Gast 70 - 3005 G443PL User manual

OI - ESS DIAPHRAGM
VACUUM PUMPS & COMPRESSORS
OPERATION & MAINTENANCE MANUA
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 your Gast Distributor/Representative
before using at high altitudes.
• This pump is oil-less and requires NO lubrication.
• Pressure units may be used for both pressure and vacuum.
Consult your Gast Distributor/Representative
to use vacuum units for pressure.
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 © 2002 Gast Manufacturing Inc. All Rights Reserved.
Model DOA Shown Model DAA Shown
1
PLEASE READ THIS MANUAL COMPLETELY BEFORE INSTALLING AND USING
THIS PRODUCT. SA E THIS MANUAL FOR FUTURE REFERENCE AND
KEEP IN THE ICINITY OF THE PRODUCT
WARNING
PART NO. 70 - 3005 G443PL (Rev. D)

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. The metal capacitor shell must
be grounded.
Determine the correct overload setting required to
protect the motor (see motor starter manufacturerʼs
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 must be able to withstand the motorʼs starting
current. Motor starters with thermal magnetic overload
or circuit breakers protect motor from overload or
reduced voltage conditions.
The wiring diagram supplied with the product provides
required electrical information. Check that power
source is correct to properly operate the dual-voltage
motors.
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 donʼt follow
instructions.
You can be killed or seriously injured if you donʼt 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.
Accessories
Filters and mufflers are supplied with some models.
These should be checked periodically and replaced
when necessary. Please consult your Gast
Distributor/Representative for additional filter
recommendations.
DANGER
Plumbing
Remove plugs from the IN and OUT ports. Connect
with pipe and fittings that are the same size or larger
than the productʼs threaded ports. Be sure to connect
the intake and exhaust plumbing to the correct inlet and
outlet ports. Ports will not support the weight of the
plumbing.
Install relief valves and gauges at inlet or outlet, or both,
to monitor performance. Check valves may be required
to prevent back streaming through the pump.
Electrical Connection
2
INSTA ATION
Electrical Shock Hazard
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.
Electrical Shock Hazard
This product must be properly grounded.
Do not modify the plug provided. If it will not
fill 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.

It is your responsibility to operate this product at
recommended pressures or vacuum duties and room
ambient temperatures. Do not start against a vacuum
or pressure load.
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.
OPERATION
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)
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.
Grounded Plug
Grounding Pin
Grounded Outlet
120-volt grounded connectors
shown. 220/240-volt grounded
connectors will differ in shape.
DIAGRAM A
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.
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.
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.
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 gage wire of the extension cord is the
correct size wire to carry the current this product will
draw.
-Minimum gage for extension cords
Amps Volts ength 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 88
5-6 18 16 14 12 10 10 888
6-8 18 16 12 10 10 8666
8-10 18 14 12 10 88664
10-12 16 14 10 886644
12-14 16 12 10 866642
14-16 16 12 10 866442
16-18 14 12 8864422
18-20 14 12 8664422
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. The following table
indicates the correct size 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. 3
Injury Hazard
Install proper safety guards as needed.
Use only recommended air handling parts acceptable
for pressure not less than 70 psi.
Keep fingers and objects away from openings and
rotating parts.
When provided, motor terminal covers must be in
place for safe operation.
Product surfaces become very hot during operation,
allow product 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.
Wear hearing protection. Sound level from motor
may exceed 70 dBA.
Failure to follow these instructions can result in
burns, eye injury or other serious injury.

SHUTDOWN PROCEDURES
It is your responsibility to follow proper shutdown
procedures to prevent product damage. Store pump
indoors. Do Not expose to wet weather conditions.
NEVER ADD OI TO THIS OI - ESS PUMP.
Proper shutdown procedures must be followed to
prevent pump damage. Failure to do so may result in
premature pump failure. Gast Manufacturing Rocking
Piston Oil-Less pumps are constructed of ferrous metals
or aluminum which are subject to rust and corrosion
when pumping condensable vapors such as water.
Follow the to assure correct storage and shutdown
between operating periods.
Check that all external accessories such as relief valves
and gauges are attached to cover and are not damaged
before re-operating product.
3. Check to see that the head gasket on the valve plate
is not compromised in any way, remove from valve
plate, and set aside for reinstallation after cleaning
valve plate.
4. Gently remove valve plate from body of unit
(CAUTION: DO NOT LOSE THE SHIM
WASHERS THAT ARE UNDER EACH
CORNER BOLT HOLE BETWEEN THE VALVE
PLATE AND BODY. THEY MUST GO BAC
BETWEEN THE VALVE PLATE AND BODY
EXACTLY AS THEY CAME OUT). Clean the valve
plate with soap and water and carefully blow off
with compressed air.
5. Reinstall shim washers at each bolt hole on the body
and carefully reinstall valve plate over the pump
body.
6. Reinstall head gasket on the valve plate, place head
over valve plate, install four bolts to hold assembly
to body. Torque each bolt in a cross pattern to
90-100 in. lbs.
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 productʼs
performance and service life.
Solvent Cleaning
Use only Gast recommended Solvent or other
non-petroleum based solvent. Do Not use kerosene
or ANY other combustible solvent to clean product.
1. Remove the four bolts holding the head on.
2. Remove filters and clean with Gast recommended
solvent or other non-petroleum based solvent.
Use compressed air to dry filters and make sure
that all moisture is removed. Reinstall filters in
head, set aside.
1. Disconnect plumbing.
2. Operate product for at least 5 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.
4
MAINTENANCE
Electrical Shock Hazard
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.
Injury Hazard
Product surfaces become very hot during operation,
allow product surfaces to cool before handling.
Do not direct air steam 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
Solvent Stream
May contain solid or liquid material
that can result in eye or skin damage.
Wear eye protection when using this product.
Electrical Shock Hazard
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.
SERVICE KIT INSTA ATION

Do Not replace the connecting rod or motor bearings.
Check that all external accessories such as relief valves
and gauges are attached to cover and are not damaged
before re-operating product.
If pump still does not produce proper vacuum or
pressure, send unit to a Gast Authorized Service Facility
for repair.
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. Gastʼs
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. GASTʼS 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, BUYERʼS
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 GASTʼS 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 customerʼs responsibility.
CUSTOMER IS RESPONSIBLE FOR DETERMINING THE SUITABILITY OF GAST PRODUCTS FOR CUSTOMERʼS
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.
5
1. Put on eye protection.
2. Disconnect electrical power to pump.
3. Disconnect air supply and vent all air lines to
release pressure or vacuum.
4. Remove the socket cap screws from the head of the
pump. Remove the head and valveplate from the
pump. (Caution: Do not lose the shim washers
that are at each corner between the valveplate and
body of the unit. Upon reistallation, these shims
must be put back in the same position they were
taken from to maintain proper had clearances.
Replacing Diaphragm
1. Remove the two Phillips-head screws then
the retainer plate and diaphragm.
2. Install the new diaphragm in any position onto
the connecting rod.
3. Replace the retainer plate and attach with two
screws. Torque the screws to 30 in. lbs.
Replacing Inlet and Outlet Valves
1. Remove the slotted machine screw that holds
each valve in place.
2. Clean the stainless steel valves with water.
Valves are interchangeable.
3. Replace both valves or install new valves making
sure that the valves completely cover the raised
valve seat. Check that the notch marked on the
inlet valve is in the lower right hand corner
towards the inlet of the air chamber.
4. Replace the head on the pump. Torque the
socket cap screws to 90-100 in. lbs.
Gast will NOT guarantee field-rebuilt product
performance. For performance guarantee, the product
must be returned to a Gast Authorized Service Facility.
Service it contents vary. Most contain gaskets and
filter parts.
WARRANTY

PARTS & ORDERING INFORMATION
REF DESCRIPTION QTY DOA-P701-AA DAA-P501-EB*
DO -701-AA DAA-V701-EB*
DOA-P501-BN
DOA-P501-JH
1 HEAD 1 AP500
2AP500
2 ∆ HEAD O-RING 1 AP513
2 AP513
3∆ FI TER/MUFF ER E EMENT 2 AT712A
4AT712A
4∆ VA VE IMITER 1 AP110
2 AP110
5 ∆ EAF VA VE 2 AF817
4AF817
6VA VE P ATE 1 AP504
2 AP504
7 ∆ VA VE RETAINER 1 AF819A
2 AF819A
8 ∆ VA VE SCREW 1 BB330A
2 BB330A
9 RETAINER P ATE 1 AF809
2 AF809
10 DIAPHRAGM–COMPRESSOR 1 AF818A
2 AF818A
10 DIAPHRAGM–VACUUM 1 AF818B
2 AF818B
11 FE T SPACER 3 AA929
3 AA929
12 SPACER 1 AD996
2 AD996
13 FAN - DOA, DO 1 AF533 AF533
FAN - DAA 1 AF533A
14 GRI E 1 AF807
2 AF807
15 RIVET 4 AP534
8 AP534
16 VA VE P ATE ASSEMB Y 1 AP519
2 AP519
17 CRANKCASE COVER 1 AP526
2 AP526
18 CRANKCASE COVER SCREW 2 AP525
4 AP525
*** SERVICE KIT 1 K294A
2 K294A
DAA / DOA / DO SERIES
Please reference the exploded views on the next page for the following model and parts table.
* DOA shown. The double-ended DAA models (not illustrated) are two DOAs mounted back to back with heads rotated.
*** Item not shown.
∆ Denotes parts included in the Service it.
∆ The service kit may contain parts for more than one model or style diaphragm pump.
Parts not needed may be discarded.
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.
6

EXP ODED PRODUCT VIEWS - MODE DOA & VA VE P ATE ASSEMB Y
Valve Plate Assembly (available separately)
(Valve Plate Assembly also includes items 7 & 8,
as shown in the main exploded view)
7

Low High Pump Motor Excess Reason and remedy
Vacuum Pressure Vacuum Pressure Overheat Overload Noise for problem.
TROUB ESHOOTING CHART
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
PART NO. 70 - 3005 G443PL (Rev. D)
Gast Manufacturing, Inc.
2300 S. Highway M139
Benton Harbor, MI,49022
Ph: 269/926-6171
FAX: [phone]
www.gastmfg.com
Gast Hong Kong
Room 6/9.,
New Commerce Centre
19 On Sum St., Shatin
N. T. Hong ong
Ph: (852) 2690 1066
Fax: [phone]
www.gasthk.com
For the name of the nearest authorized service facility, contact one of our offices below or visit our website
at www.gastmfg.com.
Filter dirty. Clean or replace.
Muffler dirty. Clean or replace.
Valves dirty or valves bent.
Clean or replace.
Relief valve set too high.
Inspect and adjust.
Relief valve set too low.
Inspect and adjust.
Plugged vacuum/pressure line.
Inspect and repair.
Collapsed vacuum line.
Inspect and repair.
Low voltage, wonʼt start.
Check power source.
Voltage wrong.
Check power source.
Cylinder misadjustment.
Realign.
Leaky hose or check valve.
Replace.
Dirt or liquid on top of piston.
Inspect and clean.
Motor not wired correctly.
Check wiring diagram/line voltage.
Blown head gasket.
Replace.
••At Pump
•• At pump
••
•
••
••At pump At pump
• At pump
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European Sales & Service
Headquarters
Gast Group Limited
A Unit of IDEX Corporation
Unit 11, The I O Centre
Nash Road
Redditch B98 7AS
United ingdom
Tel: [phone]
Fax: [phone]
www.gastmfg.com
www.jun-air.com