freight collect.
7Any 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.
8 All warranty claims must be pre-approved by Vanair or they will not be accepted.
Qty. Part # Description Reason for return
Final Disposition of Goods Notifications Additional Notes
No Credit Return to Customer Quality Control
Return to Stock Issue Credit for Parts Operations
Scrap Goods Issue Credit for Freight Purchasing
Ret to Vendor Accounting
Part Invoice #: Shipping

AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®INTRODUCTION
090012-OP_r0 PAGE - 1
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.
This unit is designed to operate in an industrial
environment, and with proper maintenance it should
provide years of reliable service. This unit is weather-
proof and able to operate in temperature extremes
ranging from 0°F to 110°F (-18°C to 43°C); with available
cold weather kit, operation further extends from below 0°
to -40°F (-18°C to -40°C). Refer to Section 5.8, Extreme
Condition Operation.
The AC generator features a brushless, maintenance-
free design, and is completely separate from the DC
welding generator.
NOTE
Due to the caustic nature of “un-sealed”
lead acid batteries Vanair Mfg., Inc. does
not recommend the use of this style of
battery. Acid fumes can cause damage to
the machine and void the warranty.

INTRODUCTION AIR N ARC®300 SERIES ALL-IN-ONE POWER SYSTEM®
PAGE - 2 090012-OP_r0
The All-In-One Power System can support a multi-user
operation. However, simultaneously using any two
functions to their maximum output will cause a drop in
RPM of the engine. This RPM drop will reduce the
voltage output of the AC generator, which can cause
damage to power tools being used. The operator must
monitor the AC voltage at all times to insure proper
voltage output.
This publication contains the latest information available
at the time of preparation. Every effort has been made to
ensure accuracy. However, Vanair®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. This manual is presented in a two-
column per page sequence. As shown in the figure, the
inner columns represent the machine application data in
a continuous page-by-page flow. The outer columns are
reserved for auxiliary information relating to the specific
data put forth in the inner column. This auxiliary data can,
for example, be a relative warning or note detail. It will
support the concept which is listed nearby in the inner
column.
Sometimes, if an illustration is too large to fit in the outer
column, or if a large table matrix is present, it may occupy
the two-column space of a page. In such cases the inner
column will always be continued on the next available
page after the illustration.
KEY DESCRIPTION
AINNER PAGE COLUMNS:
Main text flow of information layout represents the main
body of machine applications divided into sections and
sub-sections.
BOUTER PAGE COLUMNS:
Contain auxiliary information such as notes, warnings,
and small illustrations. This information is related, and
will be located in proximity, to the main, inner page col-
umn application.
Figure M-1: Manual Layout Navigation
B A A B