Gast DDL30 Manual

OIL-LESS COMPRESSORS
OPERATION & MAINTENANCE MANUAL
Product Use Criteria:
•Pump only clean, dry air.
•Operate at 40ºF - 104ºF (4.4ºC - 40ºC).
•Protect unit from dirt & moisture.
•Do not pump flammable or explosive gases or
use in an atmosphere that contains such gases.
•Corrosive gases and particulate material will
damage unit. Water vapor, oil-based contaminants
or other liquids must be filtered out.
•Oil-less compressors require NO lubrication
•Consult your Gast Distributor/Representative
before using at high altitudes.
IMPORTANT:PLEASE READ THIS MANUAL AND SAVE FOR FUTURE REFERENCE.
Thank you for purchasing this Gast product. It is manufactured to the highest standards
using quality materials. Please follow all recommended maintenance, operational
and safety instructions and you will receive years of trouble free service.
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
®Registered Trademark/™Trademark of Gast Manufacturing Inc., Copyright © 2003 Gast Manufacturing Inc. All Rights Reserved.
Model DDL30 Shown Model DDL40B Shown Model DDL120 Shown
PART NO. 70 - 1570 F1-210 (REV-C)
1

Motor Control
Itis your responsibility to contact a qualified
electrician and assure that the electrical installation is
adequate and in conformance with all national and local
codes and ordinances.
Correct installation is your responsibility.Make sure you
have the proper installation conditions and that
installation clearances do not block air flow.
Mounting
This product must be installed on a flat, horizontal
surface. Mounting the product to a stable, rigid
operating surface and using shock mounts will reduce
noise and vibration.
INSTALLATION
c
Disconnect electrical power at the circuit breaker
or fuse box before installing this product.
Install this product where it will not come into
contact with water or other liquids.
Install this product where it will be weather
protected.
Electrically ground this product.
Failure to follow these instructions can result in
death, fire or electrical shock.
WARNING
Electrical Shock Hazard
Plumbing
Remove plug from the OUT port. Connect with pipe
and fittings that are the same size or larger than the
product’s port.
Accessories
Install relief valve and gauge at outlet to monitor
performance. A check valve may be required to prevent
back streaming through the compressor.
WARNING
DANGER
Your safety and the safety of others
isextremely important.
We have provided many important safety messages
in this manual and on your product. Always read
and obey all safety messages.
This is the safety alert symbol. This symbol
alerts you to hazards that can kill or hurt you and
others. The safety alert symbol and the words
“DANGER” and “WARNING” will precede all safety
messages. These words mean:
You will be killed or seriously injured if you don’t
follow instructions.
You can be killed or seriously injured if you don’t
follow instructions.
All safety messages will identify the hazard, tell you
howto reduce the chance of injury, and tell you
what can happen if the safety instructions are not
followed.
2
c
This product must be properly grounded.
Do not modify the plug provided. If it will not
fit the outlet, have the proper outlet installed
by a qualified electrician.
If repair or replacement of the cord or plug is
necessary, do not connect the grounding wire
to either flat blade terminal. The wire with
insulation that is green with or without yellow
stripes is the grounding wire.
Check the condition of the power supply wiring.
Do not permanently connect this product to
wiring that is not in good condition or is
inadequate for the requirements of this product.
Failure to follow these instructions can result in
death, fire or electrical shock.
WARNING
Electrical Shock Hazard
ELECTRICAL CONNECTION
Grounded Plug
Grounding Pin
Grounded Outlet
120-volt grounded connectors
shown. 220/ 240-volt grounded
connectors will differ in shape.
DIAGRAM A
Model with a power supply cord:
This product must be grounded. For either 120-volt or
220/240-volt circuits connect power supply cord
grounding plug to a matching grounded outlet. Do not
use an adapter. (See DIAGRAM A)

3
Check with a qualified electrician or serviceman if the
grounding instructions are not completely understood, or
if you are not sure whether the product is properly
grounded. Do not modify the plug provided. If it will not
fit the outlet, have the proper outlet installed by a qualified
electrician.
In the event of an electrical short circuit, grounding
reduces the risk of electric shock by providing an
escape wire for the electric current. This product may
be equipped with a power supply cord having a
grounding wire with an appropriate grounding plug.
The plug must be plugged into an outlet that is properly
installed and grounded in accordance with all local
codes and ordinances.
Model that is permanently wired:
This product must be connected to a grounded,
metallic, permanent wiring system, or an equipment
grounding terminal or lead on the product.
Extension cords:
Use only a 3-wire extension cord that has a 3-blade
grounding plug. Connect extension cord plug to a
matching 3-slot receptacle. Do not use an adapter.
Make sure your extension cord is in good condition.
Check that the wire gage of the extension cord is the
correct size wire to carry the current this product will
draw. An undersized cord is a potential fire hazard, and
will cause a drop in line voltage resulting in loss of
power causing the product to overheat. DIAGRAM B
indicates the correct gage cord for length required and
the ampere rating listed on the product nameplate. If in
doubt, use the next heavier gage cord. The smaller the
gage number, the heavier the wire gage.
DIAGRAM B – Minimum Gage For Extension Cords
Amps Volts Length of cord in feet
120v 25 50 100 150 200 250 300 400 500
240v 50 100 200 300 400 500 600 800 1000
0-2 18 18 18 16 16 14 14 12 12
2-3 18 18 16 14 14 12 12 10 10
3-4 18 18 16 14 12 12 10 10 8
4-5 18 18 14 12 12 10 10 8 8
5-6 18 16 14 12 10 10 8 8 8
6-8 18 16 12 10 10 8 6 6 6
8-10 18 14 12 10 8 8 6 6 4
Power supply wiring must conform to all required safety
codes and be installed by a qualified person. Check
that supply voltage agrees with that listed on product
nameplate. WARNING – Read and follow all safety instructions. To
guard against injury, basic safety precautions should be
observed.
Precautions for aquarium use:
1. If the air pump falls into the water, DO NOT reach
into the water to retrieve it.
2. Carefully examine the appliance after installation. It
should not be plugged into electrical power if there
is water found on any part of the pump.
3. DO NOT operate any air pump if it has a damaged
cord or plug, or if it is malfunctioning or has been
dropped or damaged in any manner.
4. To avoid the possibility of the air pump plug or
receptacle getting wet, position the aquarium stand
and tank to one side of a wall-mounted receptacle to
prevent water from dripping onto the receptacle or
plug. A“drip loop,” shown above in the AQUARIUM
SETUP DIAGRAM, should be arranged by the user
for each cord connecting an aquarium air pump to a
receptacle. The “drip loop” is that part of the cord
below the level of the receptacle, or the connector if
an extension cord is used, which prevents water
travelling along the cord from coming into contact
with the receptacle.
5. If the plug or receptacle do get wet, DO NOT grasp
the plug to disconnect the air pump. Instead
disconnect the fuse or circuit breaker supplying
power to the receptacle. Then unplug the air pump
and examine for the presence of water on the plug
or receptacle.
DANGER – To avoid possible electrical shock, special
care should be taken since water is employed in the
use of aquarium equipment. If the air pump, cord or
plug are damaged in any way whatsoever, DO NOT
attempt repairs by yourself, return the air pump to a
Gast Authorized Service Facility for inspection and
repair.
AQUARIUM SETUP DIAGRAM
Guidelines for aquarium use:
1. Close supervision is necessary when any air pump
is used by or near children.
2. To avoid injury, DO NOT disassemble the air pump.
3. Always unplug an air pump from an outlet when not
in use, before putting on or taking off parts and
before cleaning. NEVER yank a cord to remove the
plug from the receptacle. Grasp the plug and pull to
disconnect.
IMPORTANT SAFETY INSTRUCTIONS
FOR AQUARIUM USE

4
OPERATION
Injury Hazard
Use only recommended air handling parts
acceptable for pressure not less than 10 psi.
When provided, motor terminal covers must be in
place for safe operation.
Product surfaces may become hot during operation,
allowproduct surfaces to cool before handling.
Do Not direct air stream at body. Air stream from
product may contain solid or liquid material that can
result in eye or skin damage, wear proper eye
protection.
Do Not spray flammable or combustible liquid.
Failure to follow these instructions can result in
burns, eye injury or other serious injury.
WARNING
It is your responsibility to operate this product at
recommended pressure duty and room ambient
temperature.
Start Up
If pump fails to start or slows down significantly under
load, shut offand disconnect from power supply.Check
that the voltage is correct for the pump.
MAINTENANCE
c
Disconnect electrical power supply cord before
performing maintenance on this product.
If product is hard wired into system, disconnect
electrical power at the circuit breaker or fuse box
before performing maintenance on this product.
Failure to follow these instructions can result in
death, fire or electrical shock.
Electrical Shock Hazard
WARNING
4. DO NOT use an aquarium air pump for other than
its intended use. The use of attachments which are not
recommended or sold by Gast Manufacturing, Inc.
may cause an unsafe condition.
5. DO NOT install or store the air pump where it will be
exposed to the weather or to temperatures below
freezing.
6. Make sure an air pump mounted on a tank is
securely installed before operating it.
7. Read and observe all the important notices on the
air pump.
It is your responsibility to:
• Regularly inspect and make necessary repairs to
product in order to maintain proper operation.
•Make sure that pressure is released from product
before starting maintenance.
• Never add oil to this oil-less compressor.
Cleaning
Do Not use kerosene or ANY other combustible solvent
to clean product.
Check that all external accessories such as relief valves
and gauges are attached to cover and are not damaged
before re-operating product.
1. Remove filter and clean using detergent and water.
2. Rinse filter well and air dry.
Check intake filter after first 500 hours of operation.
Clean filter and determine how frequently filter should
be checked during future operation. This one
procedure will help to assure the product’s performance
and service life.
SERVICE KIT INSTALLATION
c
Disconnect electrical power supply cord before
installing Service Kit.
If product is hard wired into system, disconnect
electrical power at the circuit breaker or fuse box
before installing Service Kit.
Disconnect air supply and vent all air lines to
release pressure or vacuum.
Failure to follow these instructions can result in
death, fire or electrical shock.
WARNING
Electrical Shock Hazard
Injury Hazard
Product surfaces may become hot during operation,
allow product surfaces to cool before handling.
DoNot direct air stream at body. Air stream from
product may contain solid or liquid material that can
result in eye or skin damage, wear proper eye
protection.
Clean this product in a well ventilated area.
Failure to follow these instructions can result in
burns, eye injury or other serious injury.
WARNING
SAVE THESE INSTRUCTIONS.

5
Gast will NOT guarantee field-rebuilt product
performance. For performance guarantee, the product
must be returned to a Gast Authorized Service Facility.
Replacing Head and Diaphragm Assemblies
(DDL8 through DDL150 SERIES
(Refer to Diagrams D and E)
Disassembly
1. Remove the four corner screws located on each end
of the pump (Diagram C).
2. Gently lift out the casing block.
3. Remove heads and discard if replacing. Valves are
attached to head and can not be removed.
4. Remove hex nut in center of diaphragm. Remove
the diaphragm from the diaphragm block, noting
the two locating notches for re-assembly
(Diagram D).
Re-assembly
1. Install new diaphragm into the diaphragm block
matching the locating notches.
2. Insert hex nut and tighten.
3. Reinstall diaphragm assembly.
4. Install new head assembly.
5. Reattach the four corner screws.
If compressor still does not produce proper pressure,
send unit to a Gast Authorized Service Facility for
repair.
DIAGRAM E
DIAGRAM D DIAPHRAGM
MOUNTING
BLOCK
DIAPHRAGM
L-TUBE U-NUT
DIAPHRAGM
MOUNTING
BLOCK
WASHER ROD
U-NUT
CASING
BLOCK
Service Kit contents vary with compressor models.
Replacing Head and Diaphragm Assemblies
(DDL5 SERIES)
Refer to Diagram C
Disassembly
1. Remove hex nuts from cover (Refer to Fig.11).
2.Remove cover and cover gasket.
3. Gently lift out electromagnet and casing block.
4. Remove head asembly from diaphragm casing
block, discard if replacing.
5. Remove phillips screw from center of diaphragm and
remove the diaphragm.
Re-assembly
1. Reinstall new diaphragm, being sure it fits securely
into diaphagm casing (note the two locating notches
for re-assembly).
2. Reinstall and tighten the phillips screw
3. Reinstall or replace the head assembly.
3. Fit electromagnet unit over casing mechanism and fit
components back into housing of pump
4. Reinstall cover gasket and cover.
5. Tighten hex nuts in place
If compressor still does not produce proper pressure,
send unit to a Gast Authorized Service Facility for
repair.
GROUND SCREW
DIAPHRAGM
ASSEMBLY
HEAD
CASING
MAGNET
ELECTRO
GASKET
COVER
COVER
VALVE
EXHAUST
VALVE
INTAKE

6
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION
REF DESCRIPTION
1COVER BOLT
2 FILTER COVER
3 SEMI COVER PACKING
4 FILTER
5UPPER HOUSING
6SOUND ABSORBER
7 THERMAL PROTECTOR
8ELECTROMAGNET
9L-TUBE
10 HOSE BAND
11 HEAD ASSEMBLY
12 DIAPHRAGM MOUNTING BLOCK
13 ACTIVATING ARM
14 SCREW
15 VIBRATION CONTROL RUBBER
16 COIL FRAME
17 U-NUT
18 POWER CORD
19 CORD RELIEF
20 CORD STOPPER
21 CENTER PLATE
22 GASKET
23 LOWER HOUSING
24 RUBBER FEET
*Your model may vary in appearance and configuration. However, internal components will be similar to those shown.
Parts shown are for stock models. For specific OEM models, please consult the factory.
When corresponding or ordering kits, please give complete model and serial numbers.
DDL8-150 SERIES *

SERIES DIAPHRAGM FILTER
&HEAD ASSY
60 Hz 50 Hz
DDL5 K898 -- N/A
DDL8 K890 -- N/A
DDL8B K890 -- N/A
DDL15 K890 -- N/A
DDL15B K890 -- N/A
DDL30 K887 K932 K891
DDL30B K887 K932 N/A
DDL40 K887 K932 K891
DDL40B K887 K932 N/A
DDL60 K888 K931 K891
DDL80 K888 K931 K891
DDL120 K889 K930 K892
DDL150 K889 K950 K892
7
DDL SERIES SERVICE KITS*
*The service kit may contain parts for more than one model or style of linear pump. Parts not needed may be discarded.
Kits listed are for stock models. For specific OEM models, please consult the factory.
When corresponding or ordering kits, please give complete model and serial numbers.
SERVICE KITS, PARTS & ORDERING INFORMATION
Gast finished products, when properly installed and operated under normal conditions of use, are warranted by Gast to
be free from defects in material and workmanship for a period of twelve (12) months from the date of purchase from
Gast or an authorized Gast Representative or Distributor. In order to obtain performance under this warranty, the buyer
must promptly (in no event later than thirty (30) days after discovery of the defect) give written notice of the defect to
Gast Manufacturing Incorporated, PO Box 97, Benton Harbor Michigan USA 49023-0097 or an authorized Service
Center (unless specifically agreed upon in writing signed by both parties or specified in writing as part of a Gast OEM
Quotation). Buyer is responsible for freight charges both to and from Gast in all cases.
This warranty does not apply to electric motors, electrical controls, and gasoline engines not supplied by Gast. Gast’s
warranties also do not extend to any goods or parts which have been subjected to misuse, lack of maintenance,
neglect, damage byaccident or transit damage.
THIS EXPRESS WARRANTY EXCLUDES ALL OTHER WARRANTIES OR REPRESENTATIONS EXPRESSED OR
IMPLIED BY ANY LITERATURE, DATA, OR PERSON. GAST’S MAXIMUM LIABILITY UNDER THIS EXCLUSIVE
REMEDY SHALL NEVER EXCEED THE COST OF THE SUBJECT PRODUCT AND GAST RESERVES THE RIGHT,
AT ITS SOLE DISCRETION, TO REFUND THE PURCHASE PRICE IN LIEU OF REPAIR OR REPLACEMENT.
GAST WILL NOT BE RESPONSIBLE OR LIABLE FOR INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND,
however arising, including but not limited to those for use of any products, loss of time, inconvenience, lost profit, labor
charges, or other incidental or consequential damages with respect to persons, business, or property, whether as a
result of breach of warranty, negligence or otherwise. Notwithstanding any other provision of this warranty, BUYER’S
REMEDY AGAINST GAST FOR GOODS SUPPLIED OR FOR NON-DELIVERED GOODS OR FAILURE TO FURNISH
GOODS, WHETHER OR NOT BASED ON NEGLIGENCE, STRICT LIABILITY OR BREACH OF EXPRESS OR
IMPLIED WARRANTY IS LIMITED SOLELY, AT GAST’S OPTION, TO REPLACEMENT OF OR CURE OF SUCH
NONCONFORMING OR NON-DELIVERED GOODS OR RETURN OF THE PURCHASE PRICE FOR SUCH GOODS
AND IN NO EVENT SHALL EXCEED THE PRICE OR CHARGE FOR SUCH GOODS. GAST EXPRESSLY DISCLAIMS
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE WITH RESPECT
TOTHE GOODS SOLD. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTIONS SET
FORTH IN THIS WARRANTY, notwithstanding any knowledge of Gast regarding the use or uses intended to be made
of goods, proposed changes or additions to goods, or any assistance or suggestions that may have been made by Gast
personnel.
Unauthorized extensions of warranties by the customer shall remain the customer’s responsibility.
CUSTOMER IS RESPONSIBLE FOR DETERMINING THE SUITABILITY OF GAST PRODUCTS FOR CUSTOMER’S
USE OR RESALE, OR FOR INCORPORATING THEM INTO OBJECTS OR APPLICATIONS WHICH CUSTOMER
DESIGNS,ASSEMBLES,CONSTRUCTS OR MANUFACTURES.
This warranty can be modified only byauthorized Gast personnel by signing a specific, written description of any
modifications.
WARRANTY

Low High Pump Motor Excess Reason and remedy
Pressure Pressure Overheat Overload Noise for problem.
•Filter dirty.
Clean or replace.
• Valves dirty or valves bent.
Clean or replace.
• • • Worn or torn diaphragm.
Repair or replace.
• Relief valve set too high.
Inspect and adjust.
• Relief valve set too low.
Inspect and adjust.
• Plugged pressure line.
Inspect and repair.
• Low voltage, won’t start.
Check power source.
• • • • Voltage wrong.
Check power source.
• • Rod magnet misalignment.
Realign.
• Leaky hose or check valve.
Replace.
• • • • Dirt or liquid in compressor.
Inspect and clean.
• • Blown or leaking head gasket
or tubes. Replace.
TROUBLESHOOTING CHART
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
8
PART NO. 70 - 1570 F1-210 (REV-C)
We have Gast Authorized Repair Facilities throughout the world. For the most
up-to-date listing, contact one of our sales offices below:
World Headquarters
P
.O. Box 97
2550 Meadowbrook Rd.
Benton Harbor, MI
49023-0097
Ph: 269/926-6171
FAX: [phone]
www.gastmfg.com
Gast Hong Kong
Unit 12, 21/F,Block B
New Trade Plaza
6, On Ping Street, Shatin
N. T. Hong Kong
Ph: (852) 2690 1008
Fax: [phone]
www.gasthk.com