23 SERIES OIL-LESS
VACUUM PUMPS & COMPRESSORS
O
PERATION
& M
AINTENANCE
M
ANUAL
Product Use Criteria:
Pump only clean, dry air.
Operate at 32F - 104F (0C - 40C).
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 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.
Model #0523-101 Shown
Model #1023-101Q Shown
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.
General information
Clearances:
Top: .002"
Ends:
.0015" - .005"
Vane Life:
5,000-15,000 hours depending
upon application
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.
ISO 9001 & 14001 CERTIFIED
ΖRegistered Trademark/TMTrademark of Gast Manufacturing Inc., Copyright © 2001 Gast Manufacturing Inc. All Rights Reserved.
PART NO. 70 - 290 G375PL (REV-G)
Model #1023-V103 Shown
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.
Accessories
The product's intake and exhaust filters will provide
adequate filtration in most applications. Consult your
Gast representative for additional filter
recommendations. 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.
OPERATION
WARNING
DANGER
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
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.
Failure to follow these instructions can result in
burns, eye injury or other serious injury.
WARNING
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.
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.
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 filter/muffler (#11) for compacted debris. If
debris is present, replace filter/muffler.
4. Check condition of O-ring. 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. Replace muffler box.
8. Reinstall filters or install new filters if required.
Reinstall end cap.
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 AH255B solvent and remove all
solvent from vanes.
6. Flush body, rotor and end plate with AH255B
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).
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 AH255B Flushing Solvent or other
non-petroleum based flushing solvent. Do Not use
kerosene or ANY other combustible solvents to
flush product.
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
1/4" NPT for 0323 and 0523 products, or 3/8" NPT on
one end for 0823 and 1023 products. 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
AH255B, spray solvent 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 Kit 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.
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.
Flush this product in a well ventilated area.
Failure to follow these instructions can result in
burns, eye injury or other serious injury.
WARNING
Gast will NOT guarantee field-rebuilt product
performance. For performance guarantee, the
product must be returned to a Gast-authorized
facility.
Service Kit 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.
7. Check end plate, rotor and body for scoring.
Severe scoring or worn bearings will require
service at a Gast-authorized facility.
DO NOT remove rotor or motor bolts.
8. Insert vanes, checking that the bevel edges are in
the correct direction.
SERVICE KIT 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.
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
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.
* Denotes parts included in the Service Kit. Parts listed are for stock models.
** No Service Kit available, order parts separately. *** Not shown.
For specific OEM models, please consult the factory.
When corresponding or ordering parts, please give complete model and serial numbers.
REF
DESCRIPTION
QTY
0323-101 0323-101Q
0523-101 0523-101Q 0523-V103
1
BODY
1
AK503
AK503
AK505
AK505
AK505
2
*
VANE
4 AH850A
AH850A
AH850A
AH850A
AH805A
3
SHROUD
1 AK502
AK502
AK502
AK502
AK502
4
END PLATE
1 AK516A
AK501
AK516A
AK501
AK516A
5
*
GASKET
1
AK521
AK521
6
MUFFLER BOX
1
AK519
AK519
7
*
O-RING
2
AK473
AK473
8
*
FELT
2
AK524
AK524
9
END CAP
2
AK510
AK510
10
END CAP ASSEMBLY
2
AK526
AK526
11
FILTER / MUFFLER
1
AK840A
AK840A
12
FOOT SUPPORT
1
AC136
AC136
13
ELBOW
***
2
AD997
14
MUFFLER ASSEMBLY
1
V425L
15
JAR
2
AA125A
16
COVER
1
AV427
17
FELT FILTER
4
B344A
18
SUPPORT
1
B345A
19
COVER GASKET
2
B62A
20
FILTER ASSEMBLY
1
V400G
21
COVER
1
AV402CPC
22
FILTER ASSEMBLY
1
B343B
23
SCREEN CAP
1
AJ571
24
FELT SUPPORT
1
B347
SERVICE KIT
1
K478A
K478
K478A
K478
**
Muffler
Assembly
Vacuum Intake
Filter Assembly
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION
REF DESCRIPTION
QTY 0823-101 0823-101Q 1023-101 1023-101Q 1023-V103 1423-101 1423-101Q
1 BODY
1
AK517 AK517 AK518 AK518
AK518 AL283
AL283
2
*
VANE
4
AK513
AK513
AK513
AK513
AK513
AL284
AL284
3
SHROUD
1
AK511
AK511
AK511
AK511
AK511
AL281
AL281
4
END PLATE
1
AK515A
AK514
AK515A
AK514
AK515A
AK515A
AK514
5
*
GASKET
1
AK522
AK522
AK522
6
MUFFLER BOX
1
AK520
AK520
AK520
7
*
O-RING
2
AK473
AK473
AK473
8
*
FELT
2
AK524
AK524
AK524
9
END CAP
2
AK510
AK510
AK610
10 END CAP ASSEMBLY
2
AK526
AK526
AK526
11
FILTER / MUFFLER
1
AK840
AK840
AD432
AC432
12
ELBOW
1
BA206
BA206
12
ELBOW
***
2
AF272
13
MUFFLER ASSEMBLY
1
AB599B
13 a
NIPPLE
2
BA714
BA714
14
JAR
2
AA805
15
COVER GASKET
2
AA405
16
COVER ASSEMBLY
1
AV805BPC
17
MUFFLER ASSEMBLY
1
AC434-1
18
COUPLING
2
AC391
19
CARTRIDGE
2
AC393
20
END CAP ASSEMBLY
2
AC394
21
MUFFLER PLATE
1
AC395
22
STUD
2
AC396
23
FILTER ASSEMBLY
1
AB599
24
COVER ASSEMBLY
1
AV805APC
25
FILTER ASSEMBLY
1
AC433-1
SERVICE KIT
1
K479A
K479
K479A
K479
**
K575A
K575A
For 1423 Models only.
(Shipped unattached)
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION
*
Denotes parts included in the Service Kit. Parts listed are for stock models.
**
No Service Kit available, order parts separately. *** Not shown.
For specific OEM models, please consult the factory. When corresponding or ordering parts, please give complete model and serial numbers.
Muffler
Assembly
Vacuum Intake
Filter Assembly
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 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 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 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 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
