Page 1
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
®Registered Trademark/™Trademark of Gast Manufacturing Inc., Copyright ©2003 Gast Manufacturing Inc. All Rights Reserved.
PART NO. 70 - 3000 G442PL (REV-J)
OIL-LESS DIAPHRAGM
VACUUM PUMPS & COMPRESSORS
OPERATION & MAINTENANCE MANUAL
Model DOA Shown
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.
PLEASE READ THIS MANUAL COMPLETELY BEFORE INSTALLING AND USING
THIS PRODUCT. SAVE THIS MANUAL FOR FUTURE REFERENCE AND
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.
• 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.
Model MOA Shown
KEEP IN THE VICINITY OF THE PRODUCT
Model DAA Shown
WARNING
Page 2
Your safety and the safety of others
c
WARNING
is extremely important.
e have provided many important safety messages in
W
this manual and on your product. Always read and
obey all safety messages.
his is the safety alert symbol. This symbol
T
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
essages. These words mean:
m
Plumbing
Remove plugs from the IN and OUT ports. Connect
ith pipe and fittings that are the same size or larger
w
than the productʼs threaded ports. Be sure to connect
the intake and exhaust plumbing to the correct inlet and
outlet ports.
Accessories
ilters and mufflers are supplied with some models.
F
These should be checked periodically and replaced
when necessary. Please consult your Gast
Distributor/Representative for additional filter
ecommendations.
r
DANGER
e killed or seriously injured if you donʼt follow
b
ou will
Y
instructions.
WARNING
You can
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.
INSTALLATION
be killed or seriously injured if you donʼt follow
WARNING
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.
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.
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.
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.
OPERATION
Injury Hazard
Install proper safety guards as needed.
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.
Failure to follow these instructions can result in
burns, eye injury or other serious injury.
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.
2
Page 3
MAINTENANCE
c
WARNING
c
WARNING
WARNING
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.
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.
SHUTDOWN PROCEDURES
It is your responsibility to follow proper shutdown
procedures to prevent product damage.
NEVER ADD OIL TO THIS OIL-LESS PUMP.
roper shutdown procedures must be followed to
P
prevent pump damage. Failure to do so may result in
premature pump failure. Gast Manufacturing Oil-Less
Diaphragm Vacuum Pumps and Compressors are
onstructed of ferrous metals or aluminum which are
c
subject to rust and corrosion when pumping
condensable vapors such as water. Follow the steps
below to assure correct storage and shutdown between
perating periods.
o
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.
SERVICE KIT IN STALLAT ION
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 (MOA) or five (DOA) screws in the
top of the product. Remove the top plate.
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.
3. Clean the gasket with water and dry thoroughly.
Reinstall gasket.
4. Reinstall top plate and screws.
Check that all external accessories such as relief valves
and gauges are attached to cover and are not damaged
before re-operating 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.
Gast will NOT guarantee field-rebuilt product
performance. For performance guarantee, the product
must be returned to a Gast Authorized Service Facility.
Service Kit contents vary. Most contain gaskets and
filter parts.
1. Disconnect electrical power to pump.
2. Disconnect air supply and vent all air lines to
release pressure or vacuum.
3. Remove the socket cap screws from the head of the
pump. Remove the head of the pump.
3
Page 4
Replacing Diaphragm
1. Remove the two Phillips-head screws then the
retainer plate and diaphragm.
2. Install the new diaphragm, pattern side up for
compressors, pattern side down for vacuum
pumps,onto the connecting rod.
3. Replace the retainer plate and attach with two
screws. Torque the screws to 30 in. lbs. on DOA
and DAA units and to 12 in. lbs. on MOA and
MAA units.
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.
alves are interchangeable on DOA and DAA
V
units.
3. Replace the outlet valve or install a new valve so
that the retaining bar is near the machine screw
hole. The retainer bar holds the valve in place.
4. Replace the inlet valve or install a new valve so
that the notch marked on the 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. on the DOA and DAA
units and 30 in. lbs. on the MOA and MAA units.
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.
4
Page 5
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION
DAA / DOA SERIES
EF DESCRIPTION QTY DOA-P101-AA
R
COVER 1 AF808
1
2 ∆ HEAD GASKET 1 AF820
∆ FILTER/MUFFLER ELEMENT 2 AT713
3
∆ FILTER ELEMENT 1 AT712A
4
5 HEAD 1 AF804
∆ VALVE SCREW 2 BB317
6
7 ∆ VALVE LIMITER 1 AF856
∆ LEAF VALVE 2 AF817
8
9 ∆ VALVE RETAINER 1 AF819A
0 RETAINER PLATE 1 AF809
1
11 DIAPHRAGM 1 AF818A****
ompressor-Blue 2 AF818A****
C
DIAPHRAGM
Vacuum-RED 2 AF818B
12 FELT SPACER 3 AA929
12A SPACER 1 AD996
13 FAN - Clockwise 1 AT837 AT837
13A FAN - Counterclockwise 1 AT837A
14 GRILLE 1 AF807
15 RIVOT 4 AE946
*** SERVICE KIT 1 K294A
DOA-P101-BN DAA-V155-EB*
2 AF808
2
4 AT713
2
2 AF804
4
2 AF856
4 AF817
2
2 AF809
6 AA929
2 AD996
2 AF807
8 AE946
2 K294K
AF820
AT712A
BB317
AF819A
* DOA shown. The Double-ended (DAA – not illustrated) models are two DOAs mounted back to back with heads rotated.
*** Item not shown.
****Pattern side up for compressors. Pattern side down for vacuum pumps.
∆ Denotes parts included in the Service Kit.
∆ 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.
5
Page 6
XPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION
E
MAA / MOA SERIES
EF DESCRIPTION QTY MAA-V103-HB* MOA-P101- AA
R
COVER 1 AF780
1
2 ∆ HEAD GASKET 1 AF783
∆ FILTER/MUFFLER ELEMENT 2 AT712
3
4 ∆ NUT 1 BC164
∆ VALVE RETAINER 1 AF819A
5
5A ∆ LIMITER 1 AH406
∆ LEAF VALVE 1 AJ827
6
6A ∆ EXHAUST LEAF VALVE 1 AG973
7 ∆ SCREW 1 BB319
HEAD 1 AF779
8
9 RETAINER PLATE 1 AF778
0 DIAPHRAGM-Pressure-Red 1 AG288
1
**** DIAPHRAGM-Vacuum-Red 2 AG288
11 FAN 1 AJ856 AJ856
12 **FAN 1 AF785B AF785B
13 **GRILLE 2 AG774 AG774
*** SERVICE KIT 1 K309
AF780
2
2 AF783
AT712
4
BC164
2
2 AF819A
AH406
2
2 AJ827
AG973
2
2 BB319
AF779
2
2 AF778
2 K309
OA-P101-CD
M
MOA-P101- JH**
* MOA shown. The Double-ended (MAA – not illustrated) models are two MOAs mounted back to back with heads rotated.
**MOA-P101-JH does not have an AF785B fan and has only qty (1) AG774 Grille (#13).
*** Item not shown.
****Pattern side up for compressors. Pattern side down for vacuum pumps.
∆ Denotes parts included in the Service Kit.
∆ 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
Page 7
WARRANTY
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
ast Manufacturing Incorporated, PO Box 97, Benton Harbor Michigan USA 49023-0097 or an authorized Service
G
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
MPLIED BY ANY LITERATURE, DATA, OR PERSON. GASTʼS MAXIMUM LIABILITY UNDER THIS EXCLUSIVE
I
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, 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.
MAINTENANCE RECORD
DATE PROCEDURE PERFORMED
7
Page 8
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
®Registered Trademark/™Trademark of Gast Manu facturing Inc., Copyright © 2002 Gast Manufacturing Inc. All Rights Reserved.
PART NO. 70 - 3000 G442PL (REV-J)
ROUBLESHOOTING CHART
T
Low High Pump Motor Excess Reason and remedy
Vacuum Pressure Vacuum Pressure Overheat Overload Noise for problem.
••At Pump •• Filter dirty. Clean or replace.
•• At pump •• Muffler dirty. Clean or replace.
•• Valves dirty or valves bent.
Clean or replace.
•• Worn piston rings.
Repair or replace.
••• Relief valve set too high.
Inspect and adjust.
•• Relief valve set too low.
Inspect and adjust.
••At pump At pump •• Plugged vacuum/pressure line.
Inspect and repair.
• At pump Collapsed vacuum line.
Inspect and repair.
•• Low voltage, wonʼt start.
Check power source.
•••Voltage wrong.
Check power source.
•• •Worn rings/piston hitting cylinder.
Replace.
••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.
World Headquarters
P.O. Box 97
2300 Highway M139
Benton Harbor, MI 49022
Ph: 269/926-6171
FAX: 269/925-8288
www.gastmfg.com
Gast Hong Kong
Room 6,9/F.
New Commerce Centre19
on Sum St, Shatin
N. T. Hong Kong
Ph: (852) 2690 1008
Fax: (852) 2690 1012
www.gasthk.com
Gast Group Ltd.
A Unit of IDEX
Corporation
Unit 11, The I O Centre
Nash Road
Redditch, B98 7AS
United Kingdom
Ph: +44 (0)1527 504040
Fax +44 (0)1527 525262
8
Loading...