Vanair 050735 Operations Manual & Parts List Download

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AIR N ARC

300 SERIES ALL-IN-ONE POWER SYSTEM

SECTION 6: MAINTENANCE

090034-OP_r0

PAGE - 73

6.6 PARTS REPLACEMENT AND

ADJUSTMENT PROCEDURES

System Component or

Part Group Task

Manual

Section

Location

Parts Replacement and Adjust-
ment Procedures

6.6

page 73

Compressor Air Filter

6.6.1

page 74

Compressor Air Filter Check

6.6.1.1

page 74

Compressor Air Filter Inspection

6.6.1.2

page 75

Compressor Air Filter Replace-

ment

6.6.1.3

page 75

Repairing the Air Inlet Valve

6.6.2

page 76

Checking the Compressor Oil

6.6.3

page 78

Replacing the Compressor Oil Filter
Element

6.6.4

page 79

Changing the Compressor Oil

6.6.5

page 80

Replacing the Air/Oil Spin-on
Coalescer

6.6.6

page 81

Repairing the Compressor Shaft
Seal

6.6.7

page 82

Part I - Removing the Compres-

sor Serpentine Belt

6.6.7.1

page 82

Part II - Accessing the Compres-
sor Unit Shaft Seal

6.6.7.2

page 84

Part III - Replacing the Compres-
sor Serpentine Belt

6.6.7.3

page 85

Replacing the Air Inlet Solenoid

Valve

6.6.8

page 85

Solenoid Valve—Preparation

Before Mounting

6.6.8.1

page 87

Connecting the New Solenoid

Valve

6.6.8.2

page 87

Draining the Air Tank

6.6.9

page 88

Rebuilding the Minimum Pressure/
Check Valve

6.6.10

page 90

Setting the Minimum Pressure
Valve

6.6.10.1

page 90

Inspecting the System Coolers

6.6.11

page 91

Adjusting The Motor Speed

6.6.12

page 92

Continued on next page

CAUTION

Always wear personal protective

equipment such as gloves, safety shoes

or boots, eye, and hearing protection as

required for the task at hand.

CAUTION

Compressors and motors generate heat

and create hot surfaces. Use caution

when operating or servicing equipment.

Some surfaces and components may be

hot.

NOTE

Inspect and replace damaged

components before operation with

Genuine Vanair Replacement Parts.
Using replacement parts other than

Genuine Vanair Replacement Parts will

void the warranty.

NOTE

It may be necessary to change the

compressor oil and oil filter at earlier

intervals if the compressor oil has water

contamination or if the compressor

system is operated in a dirty

environment.

NOTE

Do not mix different compressor fluid

types. Use Vanguard compressor oil.

NOTE

Refer to the Truck Operator’s Manual for

detailed maintenance and replacement

procedures for the motor.

Summary of Contents for 050735

Page 1: ...aking 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...

Page 2: ...rcial 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 servi...

Page 3: ...A NOTE ON MANUAL LAYOUT NAVIGATION 1 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...

Page 4: ...UTTING AND GOUGING CAN CAUSE FIRE OR EXPLOSION 12 1 6 6 HOT PARTS CAN CAUSE SEVERE BURNS 12 1 6 7 READ INSTRUCTIONS 13 1 7 ADDITIONAL SYMBOLS FOR INSTALLATION OPERATION AND MAINTENANCE 13 1 7 1 FALLING UNIT CAN CAUSE INJURY 13 1 7 2 OVERHEATING CAN DAMAGE MOTORS 13 1 7 3 FLYING SPARKS CAN CAUSE INJURY 13 1 7 4 OVERUSE CAN CAUSE OVERHEATING 14 1 7 5 ENCLOSED SPACES CAN CAUSE A BUILD UP OF NOXIOUS F...

Page 5: ...6 2 4 MOTOR 26 2 5 AC GENERATOR 26 2 6 INSTRUMENTATION 27 2 6 1 VOLTS AMPS METER 28 2 6 2 WELDER FUNCTION SWITCHES 28 2 6 3 DC CHARGER MODE TOGGLE SWITCH 28 2 6 4 VOLTS AMPS MANUAL ADJUSTMENT DIAL 28 2 6 5 COMPRESSOR AIR PRESSURE GAUGE 29 2 6 6 COMPRESSOR ON OFF TOGGLE SWITCH 29 2 6 7 WELDER LEAD JUNCTION 29 2 6 8 HZ VOLTAGE METER 29 2 6 9 BATTERY CABLE RECEPTACLE 29 2 6 10 GENERATOR CONTROL ON OF...

Page 6: ...AL OVERVIEW OF INSTALLATION 38 4 4 PREPARING THE VEHICLE SERVICE BODY 38 4 4 1 MACHINE CLEARANCE ALLOWANCE 40 4 4 2 DETERMINING PROPER VENTILATION REQUIREMENTS 40 4 4 3 ROOF REQUIREMENTS IF APPLICABLE 40 4 5 MOUNTING THE MACHINE 42 4 5 1 SEPARATING THE MACHINE FROM THE CRATE MOUNTING 43 4 5 2 MARKING THE MACHINE MOUNTING LOCATION 43 4 5 3 STABILIZING PRECAUTIONS FOR MACHINE MOUNTING 44 4 6 GROUNDI...

Page 7: ...7 OPERATING THE BATTERY BOOSTER CHARGER 62 5 7 1 CONNECTION DISCONNECTION SEQUENCE AND OPERATION 62 5 8 EXTREME CONDITION OPERATION 63 5 8 1 COLD WEATHER OPERATION 64 5 8 1 1 GENERAL OPERATION 64 5 8 1 2 MACHINE OPERATION 64 5 8 2 HIGH TEMPERATURE OPERATION 64 5 8 2 1 MACHINE OPERATION 64 5 8 3 HIGH DUST CONTENT OPERATION 65 5 8 3 1 MACHINE OPERATION 65 5 8 4 HIGH ALTITUDE OPERATION 65 SECTION 6 M...

Page 8: ...OLENOID VALVE PREPARATION BEFORE MOUNTING 87 6 6 8 2 CONNECTING THE NEW SOLENOID VALVE 87 6 6 9 DRAINING THE AIR TANK 88 6 6 10 REBUILDING THE MINIMUM PRESSURE CHECK VALVE 90 6 6 10 1 SETTING THE MINIMUM PRESSURE VALVE 90 6 6 11 INSPECTING THE SYSTEM COOLERS 91 6 6 12 ADJUSTING THE MOTOR SPEED 92 6 6 13 ADJUSTING THE PRESSURE SETTING 92 6 6 14 REPLACING AND RE TENSIONING THE SERPENTINE DRIVE BELTS...

Page 9: ... CANOPY 126 9 7 INSTRUMENT PANEL 1 OF 2 128 9 7 INSTRUMENT PANEL 2 OF 2 130 9 8 GENERATORS AND PARTS 132 9 9 MOTOR ASSEMBLY 134 9 10 AIR STORAGE TANK 136 9 11 ASSEMBLY FLOW CONTROL 1 OF 2 138 9 11 ASSEMBLY FLOW CONTROL 2 OF 2 140 9 12 DECAL LOCATIONS 1 OF 3 142 9 12 DECAL LOCATIONS 2 OF 3 144 9 12 DECAL LOCATIONS 3 OF 3 146 APPENDIX A ADDITIONAL INFORMATION 149 A 1 ELECTRIC MOTOR CHART STARTING WA...

Page 10: ...TABLE OF CONTENTS AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE VIII 090034 OP_r0 BLANK PAGE ...

Page 11: ...ited 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 sec...

Page 12: ... 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 s...

Page 13: ...e 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 Ro...

Page 14: ...GLOSSARY AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE XII 090034 OP_r0 BLANK PAGE ...

Page 15: ...s 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 Notificati...

Page 16: ...erial Number Location 800 526 8817 PSIG 260940 MODEL NUMBER SERIAL NUMBER MAXIMUM PRE SSURE COMPRE SSOR INPUT RPM www vanair com DESCRIPTION COMPRESSOR SERIAL TAG SERIAL NUMBER TWO POSSIBLE LOCATIONS Figure W 2 Compressor Serial Number Locations Part No MOD No SER No Rev Lev PSmax Tmax PSmax R P M max Tmax ...

Page 17: ...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 it...

Page 18: ...contact the Service Department by email at service vanair com if you have any questions Return parts to the address listed above INSTRUCTIONS TO CUSTOMERS 1 Product 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 2 The RMA number must be placed on the outside of t...

Page 19: ...e 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 genera...

Page 20: ... 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 whic...

Page 21: ...ditions which will cause death severe injury equipment damage or destructive malfunctions WARNING Identifies actions or conditions which may cause death severe injury equipment damage or destructive malfunctions CAUTION Identifies actions or conditions which will or can cause injuries equipment damage or malfunctions NOTE Additional information or existing information which should be brought to th...

Page 22: ... and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work an...

Page 23: ...ly if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the work piece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equi...

Page 24: ...well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not...

Page 25: ...listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection 1 4 6 WELDING CAN CAUSE FIRE AND EXPLOSION Welding on closed containers such ...

Page 26: ...cable as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers boots and a cap...

Page 27: ...tor before going near arc welding gouging or spot welding operations Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully 1 4 11 CYLINDERS CAN EXPLODE IF DAMAGED Protect compressed gas cylinders from excessive heat mechanical shocks physical damage slag open flames spar...

Page 28: ...oid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with thi...

Page 29: ...re working on generator remove spark plugs or injectors to keep motor from kicking back or starting Block flywheel so that it will not turn while working on generator components 1 5 3 HOT PARTS CAN CAUSE SEVERE BURNS Do not touch hot parts bare handed Allow cooling period before working on equipment 1 5 4 ENCLOSED SPACES CAN CAUSE A BUILD UP OF NOXIOUS FUMES AND OVERHEATING Do not use in enclosed ...

Page 30: ...ggles Do not direct air stream toward self or others 1 6 4 TRAPPED AIR PRESSURE AND WHIPPING HOSES CAN CAUSE INJURY Release air pressure from tools and system before servicing adding or changing attachments or opening compressor oil drain or oil fill cap 1 6 5 HOT METAL FROM AIR ARC CUTTING AND GOUGING CAN CAUSE FIRE OR EXPLOSION Do not cut or gouge near flammables Watch for fire keep extinguisher...

Page 31: ...ories only Lift and support unit only with proper equipment and correct procedures If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit 1 7 2 OVERHEATING CAN DAMAGE MOTORS Turn off or unplug equipment before starting or stopping motor Do not let low voltage and frequency caused by low motor speed damage electric motors 1 7 3 FLYING SPARKS CAN CAUSE ...

Page 32: ...t gases can build up and machine can overheat causing fire 1 7 6 TILTING OF TRAILER CAN CAUSE INJURY Use tongue jack or blocks to support weight Properly install unit onto trailer according to instructions supplied with trailer 1 7 7 READ INSTRUCTIONS Use only genuine Air N Arc replacement parts Perform motor and air compressor if applicable maintenance and service according to this manual and the...

Page 33: ...ssors computers and computer driven equipment such as robots Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to ...

Page 34: ...g Documents phone 1 877 413 5184 web site www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arli...

Page 35: ...ning seventeen years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reache...

Page 36: ...f the machine running if the switch is trig gered the machine will shut down 1 12 DISPOSING OF MACHINE FLUIDS Always dispose of machine fluids under the guidance of all applicable local regional and or federal law Vanair encourages recycling when allowed For additional information consult the container CAUTION The machine is not designed to run with the hood open as standard operating procedure Th...

Page 37: ...AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM SECTION 1 SAFETY 090034 OP_r0 PAGE 19 ...

Page 38: ...LER V PRESSURE RELIEF VALVE 200 PSI G MINIMUM PRESSURE VALVE W PRESSURE SWITCH H AIR OIL COALESCER X LIFTING BAIL J AIR FILTER COMPRESSOR Y HYDRAULIC COOLER K COMPRESSOR OIL DRAIN TUBE Z FUSES L COMPRESSOR UNIT AA RELAYS M HYDRAULIC SUPPLY BB DC GENERATOR N HYDRAULIC RETURN P AIR MOISTURE DRAIN I Refer to Section 9 for part description details and part numbers NOTE The above figure is an at a glan...

Page 39: ...and oil are forced through the rotating screws in the compression chamber Because of this concept compressed air is generated on demand System Component or Component Group Manual Section Location COMPRESSED AIR SYSTEM 2 2 page 21 Compressor Unit 2 2 1 page 21 Electronic Air Inlet Valve 2 2 2 page 22 Air Inlet Filter 2 2 3 page 23 Secondary Spin on Air Oil Coalescer 2 2 4 page 23 Minimum Pressure C...

Page 40: ...ide the main casting and consist of a male and female rotor supported with low friction bearings sized for a long useful life 2 2 2 ELECTRONIC AIR INLET VALVE See Figure 2 3 The electronically actuated air inlet valve is a piston type valve located directly on top of the compressor assembly beneath the air inlet filter On initial start up the solenoid is energized and the inlet valve opens due to ...

Page 41: ...time as part of normal maintenance For routine maintenance of the spin on air oil coalescer consult Sections 6 2 and 6 3 for schedule intervals and Section 6 6 6 for the specific coalescer maintenance procedure 2 2 5 MINIMUM PRESSURE CHECK VALVE See Figure 2 4 This combination valve located on the control manifold serves two functions First the minimum pressure valve maintains a pressure of approx...

Page 42: ... 6 6 14 2 2 8 OIL RESERVOIR AND PRIMARY AIR OIL SEPARATOR The main casting of the compressor unit which contains the screw compressor is also the oil reservoir and primary oil separation unit The initial primary oil separation is caused by both changes in velocity and direction The main casting also contains the oil fill tube and drain hose assembly A separate oil reservoir is not required 2 3 OIL...

Page 43: ...IN ONE POWER SYSTEM SECTION 2 DESCRIPTION 090034 OP_r0 PAGE 25 KEY DESCRIPTION A PRESSURE SWITCH Figure 2 6 Pressure Switch Location A KEY DESCRIPTION A HYDRAULIC FAN COOLER B COMPRESSOR FAN COOLER Figure 2 7 Cooling System A B ...

Page 44: ...h shuts down machine at 185 psi 2 3 2 COMPRESSOR SPIN ON OIL FILTER See Figure 2 9 The compressor system is also supplied with a spin on oil filter positioned off the lower corner of the compressor This element requires regular replacement to prolong the life of the compressor system For routine maintenance of the spin on filter consult Sections 6 2 and 6 3 for maintenance schedules and Section 6 ...

Page 45: ...Component or Component Group Manual Section Location INSTRUMENTATION 2 6 page 27 Volts Amps Meter 2 6 1 page 28 Welder Function Switches 2 6 2 page 28 DC Charger Mode Toggle Switch 2 6 3 page 28 Volts Amps Manual Adjustment Dial 2 6 4 page 28 Compressor Air Pressure Gauge 2 6 5 page 28 Compressor ON OFF Toggle Switch 2 6 6 page 29 Welder Lead Junction 2 6 7 page 29 Hz Voltage Meter 2 6 8 page 29 B...

Page 46: ...he volts amps meter shows the amount of volts and or amp level while welding or boosting 2 6 2 WELDER FUNCTION SWITCHES The constant current CC or constant voltage CV toggle switch lets the operator choose the type of power supply desired CC Mode Constant Current CV Mode Constant Voltage The three position DC charger welder toggle switch serves as the battery charge enabling switch power enabling ...

Page 47: ...ight so as long as the green light or the green and red light located to the right of it are on the machine is at proper speed If under use the user only sees three 3 red lights then the load is too heavy and should be reduced The voltage is also shown on this meter but is only accurate during AC use When the generator switch is ON but the generator is not being used the voltage is inaccurate 2 6 ...

Page 48: ...HARGER MODE TOGGLE SWITCH 2 6 3 P FRONT ACCESS PANEL OPEN LAMP 2 6 13 SHUT DOWN E VOLTS AMPS MANUAL ADJUSTMENT DIAL 2 6 4 Q COMPRESSOR OVER PRESSURE LAMP 2 6 14 SHUTDOWN F COMPRESSOR AIR PRESSURE GAUGE 2 6 5 R COMPRESSOR OVERTEMP LAMP 2 6 15 SHUT DOWN G COMPRESSOR ON OFF TOGGLE SWITCH 2 6 6 S HYDRAULIC OVERTEMP LAMP 2 6 16 SHUT DOWN H WELDER LEAD CONNECTION 2 6 7 T MACHINE ACTIVE RESET SWITCH 2 6 ...

Page 49: ...vice Department 2 6 13 FRONT ACCESS PANEL OPEN INDICATOR LAMP The front access panel open indicator lamp signals that the front panel is not in place or not fastened properly the machine will not start if the door panel is open 2 6 14 COMPRESSOR OVER PRESSURE INDICATOR LAMP If the compressor system sees 185 psi the machine will shut down and cause this lamp to flash After the problem has been corr...

Page 50: ...integral to all the functions of the 300 Series Power System Consult the various operating procedures as found in Section 4 Operation to determine the integration of the motor with each separate system function If shutdown occurs this switch must be reset and turned back on for operation after the problem has been fixed 2 6 18 HOUR METER The hour meter records the total accumulated hours that the ...

Page 51: ...nation class NAS1638 9 ISO 4406 20 18 15 Achieved with filter ß10 c 75 10mm Operating Temperature Limits 0 F to 110 F 18 C to 43 C Cold Weather Kit extends temperature range from 0 F to 40 F 18 C to 40 C TABLE 3C SPECIFICATIONS AIR COMPRESSOR COMPRESSOR INFORMATION SPECIFICATION Compressor Type Single Stage Oil Injected Rotary Screw Air Compressor Capacity 40 CFM 175 PSI Inlet Control Zero 0 No Lo...

Page 52: ...30 23 40 30 45 35 49 39 3 8 24 22 16 35 25 45 35 50 40 54 44 7 16 14 24 17 50 35 60 45 70 55 76 61 7 16 20 34 26 55 40 70 50 80 60 85 68 1 2 13 38 31 75 55 95 70 110 80 113 90 1 2 20 52 42 90 65 100 80 120 90 126 100 9 16 12 52 42 110 80 135 100 150 110 163 130 9 16 18 71 57 120 90 150 110 170 130 181 144 5 8 11 98 78 150 110 140 140 220 170 230 184 3 4 10 157 121 260 200 320 240 380 280 400 320 3...

Page 53: ... Welder OCV Voltage 70 Welder Max Amperage 300 Welder Max CV Voltage 40 Welder Min CV Voltage 15 Welder 12V charge voltage 14 Welder 12V boost voltage 16 Welder 24V boost voltage 30 TABLE 3G GENUINE VANGUARD OIL CHARACTERISTICS Viscosity 178 SUS at 100 F 38 C Flashpoint 495 F 257 C Pour point 49 F 45 C Contains Rust and Oxidation Inhibitors Contains Detergents TABLE 3H MACHINE PACKAGE DIMENSIONS F...

Page 54: ...SECTION 3 SPECIFICATIONS AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 36 090034 OP_r0 BLANK PAGE ...

Page 55: ...hine 4 6 page 45 Installing the Control Trunk Line 4 7 page 45 Installing the Optional Remote Control Panel 4 8 page 45 Installing the Remote Air Tank 4 9 page 45 Post Set Up Initial Test Function 4 10 page 46 Compressor Flow Schematic Diagram 4 11 page 48 Installation and Dimensions Diagram 4 12 1 of 2 page 49 Installation and Dimensions Diagram 4 12 2 of 2 page 50 DANGER DO NOT install in enclos...

Page 56: ...need to integrate with the vehicle s layout and systems Depending upon the customer specified machine order an installation may include all or part of the following major task list breakdown Machine mounting Air tank mounting skid mounted model Instrument panel mounting Connecting service and auxiliary lines and electronics 4 4 PREPARING THE VEHICLE SERVICE BODY NOTE Although much of the informati...

Page 57: ... underdeck or chasis wiring piping etc Clear pathways for route lines and wires which are free of sharp edges sharp angles and heat contact if applicable Service output location Additional service body preparation includes the following Ensure that the mounting surface for the machine as well as any remote component s are level cleared of debris and able to support the machine and or its component...

Page 58: ...er Measurements 4 4 2 DETERMINING PROPER VENTILATION REQUIREMENTS The Air N Arc All In One Power System 300 Series machine is air cooled adequate provision for supply of cool air to the engine compressor and generator is required The air requirements for proper ventilation need to be considered when preparing to install the Air N Arc 300 Series machine 4 4 3 ROOF REQUIREMENTS IF APPLICABLE If a ro...

Page 59: ...IPTION A WIDTH SIDES Six 6 inches clearance space allowance B HEIGHT ABOVE MACHINE 16 19 inches of clear ance space allowance for opening hood Figure 4 1 Minimum Cooling Space Requirements A A B NOTE If one side of machine is restricted to the minimum 6 clearance then the other side should be left open to fresh air ...

Page 60: ...Group Task Manual Section Location Mounting the Machine 4 5 page 42 Separating the Machine From the Shipping Crate Mounting 4 5 1 page 43 Marking the Machine Mounting Location 4 5 2 page 43 Stabilizing Precautions for Machine Mounting 4 5 3 page 44 KEY DESCRIPTION KEY DESCRIPTION A BASE COVER E MOUNTING BOLT 1 2 x 4 B TRUSS SCREW 1 4 x6 F SHIPPING CRATE SKID PLATFORM C NYLON FLAT WASHER 1 4 x6 G A...

Page 61: ... 4 5 3 the mounting bolts may not be long enough to secure the machine package The minimum thread clearance is 2 1 2 threads showing above the nut with the machine fastened in place Figure 4 3 4 5 2 MARKING THE MACHINE MOUNTING LOCATION 1 Using a proper hoist lift and place the unit into a preliminary position on the service body of the vehicle so that access is easily attained the control trunk l...

Page 62: ...per machine clearances will be maintained Then temporarily move the machine so that the service body floor can be drilled Drill four 4 9 16 mounting holes in the service body floor at the scribed markings made in step 4 4 5 3 STABILIZING PRECAUTIONS FOR MACHINE MOUNTING Refer to Figure 4 6 Machine should be mounted to vehicle using a minimum of four 4 isolators Isolators NOTE Do not bolt and torqu...

Page 63: ...stall the optional remote control panel at the desired location on the service body and route the control trunk line to the location where the unit will mount Ensure that all sharp edges that the trunk line contacts are shielded or grommetted and that there are no excessively sharp bends in the trunk line Ensure the trunk line does not come in contact with exhaust parts 4 9 INSTALLING THE REMOTE A...

Page 64: ...mpting the post set up initial test function review all of the tasks laid forth in Sections 4 4 through TOOLS ITEMS NEEDED REPLACEMENT PART S Air Tank and Mounting HardwareI Relief Valve 200 psi supplied CO450008 Discharge Piping see below Wrenches I NOTE If tank is larger than 6 OD it must be ASME rated NOTE When determining the location of the air tank keep in mind that the drain valve will need...

Page 65: ...tom through the four mounting bolt holes of the base frame refer to Section 4 5 3 and Figure 4 6 See Section 4 10 Parts 1 and 2 for base mounting pattern etc Note that with the addition of the vehicle mounting surface and the isolator thickness the bolt must have a minimum clearnance of 2 1 2 threads above the fastening nut after final tightening see Figure 4 3 Should the mounting bolts from the s...

Page 66: ...SECTION 4 INSTALLATION AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 48 090034 OP_r0 4 11 COMPRESSOR FLOW SCHEMATIC DIAGRAM A B C D E F G H J K L M N P Q R S T 271384_r1 ...

Page 67: ...AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM SECTION 4 INSTALLATION 090034 OP_r0 PAGE 49 050735ID_1of2_r0 4 12 INSTALLATION AND DIMENSIONS DIAGRAM PART 1 OF 2 ...

Page 68: ...SECTION 4 INSTALLATION AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 50 090034 OP_r0 4 12 INSTALLATION AND DIMENSIONS DIAGRAM PART 2 OF 2 050735ID_2of2_r0 ...

Page 69: ...AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM SECTION 4 INSTALLATION 090034 OP_r0 PAGE 51 BLANK PAGE ...

Page 70: ...R MODE TOGGLE SWITCH 2 6 3 P FRONT ACCESS PANEL OPEN LAMP 2 6 13 SHUT DOWN E VOLTS AMPS MANUAL ADJUSTMENT DIAL 2 6 4 Q COMPRESSOR OVER PRESSURE LAMP 2 6 14 SHUTDOWN F COMPRESSOR AIR PRESSURE GAUGE 2 6 5 R COMPRESSOR OVERTEMP LAMP 2 6 15 SHUT DOWN G COMPRESSOR ON OFF TOGGLE SWITCH 2 6 6 S HYDRAULIC OVERTEMP LAMP 2 6 16 SHUTDOWN H WELDER LEAD CONNECTION 2 6 7 T MACHINE ACTIVE RESET SWITCH 2 6 17 J A...

Page 71: ...thoroughly and familiarize yourself with the controls and indicators their purpose location and use System Operation Group Manual Section Location Machine Start up and Shutdown Procedure 5 2 page 54 Machine Start up 5 2 1 page 54 Machine Shutdown 5 2 2 page 55 Motor Throttle Control Functions 5 3 page 56 Operating the Welder 5 4 page 56 Welder Operating Procedure 5 4 1 page 57 CC Constant Current ...

Page 72: ...ine Operation 5 8 1 2 page 64 High Temperature Operation 5 8 2 page 65 Machine Operation 5 8 2 1 page 65 High Dust Content Operation 5 8 3 page 65 Machine Operation 5 8 3 1 page 65 High Altitude Operation 5 8 4 page 65 NOTE If start up and shut down procedures are not followed damage to the system and its components may occur System Operation Group Manual Section Location Machine Start up and Shut...

Page 73: ...imal condition and minimimize undue stress that may occur during the next start up session if some of the machine conditions were left in working mode s or had auxiliary power draws left intact such as a tool receptacle left plugged into the generator etc To prepare the machine for shutdown NOTE Refer to Truck Operator s Manual for additional information pertaining to the starting of the truck CAU...

Page 74: ... panel and the use of the welder 3 The position of the generator switch on the control panel Consult Table 5A Motor Throttle Control Function Conditions to understand how the motor speed relates to the demand s of the machine system s output functions 5 4 OPERATING THE WELDER Consult Figure 5 4 The variable power dial adjusts the welder amperage 30 to 300 amps or voltage 15 to 40 volts for the des...

Page 75: ...ue five 5 seconds after the dial has been adjusted WARNING Do not rely on the thermal overload circuit breakers on the generator to protect personnel power tools or the generator The thermal overload circuit breakers on the generator require time to overheat when the generator is operating in an overload condition they do not provide instant protection against short circuiting or overload conditio...

Page 76: ...ATIONS for electrode amperage ratings At anytime during welding the power dial may be adjusted to the desired amperage level 6 When you strike the electrode against the material being welded the motor will go to full speed and deliver the selected amperage through the electrode Now you may begin to weld 7 After a weld has been completed and there is no contact between the electrode and the metal f...

Page 77: ...welded Adjust the power dial on the suitcase feeder for the material being welded At anytime during welding the power dial may be adjusted to the desired voltage level 5 4 1 3 CV CONSTANT VOLTAGE MODE USING A SPOOL GUN CV Constant Voltage Mode commonly referred to as Wire Welding MIG welding or Gas Metal Arc Welding GMAW 1 With the motor shut off insert the twist lock connection of the ground clam...

Page 78: ...rt a multi function project However if the generator is operating at a high percentage of its rated capacity and the welder and air compressor are also being used the resulting drop in motor speed may produce a low voltage condition that will damage the generator and power tools being used TABLE 5C WELDING ROD TYPE POLARITY AND FLUX CODES DIGIT TYPE OF COATING WELDING CURRENT 10 High cellulose sod...

Page 79: ...art for information on the compressed air requirements of common tools If the equipment is not listed in Section A 4 check the desired power tool manufacturer s specifications NOTE Only plug power cords into the generator receptacles AFTER the machine is running at full speed Be careful not to overload the rated capacity of the generator 6 800 watts 28 amps 240V continuous CAUTION Exposed high pre...

Page 80: ...art Group Task Manual Section Location Operating the Battery Boost Charger 5 7 page 62 Connection Disconnection Sequence and Operation 5 7 1 page 62 WARNING DO NOT charge or boost while in Weld Mode Personal injury or damage may occur IMPORTANT Never attach boost cables to the panel before attaching to the battery Always attach cables to the battery first IMPORTANT To prevent damaging voltage spik...

Page 81: ...ating in extreme cold or hot conditions ranging from 0 F to 110 F 18 C to 43 C 0 F to 40 F 18 C to 40 C with cold weather kit in the presence of high humidity or at a high altitude extra attention should be given to any indication that could lead to a serious problem If the ambient temperature varies largely the environment is dusty or the motor is operated at a high altitude the motor performance...

Page 82: ...uard Premium Synthetic Oil is suitable for use from 40 F to 110 F 40 C to 43 C Drain the moisture from the tank when it is warm from extended operation 5 8 1 2 MACHINE OPERATION At an extremely cold temperature the viscosity of hydraulic fluid and lubrication oil may increase hindering proper starting Additional care should be taken under consideration when operating the package in extreme cold we...

Page 83: ...rs when operating in areas that contain a high dust content If the machine is not being used for an extended period of time an additional precaution such as covering the machine with a tarp will help to keep the inside of the machine free of dust particle accumulation 5 8 4 HIGH ALTITUDE OPERATION Motor horsepower will decrease by 3 5 for every 1 000 ft increase in altitude At high altitude overal...

Page 84: ...SECTION 5 OPERATION AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 66 090034 OP_r0 BLANK PAGE ...

Page 85: ...outine Maintenance Schedule 6 2 page 67 Maintenance Schedule Table 6 3 page 69 Replacement Parts 6 4 page 72 Maintenance Access 6 5 page 72 Parts Replacement and Adjustment Procedures 6 6 page 73 Servicing the System Fuses and Cir cuit Breakers 6 7 page 99 Storage and Intermittent Use 6 8 page 99 WARNING Follow all applicable safety recommendations as outlined in Section 1 Safety of this manual SE...

Page 86: ... routine log For assistance in obtaining routine maintenance or replacement parts consult Section 9 1 Parts Ordering Procedure and Table 9A Recommended Spare Parts List WARNING Follow all applicable safety recommendations as outlined in Section 1 Safety of this manual NOTE Follow the prescribed periodic maintenance PM schedule as recommended Perform the required PM schedule at recommended interval...

Page 87: ...Consult Section 6 6 15 1 2 Check air tank for water accumulation Drain any water from the air tank per procedure in Section 6 6 9 3 Check air compressor oil level Check resting oil level follow compressor fill procedure Section 6 6 3 if low 4 Inspect unit for oil leaks or damage Visually note any leaks or evidence of leaks around the compressor unit and hose connections Tighten any loose connectio...

Page 88: ... element Compressor Oil Sections 6 6 3 and 6 6 5 Compressor Oil Filter Section 6 6 4 Coalescer Element Section 6 6 6 9 Inspect air compressor drive belt and serpentine welder drive belt for wear damage or excessive cracking Ensure that drive belts are in satisfactory operating condition and are tensioned adequately Should a belt need to be re tensioned or replaced consult Section 6 6 15 10 Check b...

Page 89: ...d Ensure that the motor speed is running at correct interval Adjust if necessary per Section 6 6 13 15 Inspect the welding leads and battery charging cables If so equipped ensure that welding leads are satisfactory for operation no cracks or advanced wear Repair or replace as necessary 16 Inspect welding electrode clamp and ground clamp Ensure that welding electrode and ground clamps are in satisf...

Page 90: ... SECTION LOCATION Compressor oil filter easier to access with panels removed 6 6 4 Oil Filter Change I Belt Replacement I Pressure Switch Adjustment 6 6 13 Main Cooler Assembly Cleaning thorough 6 6 11 Replace Fuses and Circuit Breakers 6 7 Generator Fuse Replacement 6 7 I Refer to the Motor Operator s Manual NOTE If additional spare parts are being stored for future use make certain that they are...

Page 91: ...ounting 6 6 8 1 page 87 Connecting the New Solenoid Valve 6 6 8 2 page 87 Draining the Air Tank 6 6 9 page 88 Rebuilding the Minimum Pressure Check Valve 6 6 10 page 90 Setting the Minimum Pressure Valve 6 6 10 1 page 90 Inspecting the System Coolers 6 6 11 page 91 Adjusting The Motor Speed 6 6 12 page 92 Continued on next page CAUTION Always wear personal protective equipment such as gloves safet...

Page 92: ... or damage NOTE To perform a more thorough inspection of the compressor air filter element refer to Section 6 6 1 2 If element is in adequate shape to continue using 5 Re seat the filter element C onto the air filter mounting posts D Adjusting The Pressure Setting 6 6 13 page 92 Replacing and Re tensioning the Serpentine Drive Belts 6 6 14 page 94 Re tensioning the Air Compressor Serpentine Drive ...

Page 93: ...ter element uses a pleated paper type filter to carefully remove accumulated dirt before compression can begin DO NOT clean the compressor air filter element To replace worn or damaged air filter with new filter consult Figure 6 2 and the following procedure 1 With the machine off and the ignition key removed open the hood panel and locate the compressor air filter 2 Remove two 2 wing nuts A from ...

Page 94: ...ot get damaged or soiled the full air filter inlet valve D is now accessible 4 Remove the two 2 nuts E and two 2 washers F from the mounting posts V 5 Grasp the governor body P and pull upwards to disengage the valve from its seating 6 Disassemble the valve and replace used parts with new parts found in the kit Refer to Figure 6 4 to assure correct part positions for re assembly 7 Once the valve s...

Page 95: ... MOUNTING COVER N V RING C AIR FILTER ELEMENT P GOVERNOR HOUSING D AIR INLET VALVE COMPLETE ASSEMBLY Q O RING E NUT x 2 R LOCK WASHER F WASHER x 2 S PLATE SET G SPRING GUIDE S1 VALVE HEAD H SPRING S2 WEIGHT J NUT T O RING K SPRING GUIDE U CONTROL LINKAGE L SPRING V MOUNTING POSTS Order Air Inlet Valve Rebuild Kit no 264154 102 Figure 6 4 Air Inlet Valve Rebuild Kit A C B D E F G H J K L M N Q T S1...

Page 96: ... life Checking the compressor oil is the most important service to perform on the 300 Series All In One Power System package Consult Section 6 3 Maintenance Schedule Table for routine compressor oil inspection intervals DANGER NEVER check the compressor oil level with the compressor running Hot oil is under pressure and will spray causing severe burns When checking compressor oil level blow down t...

Page 97: ...ion 6 3 Maintenance Schedule Table for routine compressor oil element change intervals 1 With the machine off and the ignition key removed open the hood panel access door TOOLS ITEMS NEEDED REPLACEMENT PART S Strap Wrench Vanguard Premium Synthetic Oil No 264626 1GAL Adjustable Wrench NOTE For ease of access the maintenance access panel assembly will need to be removed Consult Section 6 5 TOOLS IT...

Page 98: ...o check and or replace or refill the compressor system refer to Section 6 6 5 6 6 5 CHANGING THE COMPRESSOR OIL During periodic maintenance intervals or more frequently if needed it will be necessary to perform a complete compressor system oil change Follow the procedure below along with Figure 6 7 and Sections 6 6 3 6 6 4 and 6 6 6 to change the oil TOOLS NEEDED REPLACEMENT PART S Clean Utility H...

Page 99: ...nit reservoir 6 Run the compressor momentarily turn off and verify that the level of compressor oil G is within satisfactory range 6 6 6 REPLACING THE SPIN ON AIR OIL COALESCER The air oil coalescer element is a spin on disposable type Consult Figure 6 8 and use the following procedure to replace the coalescer element Consult Section 6 3 Maintenance Schedule Table for routine coalescer element cha...

Page 100: ...ft seal requires servicing order shaft seal repair kit no 270766 The compressor belt and compressor drive sheave must first be removed in order to access the seal components Refer to Figure 6 9 and the following procedure to perform maintenance on the compressor shaft seal 6 6 7 1 PART I REMOVING THE COMPRESSOR SERPENTINE BELT 1 With the truck vehicle off and the ignition key removed open the fron...

Page 101: ...D SHEAVE WASHER P SEAL O RING E DRIVE SHEAVE Q INNER RING F CAPSCREW M8 x 1 25 x 30MM x4 for Plate R SPACER G LOCK WASHER M8 x4 for Plate S NEEDLE BEARING H SHEAVE WASHER M8 x4 for Plate T KEY J AIR END TENSIONER PLATE U MALE ROTOR DRIVE SHAFT J1 TENSIONER PLATE ADJUSTMENT refer to Section 6 6 15 1 V COMPRESSOR TENSIONER SHEAVE K PAN HEAD SCREW Order Shaft Seal Rebuild Kit no 270766 Figure 6 9 Com...

Page 102: ... from the end of the male rotor drive shaft Z 7 Wipe down any excess contaminants that may have accumulated on the male rotor drive shaft 8 Replace the needle bearing X and spacer W with their new counterparts from the kit 9 Replace inner ring V with its new counterpart from the kit the inner ring should be gently tapped into place using the tool as a guide Note that it should seat snugly on the s...

Page 103: ...to allow for repositioning of the tensioner sheave serpentine belt 6 6 7 3 PART III REPLACING THE COMPRESSOR SERPENTINE BELT 1 Replace re thread the serpentine belt F back onto the motor sheave and compressor drive sheave K making sure that the belt lies over the compressor tensioner sheave AA as shown in insert P1 2 For details on how to adjust the compressor belt tension consult Section 6 6 15 1...

Page 104: ...OLLAR CONNECTOR HEAD I L PRY SLOT D SEAL M CONNECTOR HEAD BASE E CONNECTION PINS N PIN RE CONFIGURATION F PNEUMATIC TUBE CONNECTORI P SEATING THE CONNECTOR BASE G VALVE BODY Q SOLENOID VALVE location H MOUNTING SCREW x 4 I Not used discard Order Solenoid Replacement Kit no 270775 Figure 6 11 Air Inlet Valve Solenoid Replacement A B C D E F G B L M N P H J K Q ASSEMBLY PART KIT REPLACEMENT PART ...

Page 105: ...crewdriver into the access indent on the base K Apply prying pressure to the pry slot L so that the base comes away from the connector head shown in M 6 Rotate the base so that the slit corresponding to the only flat pin is closest to the wire connection end of the valve connector head as shown in N 7 While holding the connector with your thumbs push the base into the connector head until it snaps...

Page 106: ...r unit 7 Use the four 4 mounting screws from the kit H to secure the new valve body to the compressor unit 8 Unplug the connector head from the new solenoid body but leave the seal in place 9 Unscrew the collar C from the new connector head 10 On the wire replace the old connector collar with the new one from the new connector head 11 Run the collar up the wire and secure it to the valve connector...

Page 107: ...machine For areas of high ambient moisture content the valve may need to be checked more than once per day This valve may be accessed at any time including while the machine is in operation 1 Turn handle of drain valve A to release moisture buildup If preferred place a container below the valve to catch discharge 2 Close the valve after the water has drained off TOOLS NEEDED REPLACEMENT PART S Cat...

Page 108: ...osen and carefully remove the valve body D which holds the internal parts in place The internal parts will be freed to drop out with the removal of the valve body 6 Wipe internal surface of valve body D with a clean cloth 7 Consult Figure 6 13 and re assemble the kit by replacing all old parts with corresponding part provided in the kit 8 Once the kit parts parts E through L have been situated in ...

Page 109: ... Section 6 3 Maintenance Schedule Table inspect the cooler fins of both the motor and the compressor for any build up of dirt KEY DESCRIPTION KEY DESCRIPTION ASSEMBLY PART KIT REPLACEMENT PART A MINIMUM PRESSURE CHECK VALVE G O RING B LOCK NUT H PISTON with o ring C GRUB SCREW COMPLETE J SPRING D VALVE BODY K VALVE HEAD with o ring E SPRING GUIDE L O RING F PRESSURE SPRING M CONTROL MANIFOLD Order...

Page 110: ...sure in which the compressor starts pumping Anytime the pressure in the tank falls below this pressure the compressor is allowed to start pumping NOTE Do not tamper with the flow control setting to increase the maximum motor speed Overspeed is hazardous and will void the motor warranty WARNING The compressor cut in cut out pressures have been factory adjusted within the limits of the compressor ma...

Page 111: ...oth of these settings For such cases consult Figure 6 15 and the following procedure 1 Locate the air pressure control switch A at the rear side of the generator support bracket Remove the cover retaining screw fastening the cover to the switch and remove the cover 2 To adjust the compressor pressure turn the cut in pressure adjustment screw B clockwise to increase the pressure and counterclockwis...

Page 112: ...ate slide along the grooves in the plate while still in position DO NOT remove 3 Use a 1 2 drive torque wrench applied to the square tensioning hole D to manually rotate the plate idler about the loosened but anchored mounting bolt Apply torque of 51 ft lbs 4 Once a position is achieved that accounts for a satisfactory tension in the belt torque the four 4 tensioner plate bolts A to 12 ft lbs 16 3...

Page 113: ...re 6 17 TOOLS NEEDED REPLACEMENT PART S Socket Wrench Size 6 mm Hex Head for Tensioner Plate Bolts Serpentine Belt No DR27584 Torque Wrench 1 2 Drive Ratchet 1 2 with Extension KEY DESCRIPTION KEY DESCRIPTION A TENSIONER PLATE MOUNTING AND ADJUSTMENT BOLTS E Loosen bolts to allow tensioner plate to pivot man ually to achieve new belt tensioned position B IDLER F Pivot plate by applying torque wren...

Page 114: ...he truck s ignition key removed open and remove the front panel NOTE After replacing the serpentine belt the belt will need to be checked for proper tension Consult Section 6 6 15 1 on how to check and adjust the air compressor serpentine belt tension TOOLS NEEDED REPLACEMENT PART S Wrench Size 3 8 Not Applicable Tension Tester Figure 6 17 Compressor Serpentine Belt Positioning A B C D E KEY DESCR...

Page 115: ...Nm to secure the tensioner plate B into position 6 6 14 4 REPLACING THE GENERATOR SERPENTINE DRIVE BELT TOOLS NEEDED REPLACEMENT PART S Wrench Size 5 16 for Tensioner Bolt Serpentine Belt No DR62184 Tension Tester Socket Wrench Size 3 4 KEY DESCRIPTION KEY DESCRIPTION A IDLER SHEAVE C TENSIONER PLATE MOUNTING AND ADJUSTMENT BOLT Loosen bolt to allow tensioner plate to pivot manually to achieve new...

Page 116: ...ed Refer to Figure 6 19 and the following steps 2 Using a 3 4 socket wrench on tensioner plate bolt H pivot the belt tensioner G to relieve enough tension on the sheave C in order to remove the belt D remove belt D 3 Position and route the new generator serpentine belt as shown in Figure 6 19 4 Replace the compressor serpentine belt refer to Section 6 6 15 2 KEY DESCRIPTION KEY DESCRIPTION A DC GE...

Page 117: ...ration such as visible surface cracks stiffness or discoloration 6 8 2 LONG TERM STORAGE Disconnect the battery cable that is connected to the positive side of the battery System Component or Part Group Task Manual Section Location Storage and Intermittent Use 6 8 page 99 Intermittent Use 6 8 1 page 99 Long term Storage 6 8 2 page 99 NOTE Compressor belt goes on the outer track of the motor sheave...

Page 118: ... R1 A C GENERATOR F 15 AMP FUSE WELDER FIELD B R2 SWITCHED POWER G 15 AMP FUSE COMPRESSOR FAN C R3 HYDRAULIC FAN H 25 AMP FUSE HYDRAULIC FAN D R4 COMPRESSOR FAN J 50 AMP CIRCUIT BREAKER AUTO RESET E 5 AMP FUSE PANEL SWITCHED POWER K A C GENERATOR CIRCUIT BREAKERS Figure 6 20 Power System Fuse Locations A B C D E F G H J K ...

Page 119: ...l trou bleshooting information may be found in other sources such as the Engine Operator s Manual and the Generator Operator s Manual Should the situa tion remain unresolved after exhausting available sources contact the Vanair Service Department at Phone 800 526 8817 toll free Phone 219 879 5100 ext 400 Fax 219 879 5335 NOTE When contacting the Vanair Service Department please have machine serial...

Page 120: ...lace if necessary Compressor oil filter plugged Replace filter refer to Section 6 6 4 Replacing the Compressor Oil Filter Element Input rpm too high Adjust to proper setting refer to Section 6 6 12 Adjusting the Motor Speed Fan not operating Low oil check oil level and refill to proper level if necessary ensure machine is parked on a level surface Refer to Section 6 6 3 Checking the Compressor Oil...

Page 121: ...a level surface Refer to Section 6 6 3 Checking the Compressor Oil Air demand too high Check for leaks and take corrective action Check air tools for wear damage or malfunctions Replace or repair Compressor capacity too low to accommodate demand Substitute larger capacity compressor system Compressor air filter plugged Check air filter Replace if necessary refer to Section 6 6 1 Compressor Air Fil...

Page 122: ...led if ice is present clear and remove Damaged kinked control line Check line for damage wear kinks etc Re route re tie or replace if necessary refer to Appendix A A 6 Hose Installa tion Guide for assistance in running or checking hose lines Control line connections are not prop erly seated poor connection quality Check lines for proper seating ensure line ends have been cut cleanly and are square...

Page 123: ...ing the Pressure Setting Replace if switch continues to deviate from setting Speed is set too low Check hydraulic pressure and GPM System operating pressure below specified minimum Air demand too high Check air tools for wear damage or malfunctions Replace or repair Compressor capacity too low to accommodate demand Substitute larger capacity compressor system System leaks or is damaged Inspect for...

Page 124: ...ture in the compressed air Moisture accumulating in air tank Drain water from air tank Refer to Section 6 6 9 Draining the Air Tank Compressor not running long enough Run compressor long enough to get hot WELDER Welder and battery charger behave erratically Connection cables or receptacles are soiled contaminated Check for twisted cables and or soiled contaminated or loose receptacle connections U...

Page 125: ... slipping or damaged Re situate and adjust belt tension or replace belt if necessary Consult Section 6 6 14 Replacing and Re tensioning the Serpentine Belts Order replacement belt see Table 9A Recommended Spare Parts List Circuit breaker tripped Reset circuit breaker two located on machine and two located on panel Faulty AC generator relay Check replace if necessary Faulty capacitor Check replace ...

Page 126: ...SECTION 7 TROUBLESHOOTING AIR IN ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 108 090034 OP_r0 BLANK PAGE ...

Page 127: ...roblems that may arise while operating the All In One Power System within its intended use The flow schematic and wiring diagram should be used together when identifying any potential prob lems They are laid out in a format that is designed to be easy to read for the end user or a service techni cian NOTE For machine measurement specifications refer to Section 4 10 Installation and Dimensions Diag...

Page 128: ...SECTION 8 DIAGRAMS AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 110 090034 OP_r0 8 2 WIRING DIAGRAM AIR N ARC 300 SERIES HYDRAULIC ID271382_r2 ...

Page 129: ...CH B HYDRAULIC MOTOR L COMPRESSSOR C 12V SOLENOID VALVE M OIL FILTER D FLOW CONTROL N OIL FILL E FLOW ADJUSTMENT P COMPRESSOR COOLER F PRESSURE RELIEF VALVE Q INSTRUMENT PANEL G AIR FILTER R TANK AIR PRESSURE H COALESCER S AIR OUT J MINIMUM PRESSURE SWITCH T AIR ACCUMULATOR TANK A B C D E F G H J K L M N P Q R S T 8 3 COMPRESSOR FLOW SCHEMATIC DIAGRAM ...

Page 130: ...SECTION 8 DIAGRAMS AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 112 090034 OP_r0 BLANK PAGE ...

Page 131: ...Bill of Lading for the machine package or from the compressor unit serial number plate See Figure 9 1 for location of machine package serial plate Consult Table 9A Recommended Spare Parts List on the next page for a listing of replacement parts VANAIR MANUFACTURING INC 10896 West 300 N Michigan City IN 46360 Telephone 800 526 8817 219 879 5100 Service Fax 219 879 5335 Parts Fax 219 879 5340 Sales ...

Page 132: ...Circuit 20A 2 Figure 6 20 K 16 DR271456 Belt Serpentine Compressor 1 9 3 37 17 DR62184 Belt Serpentine Generator 1 9 8 26 19 270766 Kit Compressor Shaft Seal Rebuild 1 Figure 6 9 20 270765 Kit Minimum Pressure Check Valve Rebuild 1 Figure 6 13 21 264154 102 Kit Air Inlet Valve Rebuild 1 Figure 6 4 D IUse only Vanair Vanguard Premium Synthetic Oil and Genuine Vanair Parts Inspect and replace damage...

Page 133: ...AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM SECTION 9 ILLUSTRATED PARTS LIST 090034 OP_r0 PAGE 115 NOTES ...

Page 134: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 116 090034 OP_r0 9 2 AIR N ARC 300 SYSTEMS ASSEMBLIES PA6130044_r1 ...

Page 135: ...EP271411 1 3 AIR STORAGE ASSEMBLY PA6000027ID 1 4 ID COMPRESSOR PARTS PA6010072ID 1 5 COOLING SYSTEM ANA 300H PA6020033ID 1 6 ID COOLING SYSTEM COMPRESSOR PA6020036ID 1 7 ID FRAME CANOPY PA6030031ID 1 8 INSTRUMENT PANEL PA6040027ID 1 9 ID GENERATORS AND PARTS PA6050012ID 1 10 ID MOTOR DRIVE PARTS PA6100027ID 1 11 DECALS ANA HYDRAULIC PA6110001 1 12 ID ASS Y FLOW CONTROL PA6120097ID 1 13 KIT HOSE A...

Page 136: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 118 090034 OP_r0 9 3 COMPRESSOR AND PARTS ASSEMBLY 1 OF 2 PA6010072ID_r1 ...

Page 137: ...230 PSI X 3 FT 264480 1 12 OIL VANGUARD 3 5 QUARTS 264626 1 13 ELBOW 1 2MPT x 1 2FJIC SWVL 90 268929 008 1 14 COMPR PART VANAIR 31 EMC 12VDC STD SHAFT 269761 1 15 SWITCH TEMPERATURE ELECTRIC 270853 1 16 TEE PIPE GALV 1 2 804415 020 2 17 BUSHING RED STEEL 1 4 x 1 8 807600 005 1 18 NIPPLE PIPE XS CLOSE 1 2 822208 000 1 19 NUT HEX 1 2 13 825208 448 1 20 CAPSCREW HEX M8 1 25 x 25mm 828008 025 4 21 CAP...

Page 138: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 120 090034 OP_r0 9 3 COMPRESSOR AND PARTS ASSEMBLY 2 OF 2 PA6010072ID_r1 ...

Page 139: ...84 1 36 SHEAVE COMPRESSOR 8 GROOVE DR270371 1 37 BELT SERPENTINE 8 RIB x 55 LG EFFECTIVE LENGTH BLACK RUBBER DR271456 1 38 IDLER 1 375 WIDTH 3 3 8 DIA DR46584 1 39 SWITCH PRESSURE N C 185 PSI EL270002 1 40 WASHER 3 8ID X 13 16OD FA49463 1 41 PIPE BRASS PLUG COUNTERSUNK 1 8 NPT FI67437 1 42 CLIP DRAIN HOSE HOLDER 3 4 HA270218 1 43 HOSE COMP R DRAIN TU271455 001 1 44 HOSE COMPR TO AIR TANK TU271455 ...

Page 140: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 122 090034 OP_r0 9 4 COOLING SYSTEM PA6020033ID_r2 ...

Page 141: ...AND MOTOR ASSY 16 DIA PUSHER 266199 1 6 TEE FEMALE BRANCH 8 MJIC x 8 MJIC x 1 2 FNPT 266581 009 1 7 TEE RUN SWIVEL 3 4 268769 006 1 8 COOLER OIL RC40 2 00 CORE SINGLE PASS 269563 1 9 SWITCH TEMPERATURE ELECTRIC 270853 1 10 ELBOW 90 DEG 12 FJIC SWIVEL x 12 MSAE 271777 005 1 11 BUSHING RED STEEL 3 4 x 1 2 807603 020 1 12 NUT HEX FLANGE 1 4 20 825304 236 4 13 SCREW SER WASH 5 16 18 x 0 75 829705 075 ...

Page 142: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 124 090034 OP_r0 9 5 COOLING SYSTEM COMPRESSOR PA6020036ID_r1 ...

Page 143: ... 264138 1 3 FT 3 FAN MOTOR ASSY 13 PUSH 12V 271446 1 4 NUT HEX FLANGE 1 4 20 825304 236 4 5 CAPSCREW HEX GR5 1 4 20 x 0 75 829104 075 7 6 WASHER LOCK 1 4 838504 062 7 7 ELBOW 37FL 90M 08 x 1 2 860208 050 2 8 SHROUD COOLER A1269742 1 9 GASKET SEAL AND TRIM 16 1 2 LG PR35734 2 10 TRIM VINYL COVERED STEEL BLACK X 1 0 LG PR45785 4 11 GASKET ADHESIVE BACK D SHAPE PR81501 1 3 FT I Align weather strip wi...

Page 144: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 126 090034 OP_r0 9 6 FRAME AND CANOPY ASSEMBLY PA6030031ID_r0 ...

Page 145: ...T 1 2 838208 112 4 11 CANOPY HOOD A1269763 1 12 CANOPY SIDE LH A1269765 1 13 CANOPY SIDE RH A1269766 1 14 COVER BASE A1269769 1 15 COVER BASE WITH CUTOUT A1269980 1 16 PLATFORM A1270359 1 17 SUPPORT CROSS BRACE A1270459 2 18 CANOPY REAR A1271301 1 19 CANOPY FRONT UPPER A1271302 1 20 CANOPY FRONT LOWER A1271383 1 21 SUPPORT CROSS BRACE LESS FUEL A1271451 1 22 SWITCH HOOD SAFETY NO NC 15A 125V AC CO...

Page 146: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 128 090034 OP_r0 9 7 INSTRUMENT PANEL 1 OF 2 PA6040027ID_r1 ...

Page 147: ...SCREW HEX GR8 1 4 20 X 3 4 LG 829404 075 6 13 SCREW SER WASH 5 16 18 x 0 75 829705 075 2 14 WASHER FLAT 1 4 838204 071 2 15 WASHER LOCK 1 4 838504 062 6 16 ELBOW 37FL 90M 08 x 1 2 860208 050 1 17 PANEL CONTROL BACK A1269489 1 18 CLAMP CONTROL PANEL CABLE A1269491 1 19 COVER CONTROL PANEL CABLES A1269492 1 20 FACEPLATE CONTROL PANEL A1271379 1 21 MODULE WELD CONTROL SYS ASSY CO269598 1 22 SENSOR HA...

Page 148: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 130 090034 OP_r0 9 7 INSTRUMENT PANEL 2 OF 2 PA6040027ID_r1 ...

Page 149: ...L SWITCH EP269872 1 41 HARNESS WELD CABLE MACH EP270170 1 42 HARNESS WELD CABLE JUMPER EP270171 1 43 HARNESS A C PANEL TO MACHINE EP270230 1 44 HARNESS WIRE INST PNL DISPLAY EP270315 1 45 HARNESS WIRE INST PNL EP271381 1 46 SCREW PHILLIPS PAN HEAD 10 32 x 1 2 LG SS FA33542 7 47 PIPE BRASS BULKHEAD 1 2 NPT FI23542 2 48 PIPE BRASS CROSS 1 2 NPT FI25405 1 49 NIPPLE PIPE XS CLOSE 1 2 BRASS FI34220 2 5...

Page 150: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 132 090034 OP_r0 9 8 GENERATOR AND PARTS PA6050012ID_r1 ...

Page 151: ... HEX GR8 1 2 13 x 6 5 829408 650 1 10 SCREW SER WASH 5 16 18 x 1 829705 100 4 11 SCREW SER WASH 3 8 16 x 1 5 829706 150 1 12 WASHER FLAT 5 16 838205 071 8 13 WASHER FLAT 3 8 838206 071 2 14 WASHER FLAT 1 2 838208 112 5 15 WASHER LOCK 1 4 838504 062 3 16 WASHER LOCK 5 16 838505 078 4 17 WASHER LOCK 3 8 838506 094 2 18 WASHER LOCK 1 2 838508 125 1 19 BRACKET WELD GENERATOR A1269734 1 20 BRACKET WELD...

Page 152: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 134 090034 OP_r0 9 9 MOTOR ASSEMBLY FLOW PA6100027ID_r2 ...

Page 153: ... 20 x 1 829404 100 2 6 CAPSCREW HEX GR8 3 8 16 x 1 1 2 829406 150 2 7 WASHER FLAT 3 8 838206 071 2 8 WASHER FLAT 1 2 838208 112 4 9 WASHER LOCK 1 2 838508 125 4 10 MOUNT MOTOR A1271414 1 11 BUSHING QD STYLE QT 3 4 BORE PLATED DR268487Z 1 12 SHEAVE COMP GEN DR271303 1 13 WASHER 1 4ID x 1 2OD 2 PIECE LOCKING FA67466 2 14 MTR HYDRAULIC 2 BOLT W OUTBOARD BRG HY271406 1 15 HOSE MOTOR RETURN TO COOLER T...

Page 154: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 136 090034 OP_r0 9 10 AIR STORAGE TANK PA6000027ID_r4 ...

Page 155: ...X FLANGE 5 16 18 825305 283 4 6 NUT HEX LOCKING 1 4 20 825504 145 2 7 ELBOW 45 DEG 1 2 MPT x 8 MJIC 860008 050 1 8 CONNECTOR 37FL MPT 08 x 1 2 860108 050 1 9 TEE 37FL M BR 8 x 1 2 861708 050 1 10 TANK AIR ACCUMULATOR 4 GAL A1269633 1 11 SPACER NYLON 1 2 OD x 1 4 ID FA29036 2 12 PIPE BRASS BULKHEAD 1 2 NPT FI23542 1 13 PIPE BRASS BULKHEAD 1 8 NPT FI54337 1 14 VALVE BALL MINI 1 8NPT M F FI95272 1 15...

Page 156: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 138 090034 OP_r0 9 11 ASSEMBLY FLOW CONTROL 1 OF 2 PA6120097ID_r4 ...

Page 157: ...5 16 12 16 264322 006 1 12 SEAL KNOCKOUT 1 2 264443 1 13 TRIM LOK 1 4 GROOVE x 7 5 LONG 268080 1 14 TEE RUN SWIVEL 16 268769 008 1 15 ADAPTER 3 4 FJIC SWIVEL X 12 MSAE 270440 013 1 16 NIPPLE PIPE XS CLOSE 1 4 822204 000 1 17 NUT HEX 3 8 16 825206 337 2 18 NUT HEX LOCKING 3 8 16 825506 198 2 19 CAPSCREW HEX GR5 5 16 18 x 1 829105 100 2 20 CAPSCREW HEX GR5 3 8 16 x 3 829106 300 2 21 CAPSCREW HEX GR5...

Page 158: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 140 090034 OP_r0 9 11 ASSEMBLY FLOW CONTROL 2 OF 2 PA6120097ID_r4 ...

Page 159: ... HYDRAULIC LABEL DL271919 1 33 THERMOSTAT DISC CLOSE ON RISE 100 F EL270040 1 34 PIPE BRASS BULKHEAD 1 4 NPT FI45068 1 35 HOSE COOLER TO RETURN TU271455 007 1 36 HOSE HYDRAULIC BLOCK TO MOTOR TU271455 008 1 37 HOSE PRESSURE IN TU271455 009 1 38 HOSE EXCESS FLOW TO RETURN TU271455 010 1 39 HOSE SOLENOID TO COOLER TU271455 011 1 IItems marked with are included with P N 363878 ...

Page 160: ... batteries can cause severe injury or death Change only in well ventilated area Keep sources of ignition awa y Rotating parts can cause severe injur y Stay away while engine and compressor are in operation WARNING Accidental starts can cause severe injury or death Disconnect battery and ground spark plug lead before servicing WARNING Do not operate without fan guard in place WARNING 1 2 3 4 5 9 10...

Page 161: ...AL CARBON MONOXIDE 264376 1 5 DECAL CAP REMOVAL 049685 1 6 DECAL VANAIR INFORMATION I 1 7 DECAL HIGH PRESSURE HYDRAULIC SYSTEM 264380 1 8 DECAL ROTATING PARTS 264374 1 9 DECAL ACCIDENTAL STARTS 264373 1 10 DECAL COMPRESSOR MAINTENANCE I 1 11 DECAL FAN GUARD 264383 1 12 DECAL VANGUARD 63533 2 1 I This decal is included with decal sheet no 263452 WARNING DO NOT REMOVE OR COVER ANY SAFETY DECAL Repla...

Page 162: ...TED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 144 090034 OP_r0 HYDRAULIC HYDRAULIC RETURN HYDRAULIC SUPPLY AIR TANK DRAIN Drain Daily FRONT VIEW REAR VIEW 2 1 3 4 5 2 7 8 6 9 12 DECAL LOCATIONS 2 OF 3 ...

Page 163: ...16 5 DL269707 1 2 DECAL ANA BY VANAIR WHT 269706 2 3 DECAL HYDRAULIC SUPPLY I 1 4 DECAL HYDRAULIC RETURN I 1 5 DECAL AIR TANK DRAIN DL269676 1 6 DECAL PERF BLACK DL271389 1 7 DECAL VANAIR DL269707 1 8 DECAL ANA HYDRAULIC DL271388 1 I This decal is included with decal sheet no 263452 WARNING DO NOT REMOVE OR COVER ANY SAFETY DECAL Replace any safety decal that becomes damaged or illegible ...

Page 164: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 146 090034 OP_r0 HYDRAULIC RETURN HYDRAULIC SUPPLY AIR TANK DRAIN Drain Daily 1 2 3 4 9 12 DECAL LOCATIONS 3 OF 3 ...

Page 165: ...IONS 3 OF 3 ITEM DESCRIPTION PART NUMBER QTY 1 DECAL COMPRESSOR FLUID DRAIN 1 2 DECAL HYDRAULIC SUPPLY I 1 3 DECAL HYDRAULIC RETURN I 1 4 DECAL AIR TANK DRAIN 1 IThis decal is included with decal sheet no 263452 WARNING DO NOT REMOVE OR COVER ANY SAFETY DECAL Replace any safety decal that becomes damaged or illegible ...

Page 166: ...SECTION 9 ILLUSTRATED PARTS LIST AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 148 090034 OP_r0 ...

Page 167: ...INDUCTION MOTOR CAPACITOR MOTOR SPLIT PHASE MOTOR 1 6 275 400 600 850 1200 1 4 400 500 850 1050 1700 1 3 450 600 950 1350 1950 1 2 600 750 1300 1800 2600 3 4 850 1000 1900 2600 X 1 1000 1250 2300 3000 X 1 1 2 1600 1750 3200 4200 X 2 2000 2350 3900 5100 X 3 3000 X 5200 6800 X 5 4800 X 7500 9800 X I Approximate current requirements NOTE For pumps air compressors air conditioners inverters add at lea...

Page 168: ...0 feet 50 100 feet 100 150 f 2 240 480 22 20 18 3 360 720 22 18 16 4 480 960 20 16 16 5 600 1200 18 16 14 6 720 1440 18 16 14 8 960 1920 16 14 12 10 1200 2400 16 12 12 12 1440 2880 16 12 10 14 1680 3660 14 12 10 16 1920 3840 14 10 10 18 2160 4320 14 10 8 20 2400 4800 12 10 8 22 2640 5280 12 10 8 25 3000 6000 12 10 6 30 3600 7200 10 8 6 35 4200 8400 10 8 4 40 4800 9600 8 6 2 50 6000 12000 6 4 2 60 ...

Page 169: ...ant portable 1300 Heater portable liquid fuel 50 000 btu 675 225 100 000 btu 1260 420 150 000 btu 1875 625 Impact wrench 1 2 750 600 3 4 900 750 1 1400 1200 Milk cooler 1800 1100 Mixer 3 cubic feet 2300 1000 Motors Belt sander 2600 1200 Disc sander 2600 1200 Orbital sander 2600 1200 Chain saw 6 circular saw 2200 950 7 circular saw 2600 1200 8 circular saw 3000 1500 10 circular saw 3900 2000 Sump p...

Page 170: ...8 Drill 4 CFM Drill 4 CFM Screw Driver 2 5 CFM Impact Screw Driver 4 CFM Speed Saw 5 6 CFM Body Saw 8 CFM Jig Saw 6 CFM 16 Gauge Nibbler 4 CFM Cut Off Tool 4 CFM 150 mm Air Hammer 4 CFM 190 mm Air Hammer 4 2 CFM High Speed Grinder 8 CFM Mini Air Grinder 3 CFM Mini Angle Head Grinder 3 CFM Angle Head Grinder 8 CFM Tire Buffer 4 CFM Ratchet Wrench 3 CFM 3 8 Ratchet Wrench 4 CFM 3 8 Butterfly Impact ...

Page 171: ...p with all switches off After the machine has warmed up the compressor can be turned on 265870 1 2 BATTERY BOOST CABLES These cables are 25 feet in length with quik connect ends MA269938 1 set 3 AIR TANK AUTO DRAIN KIT Automatically drains moisture from the air reservoir MA66434 1 4 30 GALLON REMOTE AIR TANK ASSEMBLY This remote mounted air option allows for an additional capacity for air storage ...

Page 172: ...1 0 cable with electrode holder and connector 330 amp MA269814 50 1 12 WELD LEAD 25 feet in length 1 0 cable with ground clamp and connector 330 amp MA269815 25 1 13 WELD LEAD 50 feet in length 1 0 cable with ground clamp and connector 330 amp MA269815 50 1 14 WELDING ROD LaGrange 100 KSI 1 8 blue MA98018 per pound 15 WELDING ROD LaGrange 100 KSI 3 32 blue MA44890 per pound 16 WELDING ROD LaGrange...

Page 173: ...void collapsing of line and restriction of flow 3 Exceeding minimum bend radius will greatly reduce hose assembly life 4 Use elbows or other adapters as necessary to eliminate excess hose length and to insure neater installation for easier maintenance 5 When hose assembly is installed in a flexing application remember that metal hose fittings are not part of the flexible portion Allow ample free l...

Page 174: ...APPENDIX A ADDITIONAL INFORMATION AIR N ARC 300 ALL IN ONE POWER SYSTEM PAGE 156 090034 OP_r0 BLANK PAGE ...

Page 175: ...ing up a rou tine and orderly schedule to track machine maintenance and repair refer to Section 6 Maintenance and particu larly Section 6 3 Maintenance Schedule Table For procedure on ordering parts consult Section 9 Parts Ordering Procedure Table 9A Recommended Spare Parts List and Appendix A Section A 5 Air N Arc 300 Series All In One Power System Available Options List If a part needs to be rep...

Page 176: ...CE POINTS Date Completed 50 HOURS OR TWO MONTHS SERVICE POINTS Dates Completed 100 HOURS OR FOUR MONTHS SERVICE POINTS Dates Completed Parts Replaced 200 HOURS OR EIGHT MONTHS SERVICE POINTS Dates Completed Parts Replaced 300 HOURS OR ONE YEAR SERVICE POINTS Dates Completed Parts Replaced 600 HOURS OR TWO YEARS SERVICE POINTS Dates Completed Parts Replaced OTHER SERVICE NOTES ...

Page 177: ...CE POINTS Date Completed 50 HOURS OR TWO MONTHS SERVICE POINTS Dates Completed 100 HOURS OR FOUR MONTHS SERVICE POINTS Dates Completed Parts Replaced 200 HOURS OR EIGHT MONTHS SERVICE POINTS Dates Completed Parts Replaced 300 HOURS OR ONE YEAR SERVICE POINTS Dates Completed Parts Replaced 600 HOURS OR TWO YEARS SERVICE POINTS Dates Completed Parts Replaced OTHER SERVICE NOTES ...

Page 178: ...APPENDIX B MAINTENANCE AND SERVICE LOG AIR N ARC 300 SERIES ALL IN ONE POWER SYSTEM PAGE 160 090034 OP_r0 BLANK PAGE ...

Page 179: ...BLANK PAGE ...

Page 180: ...ns Subject to Change Without Prior Notice 050735 Vanair Manufacturing Inc 10896 West 300 North Michigan City IN 46360 Phone 219 879 5100 800 526 8817 Service Fax 219 879 5335 Parts Fax 219 879 5340 Sales Fax 219 879 5800 www vanair com ...

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