Gast AT03 Series Manual

Product Use Criteria:
• Pump only clean, dry air.
• Operate at 32ºF - 104ºF (0ºC - 40ºC).
• Protect unit from dirt & moisture.
• Do not pump flammable or explosive gases or
use in an atmosphere that contains such gases.
• Protect all surrounding items from exhaust air. This
exhaust air can become very hot.
• Corrosive gases and particulate material will
damage unit. Water vapor, oil-based contaminants
or other liquids must be filtered out.
• Consult manufacturer before using at high
altitudes.
• Oil-Less rotary-vanes require NO lubrication.
• Sealed bearings are grease packed.
• Use of petroleum or hydrocarbon products will
reduce carbon-vane service life.
Thank you for purchasing this 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.
PART N . 70-299 G379 (REV-C)
AT03-AT05 SERIES OILLESS
COMPRESSORS
OPERATION & MAINTENANCE MANUAL
WARNING
PLEASE READTHIS MANUAL COMPLETELY BEFORE INSTALLING AND USING
THIS PRODUCT. SAVETHIS MANUAL FOR FUTURE REFERENCE AND
KEEP INTHEVICINITY OFTHE PRODUCT.
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
®Registered Trademark/™Trademark of Gast Manufacturing Inc., Copyright ©2002 Gast Manufacturing Inc. All Rights Reserved.

2
Your safety and the safety of others
is extremely 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
how to reduce the chance of injury, and tell you what
can happen if the safety instructions are not followed.
Correct installation is your responsibility. Make sure you
have the proper installation conditions and that
installation clearances do not block air flow.
Blocking air flow over the product in any way can cause
the product to overheat.
Mounting
This product can be installed in any orientation.
Mounting the product to a stable, rigid operating surface
and using shock mounts will reduce noise and vibration.
INSTALLATION
Motor Control
It is 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.
Determine the correct overload setting required to
protect the motor (see motor starter manufacturer’s
recommendations). Select fuses, motor protective
switches or thermal protective switches to provide
protection. Fuses act as short circuit protection for the
motor, not as protection against overload. Incoming line
fuses help to withstand the motor’s starting current.
Motor starters with thermal magnetic overload or circuit
breakers protect motor from overload or reduced
voltage conditions.
The wiring diagram attached to the product provides
required electrical information. Check that power
source is correct to properly operate the dual-voltage
motor.
It is your responsibility to operate this product at
recommended pressures or vacuum duties and room
ambient temperatures.
Start Up
If motor fails to start or slows down significantly under
load, shut off and disconnect from power supply. Check
that the voltage is correct for motor and that motor is
turning in the proper direction. Vane life will be
drastically reduced if motor is not operating properly.
Vanes can break or be damaged if motor/pump runs in
the wrong direction.
OPERATION
WARNING
DANGER
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
Air stream from product may contain solid or liquid
material that can result in eye or skin damage, wear
proper eye protection.
Do not pump flammable or explosive gases or use
in atmospheres that contain such gases.
Failure to follow these instructions can result in
fire, burns, eye injury or other serious injury.
WARNING
Injury Hazard
Product surfaces become very hot during operation,
allow product surfaces to cool before handling.
Plumbing
Remove plugs from the IN and OUT ports. Connect
with pipe and fittings that are the same size or larger
than the product’s threaded ports. Install relief valves
and gauges at inlet or outlet, or both, to monitor
performance. Check valves are required to prevent
back streaming through the pump.
Model numbers ending in “X” have automatic thermal
protectors which protect the motor by shutting the motor
off if it overheats. The motor will automatically restart
once the motor has cooled.

3
It is your responsibility to:
• Regularly inspect and make necessary repairs to
product in order to maintain proper operation.
• Make sure that pressure and vacuum is released
from product before starting maintenance.
Check intake and exhaust filters after first 500 hours of
operation. Clean filters and determine how frequently
filters should be checked during future operation. This one
procedure will help to assure the product’s performance
and service life.
General Maintenance
1. Remove end cap and filters. Inspect filters for
rips,tears, cuts, brittleness and excessive foreign
material.
2. Clean filters if in good condition with
compressed air. Re-inspect for wear conditions.
Set filters aside.
3. Check both internal and external filter felts (#8 and
#11 on exploded view) for foreign material. If felts
are dirty or worn, replace with new felts.
4. Check condition of O-ring on internal filter. It should
be soft and flexible. Replace if it is not.
5. Remove and inspect muffler box. Clean box. Set
box aside. (Not all models have a muffler box.)
6. Check gasket for cracks or tears. Install new gasket
if any cracks or tears appear. Replace gasket.
7. Reinstall muffler box. Torque bolts to 90-120 in. lb.
8. Reinstall filters or install new filters if required.
Reinstall end cap finger tight.
MAINTENANCE
Option 2
1. Remove six end plate bolts. (See exploded view.)
2. Use a small hammer to carefully tap on end plate to
remove. Do not use a screwdriver to pry off.
3. Check that vanes are moving freely in and out of
vane slots. Replace vanes if more than 50% of the
vane extends past the vane slot.
4. Remove vanes and clean both sides with fine emery
cloth. Clean end-plate with fine emery cloth.
5. Flush vanes with solvent and remove all
solvent from vanes.
6. Flush body, rotor and end plate with solvent, then
remove all solvent from each part.
7. Check body, rotor and end plate for scoring. If each
part is clean and shows no signs of scoring,
re-install parts. If scoring appears,
send unit to factory or replace with new part(s).
8. Insert vanes, checking that the bevel edges are in
the correct direction.
9. Replace end plate. Torque bolts to 90-120 in. lb.
10. Check gasket for damage.
11. Reinstall muffler box. Torque bolts to 90-120 in. lb.
Check that all external accessories such as relief valves
and gauges are attached to cover and are not damaged
before re-operating product.
Flushing
Flushing this product to remove excessive dirt, foreign
particles, moisture or oil that occurs in the operating
environment will help to maintain proper vane
performance. There are 2 options for this operation.
If Option 1 does not remedy your problem, go on to
Option 2.
Use only Gast Flushing Solvent or other non-petroleum
based flushing solvent. Do Not use kerosene or ANY
other combustible solvents to flush product.
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
Option 1
You will need 2 pipe nipples at least 4 inches long with
appropriate thread size for the unit involved. No nipples
are needed if the unit does not have a muffler box.
1. Remove filter and muffler cap (#9).
2. Remove 5 bolts. Use a small hammer to tap on
muffler box to remove it. Attach pipe nipples
where muffler caps were removed.
3. Start product and add flushing solvent to the inlet
port. If using liquid solvent, pour several
tablespoons directly into the inlet port. If using Gast
spray solvent, spray for 5-10 seconds into inlet
port. Place towel over exhaust port to clean up
solvent.
4. Plug inlet port for 20-30 seconds. Listen for
changes in the sound of the pump. If pump sounds
smooth, go to next step. If pump does not sound
like it is running smoothly, installing a Service it will
be required (See Service).
5. Release vacuum.
6. Repeat steps 3-5 three or four times.
If Option 1 is not successful, remove the end plate and
examine.
Air stream from product may contain solid or liquid
material that can result in eye or skin damage.
Flush this product in a well ventilated area.
Do Not use kerosene or other combustible solvents
to flush this product.
WARNING
Injury Hazard
Wear eye protection when flushing this product.
Failure to follow these instructions can result in
eye injury or other serious injury.

4
Manufacturer will NOT guarantee field-rebuilt product
performance. For performance guarantee, the product
must be returned to the manufacturer.
Service it contents vary. Most contain vanes, gaskets
and filter parts.
1. Remove filter/muffler parts from front of muffler box.
2. Remove the 5 muffler box bolts.
3. Use a small hammer to tap on box to remove. Do
not use a screwdriver.
4. Remove the 6 end plate bolts.
5. Remove end plate. Check direction of bevel edges
of vanes then remove vanes.
6. Clean body and rotor slots with Gast flushing
solvent or equivalent flushing solvent. Hand turn
the rotor to make sure it rotates freely. Any
unusual grinding or scraping sound could indicate
worn bearings or scored parts.
7. Check end plate, rotor and body for scoring.
Severe scoring or worn bearings will require
service at the manufacturer.
DO NOT remove rotor or motor bolts.
SERVICE IT INSTALLATION
SHUTDOWN PROCEDURES
It is your responsibility to follow proper shutdown
procedures to prevent product damage.
NEVER ADD OIL TO THIS OIL-LESS PUMP.
1. Disconnect plumbing.
2. Operate product for at least five minutes without
plumbing.
3. Run at maximum vacuum for 10-15 minutes.
4. Repeat step 2.
5. Disconnect power supply.
6. Plug open ports to prevent dirt or other
contaminants from entering product.
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.
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
8. Insert vanes, checking that the bevel edges are in
the correct direction. See diagram below.
9. Replace end plate. Torque bolts to 90-120 in. lb.
10. Check gasket for damage.
11. Reinstall muffler box. Torque bolts to 90-120 in. lb.
Check that all external accessories such as relief valves
and gauges are attached and are not damaged before re-
operating product.
The vanes need to be flush with the curvature of the
rotor when installing.

18
CC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
* Denotes parts included in
the Service it. Parts listed
are for stock models.
** For specific OEM models,
please consult the factory.
When corresponding or
ordering parts, please give
complete model and serial
numbers.
***Foot support assembly
optional on some models.
REF DESCRIPTION QTY GAST PART#
1 BODY 1 A 500
2*VANE 4 AH850A
3 SHROUD 1 A 502B
4 END PLATE 1 A 501
5*GAS ET 1 A 521
6 MUFFLER BOX 1 A 519
7*O-RING 2 A 473
8*FELT 2 A 524
9 END CAP 2 A 510
10 END CAP FILTER 2 A 526
ASSEMBLY
11 FILTER / MUFFLER 1 B343B
12*** FOOT SUPPORT ASSM 1 AT209
13 FELT SUPPORT 1 B347
14 *FELT FILTER 2 B344A
15 SCREEN CAP 1 AJ571
16 TOLERANCE RING 1 AH775B
17 ROTOR 1 AF105
18 *GAS ET AMBER 1 AL408
** SERVICE IT 1 882/ 886
Intake Filter
Assembly
EXPLODED PRODUCT VIEW, PARTS AND ORDERING INFORMATION
5

MAINTENANCE RECORD
DATE PROCEDURE PERFORMED
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 twenty four (24) 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 by accident 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 IND,
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 TO THE 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 by authorized Gast personnel by signing a specific, written description of any
modifications.
WARRANTY
6

TROUBLESHOOTING CHART
PART NO. 70-299 (REV-C)
Low High Pump Motor Reason and remedy
Vacuum Pressure Vacuum Pressure Overheat Overload for problem.
GG G GFilter dirty.
Clean or replace.
GGGMuffler dirty.
Clean or replace.
GGGVacuum line collapsed.
Repair or replace.
GG GRelief valve set too high.
Inspect and adjust.
GG Relief valve set too low.
Inspect and adjust.
GG G GPlugged vacuum/pressure line.
Inspect and repair.
GG Vanes sticking.
Clean or replace.
GG Vanes worn.
Replace.
GG G GForeign material- in pump.
Inspect and clean.
GG G GMotor not wired correctly.
Check wiring diagram and line voltage.
7

8
We have Gast Certified Service Centers throughout the world. For the most up-to-date
listing, contact one of our sales offices below:
Gast Hong Kong
Unit 12, 21/F, Block B
New Trade Plaza
6, n Ping Street, Shatin
N. T. Hong Kong
Ph: (852) 2690 1066
Fax: [phone]
www.gasthk.com
Gast Manufacturing, Inc.
P. . Box 97
2300 Highway M139
Benton Harbor, MI 49022
Ph: 269/926-6171
FAX: [phone]
www.gastmfg.com
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
®Registered Trademark/™Trademark of Gast Manufacturing Inc., Copyright ©2002 Gast Manufacturing Inc. All Rights Reserved.
Gast Group Limited, United
Kingdom
Unit 11, The I Centre
Nash Road
Redditch, B98 7AS
United Kingdom
ph: [phone]
Fax: [phone]
www.gastmfg.com