Gast 81R Series Manual

81R and 82R SERIES
ROCKI G PISTO OIL-LESS PUMPS
OPERATIO & MAI TE A CE MA UAL
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.
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.
PART O. 70 - 6855 G498PL (REV-D)
odel 82R6 Shown

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 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. otor 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
“DA GER” and “WAR I G” 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. ake 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.
ounting the product to a stable, rigid operating surface
and using shock mounts will reduce noise and vibration.
I STALLATIO
Accessories
The productʼs external intake and exhaust muffler will
provide adequate filtration in most applications. Check
filters periodically and replace when necessary. Consult
your Gast Distributor/Representative for additional filter
recommendations.
WAR I G
DA GER
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 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 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
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 or green with 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
2

OPERATIO
Injury Hazard
Install proper safety guards as needed.
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.
Air stream from product may contain solid or liquid
material that can result in eye or skin damage,
wear proper eye protection.
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.
WARNING
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 above diagram.)
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.
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.
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.
ake 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.
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.
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 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
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. Check the plug, cord
and switch for damage. If so equipped, the thermal
protection switch has tripped, the motor can restart after
cooling.
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.
3

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.
MAI TE A CE
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
Injury Hazard
Product surfaces become very hot during operation,
allow product surfaces to cool before handling.
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
Check that all external accessories such as relief valves
and gauges are attached to cover and are not damaged
before re-operating product.
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.
SHUTDOW PROCEDURES
It is your responsibility to follow proper shutdown
procedures to prevent product damage.
EVER ADD OIL TO THIS OIL-LESS PUMP.
Proper shutdown procedures must be followed to
prevent pump damage. Failure to do so may result in
premature pump failure. Gast anufacturing 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 steps below to assure correct storage
and shutdown between operating periods.
1. Disconnect plumbing.
2. Operate product for at least 5 minutes without
plumbing.
3. Run at maximum vacuum for 10 to 15 minutes.
4. Repeat step 2.
5. Disconnect power supply.
6. Plug open ports to prevent dirt or other
contaminants from entering product.
Gast will OT guarantee field-rebuilt product
performance. For performance guarantee, the product
must be returned to a Gast Authorized Service Facility.
Service Kit contents vary. ost contain gasket and filter
parts.
SERVICE KIT I STALLATIO
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
1. Disconnect electrical power supply to unit.
2. Vent all air lines.
3. Remove filter cover.
4. Check filter felt. Replace felt if it is covered with
contamination or shows signs of increasing
differential pressure.
5. Reinstall felt and filter cover.
4

1. Disconnect electrical power to pump.
2. Disconnect air supply and vent all air lines to
release pressure or vacuum.
3. ark the orientation of the ports so cover will be
reinstalled correctly.
4. Remove screws from the head of the pump.
Remove the head of the pump.
5. ark orientation of valve plate(s). Remove valve
plate(s).
6. Remove and discard old cups(s), retainer screws,
cylinder O-ring(s), head O-ring(s), valves and valve
retainers.
7. Install new cup(s) on rod(s) facing up.
8. Reinstall retainer plates.
9. Apply a thread locking compound (Loctite 222) to
retainer screws. Torque screws to 34-38 in. lbs.
10. Carefully install cylinder(s) over cup(s) at an angle to
avoid damaging cup(s).
11. Clean valve plates with water based solvent. Take
care to not scratch valve seats.
12. Install valves and valve retainers. Check that the
orientation with the ports is correct.
13. Apply a thread locking compound (Loctite 222) to
retainer screws. Torque screws to 10-13 in. lbs.
14. Install cylinder O-ring(s) in the bottom of valve
plate(s).
15. Check that the orientation of valve plate(s) with the
ports is correct.
16. Install head O-rings in the O-ring grooves on top of
valve plate.
17. Reinstall head over valve plate(s) checking that
orientation with ports is correct.
18. Torque screws to 50 in. lbs.
Check that all external accessories such as relief valves
and gauges 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 anufacturing Incorporated, PO Box 97, Benton Harbor ichigan 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 OE
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
I PLIED BY ANY LITERATURE, DATA, OR PERSON. GASTʼS AXI U LIABILITY UNDER THIS EXCLUSIVE
RE EDY 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 REPLACE ENT.
GAST WILL NOT BE RESPONSIBLE OR LIABLE FOR INDIRECT OR CONSEQUENTIAL DA AGES 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, BUYERʼS
RE EDY 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
I PLIED WARRANTY IS LI ITED SOLELY, AT GASTʼS OPTION, TO REPLACE ENT OF OR CURE OF SUCH
NONCONFOR ING 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
DISCLAI S ANY WARRANTY OF ERCHANTABILITY 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.
CUSTO ER IS RESPONSIBLE FOR DETER INING THE SUITABILITY OF GAST PRODUCTS FOR CUSTO ERʼS
USE OR RESALE, OR FOR INCORPORATING THE INTO OBJECTS OR APPLICATIONS WHICH CUSTO ER
DESIGNS, ASSE BLES, CONSTRUCTS OR ANUFACTURES.
This warranty can be modified only by authorized Gast personnel by signing a specific, written description of any
modifications.
WARRA TY
5

REF DESCRIPTIO QTY 81R640-P101 82R642-P135
1A HEAD SCREW 4 AP135 AP135
1B HEAD SCREW 4 AP136 AP136
2 HEAD COVER 2 AP131BG AP131BG
3∆ HEAD O-RI G 2 AP109B AP109B
4VALVE LIMITER 2 AP110A AP110A
5 ∆ LEAF VALVE 4 AF817 AF817
6 VALVE PLATE 1 AP132BG AP132BG
7VALVE RETAI ER 2 AF819A AF819A
8A ∆ SELF TAPPI G SCREW 2 AP138 AP138
8B ∆ SELF TAPPI G SCREW 2 AP137 AP137
9O-RI G 2 AT276 AT276
10 CYLI DER 2 AP119 AT275
11 ∆ RETAI ER SCREW 4 AT283 AT283
12 RETAI ER PLATE 2 AT715 AT566A
13 ∆ PISTO CUP 2 AT329 AT280
14A FA (CW) 1 AP108A AP108A
14B FA (CCW) 1 AP108 AP108
15 GRILLE SHROUD 2 AP107A AP107A
16 PRESSURE SAFETY VALVE 1 AT954 AF592S
17 VALVE PLATE ASSEMBLY 1 AP133D AP133
18 SHROUD SCREW 8 BB411C BB411C
*** SERVICE KIT 1 K934 K933
EXPLODED PRODUCT VIEW, PARTS & ORDERI G I FORMATIO
*** Item not shown.
∆ Denotes parts included in the Service Kit.
Parts listed are for stock models. For specific OE models, please consult the factory.
When corresponding or ordering parts, please give complete model and serial numbers.
6

MAI TE A CE RECORD
DATE PROCEDURE PERFORMED
7

Low High Pump Won’t Excess Reason and remedy
Vacuum Pressure Vacuum Pressure O erheat Start Noise for problem.
••• • • Filter dirty. Clean or replace.
•• • • • uffler dirty. Clean or replace.
•• Valves dirty or valves bent.
Clean or replace.
•• Worn cup.
Repair 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.
•• •Worn cup/piston hitting cylinder.
Replace.
••Cylinder misadjustment.
Realign.
•• • Leaky hose or check valve.
Replace.
•• • ••Dirt or liquid on top of piston.
Inspect and clean.
•• • ••otor not wired correctly.
Check wiring diagram/line voltage.
•• •Blown head gasket. Replace.
TROUBLESHOOTI G CHART
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
PART O. 70 - 6855 G498PL (REV-D)
8
World Headquarters
GAST Manufacturing Inc.
A Unit of IDEX Corporation
2300 M 139 Highway
Benton Harbor, Michigan 49022
Phone [phone]
Fax [phone]
GAST Hong Kong
Room 6,9/F
New Commerce Centre
19 On Sum St, Shatin
N. T. Hong Kong
Phone [phone]
Fax [phone]
GAST GROUP LTD
A unit of IDEX Corporation
Unit 11, The I O Centre
Nash Road
Redditch, B98 7AS
United Kingdom
Phone [phone]
Fax [phone]
For the name of the nearest authorized service facility, contact one of our offices below or visit
our website at www.gastmfg.com.