Gast 16 AM User Manual
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
®Registered Trademark/™Trademark of Gast Manufacturing Inc., Copyright © 2003 Gast Manufacturing Inc. All Rights Reserved.
PART NO. 45-200 D170 Rev D-W
WARNING
PLEASE READ THIS MANUAL COMPLETELY BEFORE INSTALLING AND USING
THIS MOTOR. SAVE THIS MANUAL FOR FUTURE REFERENCE AND
KEEP IN THE VICINITY OF THE MOTOR.
AM SERIES LUBRICATED AIR MOTORS
OPERATION & MAINTENANCE MANUAL
Model 2AM Shown
Thank you for purchasing this Gast product. It is manufactured to the highest standards
using quality materials. This manual includes general safety instructions for operation under normal conditions and for
operation in hazardous conditions. Please follow all recommended maintenance, operational and safety instructions
General information
Operating Pressure Limits: Model Pressure
Model 4AM Shown
and you will receive years of trouble free service.
1AM 100 PSI / 7 bar
1 UP 80 PSI / 5.6 bar
2 AM 100 PSI / 7 bar
4 AM 100 PSI / 7 bar
6 AM 100 PSI / 7 bar
8 AM 100 PSI / 7 bar
16 AM 100 PSI / 7 bar
Model 6AM Shown
Model 16AM Shown
Product Use Criteria:
• Normal conditions: Operate at temperatures up to
250ºF (121ºC).
• Hazardous conditions: Operate at temperatures up to
104ºF (40ºC).
• Protect unit from dirt and moisture.
• Use ONLY compressed air to drive motor.
• Air lines connected to motor should be the same size or
the next size larger than the inlet port for efficient
output and speed control.
• Protect all surrounding items from exhaust air.
• Bearings are grease packed.
• Use Gast #AD220 or a detergent SAE#10 automotive
engine oil for lubricating.
• Motors are to be used in commercial installations only.
• This symbol appears on labels of air motors that
are designed for use in hazardous atmospheres.
These air motors comply with the applicable
standards and specifications and meet the
requirements of the guidelines of the EC directive
94/9EC (ATEX 100a). They are intended to be used in
zones 1 and 2 where explosive atmospheres are likely
to occur.
• Air supply, directional control valve and pressure regulator
should be selected based upon the air consumption
of the motor.
Your safety and the safety of others
WARNING
Injury Hazard
Wear eye protection when installing this product.
Install proper guards around output shaft as needed.
Air stream from product may contain solid or liquid
materials that can result in eye or skin damage.
Failure to follow these instructions can result in
serious injury or property damage.
CODE SYMBOLS
Hazard. Possible consequences: death or
severe injuries.
Hazardous situation. Possible
consequences: slight or mild injuries.
Dangerous situation. Possible
consequences: damage to the drive or the
environment.
Important instructions on protection
against explosion.
Application tips and useful
information.
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:
DANGER
You will
instructions.
be killed or seriously injured if you donʼt follow
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.
be killed or seriously injured if you donʼt follow
Complete the following checklist prior to
starting installation in a hazardous area. All
actions must be completed in accordance with ATEX
100a.
Checklist for installation in hazardous areas:
Read air motor label to check that
motor has been designed for use
in a hazardous application:
• Hazardous zone
• Hazardous category
• Equipment group
• Temperature class
• Maximum surface temperatures
Example:
Model designation: 1UP-NRV-10
Year manufactured: 2003
Gast Mfg. Corp.
II 2GD c +1Cº Ta +40Cº
Benton Harbor, MI USA
Telephone: 269.926.6171
* Legend:
II Equipment group II
2 Equipment category 2
G Gas atmospheres
D Dust atmospheres
c Constructional safety
+1CTa +40C* Max. surface temp. 275ºF/135ºC
Ambient range +1Cº to +40ºC (34ºF/104ºF)
Check the site environment for potentially
explosive oils, acids, gases, vapors or radiation
Check the ambient temperature of the site and
the ability to maintain proper ambient
temperature.
Ambient range:
Normal conditions: 34ºF/1ºC to 250ºF/121ºC
Hazardous conditions: 34ºF/1ºC to 104ºF/40ºC
Check the site to make sure that the air motor
will be adequately ventilated and that there is
no external heat input (e.g. couplings). The
cooling air may not exceed 104ºF/40ºC.
Check that products to be driven by the air
motor meet ATEX approval.
Check that the air motor is not damaged.
Improper environment, installation and operation can
result in severe personal injury and/or damage to
property.
Qualified personnel must perform all work to assemble,
install, operate, maintain and repair air motor.
Qualified personnel must follow:
• These instructions and the warning and information
labels on the motor.
• All other drive configuration documents, startup
instructions and circuit diagrams.
• The system specific legal regulations and
requirements.
• The current applicable national and regional
specifications regarding explosion protection,
safety and accident prevention.
2
INSTALLATION
Correct installation is your responsibility. Make sure you
have the proper installation conditions.
Mounting
WARNING
Injury Hazard
Air stream from product may contain solid or liquid
material that can result in eye or skin damage
Do Not use cumbustible gases to drive this motor.
Wear hearing protection. Sound level from motor
may exceed 85 db(A).
Failure to follow these instructions can result in eye
injury or other serious injury.
This product can be installed in any orientation. Mount
the motor to a solid metal base plate that is mounted to
a stable, rigid operating surface. Use shock mounts to
reduce noise and vibration. Install a pressure regulator
or simple shut-off valve to control motor.
Connection
Check the direction of the motor airflow. A single
rotation motor will operate properly only in one direction.
Single rotation motors require a sound absorber to be
connected to the air port. Remove the plastic shipping
plugs from the ports. Save plugs for future use during
shutdown.
Install a 5-micron filter in the air line before the
connection to the motor. Next install an air pressure
regulator to control motor speed and torque.
An automatic air line lubricator should be installed in the
air line as close as possible and no more than 18
inches (1/2 meter) from the air motor. Install the
lubricator level with or above the air motor so that the oil
mist will blow directly into or fall down into the motor.
Fill the oil reservoir to the proper level with Gast
#AD220 or SAE 10W high detergent or non-detergent
motor oil. For food processing applications, White Rex
425 food grade motor oil is FDA approved. Adjust
lubricator to feed 1 drop of oil for every 50 CFM of air
while the unit is running, or 1 drop of oil per continuous
minute of run time. Do Not overfeed oil or exhaust air
may become contaminated.
Clean the compressed air connection with low pressure
air to remove any dirt from the line before connecting to
the ports.
Use the proper sized fasteners. For the most efficient
output and control of speed, use air lines that are the
same size as the motor inlet port if the connection is
less than 7 feet (2 meters). For longer connections, use
the next pipe size larger than the motor intake port.
Connect lines to motor in the proper direction.
A reversible motor will work equally well in both
directions. Connect a 4-way valve with piping to both
air ports of motor to make reversing possible. Connect
the sound absorber on the exhaust air port or valve
connection.
Do not add any thrust to the end or side of the shaft
when making connections.
Do not use a hammer on the shaft or
connections.
Lubricating the drive shaft will make assembly
easier. Use a puller for removal of pulleys,
couplings and pinions on the motor shaft.
Check that the tension on the belt pulley matches the
manufacturerʼs specifications. Do not exceed the
maximum radial and axial forces on the shaft. If the
motor shaft is connected to the part to be driven without
a coupling, check that the radial offset and axial force
effect will not cause problems.
Use only belts with < 109electrical leakage
resistance to prevent static electrical problems.
Ground the motor.
Accessories
A muffler is shipped with the air motor (except 16AM)
but is not installed. Consult your Gast
Distributor/Representative for additional filter
recommendations. Install a moisture trap and 5 micron
filter in the air line ahead of motor.
Air consumption data at various speeds and pressures
are available from your Gast Distributor/Representative
or the factory.
OPERATION
Check all connections before starting motor. It is your
responsibility to operate this product at recommended
speeds, loads and room ambient temperatures. Do not
run the motor at high speeds with no load. This will
result in excessive internal heat that may cause motor
damage.
The starting torque is less than the running torque. The
starting torque will vary depending upon the position of
the vanes when stopped in relation to the air intake
port.
Use a pressure regulator and/or simple shut-off valve to
regulate the motor’s speed and torque. This will provide
the required power and will conserve air. Open the air
supply valve to the motor. Set the pressure or flow rate
to the required speed or torque. Adjust the lubricator to
feed one drop of oil for every 50-75 CFM (1.5-2 M
minute) of air moving through motor. Check the oil level
daily. The gear reducer does not need lubrication.
3
per
3
WARNING
Injury Hazard
Disconnect air supply and vent all air lines.
Wear eye protection when flushing this product.
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.
Failure to follow these instructions can result in eye
injury or other serious injury.
Operate the motor for approximately 2 hours at
the maximum desired load. Measure the
surface temperature of the motor on the casting
opposite the pipe ports. The maximum surface
temperature listed on the motor is for normal
environmental and installation conditions. For most air
motors, the maximum surface temperature should not
exceed 266ºF/130ºC. Do not continue to operate the
motor if the measured surface temperature exceeds
temperature listed on the motor. If your measured
temperature does exceed listed value, consult with your
Gast Distributor/Representative for a recommendation.
MAINTENANCE
It is your responsibility to regularly inspect and make
necessary repairs to this product in order to maintain
proper operation.
Lubrication
Use Gast #AD220 or a detergent SAE #10 automotive
engine oil for lubricating. Lubricating is necessary to
prevent rust on all moving parts. Excessive moisture in
air line may cause rust or ice to form in the muffler
when air expands as it passes through the motor.
Install a moisture separator in the air line and an after
cooler between compressor and air receiver to help
prevent moisture problems.
Manual Lubrication
Shut the air motor down and oil after every 8 hours of
operation. Add 10-20 drops of oil to the air motor intake
port.
Automatic Lubrication
Adjust inline oiler to feed 1 drop of oil per minute for
high speed or continuous duty usage. Do Not overfeed
oil or exhaust air may become contaminated.
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 assure the motor’s performance
and service life.
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. Flush the motor if it is operating slowly or
inefficiently.
4
Use only Gast recommended Flushing Solvent. DO
NOT use kerosene or ANY other combustible solvents
to flush this product.
1. Disconnect air line and muffler.
2. Add flushing solvent directly into motor. If using
liquid solvent, pour several tablespoons directly
into the intake port. If using Gast recommended
spray solvent for 5-10 seconds into intake port.
3. Rotate the shaft by hand in both directions for a
few minutes.
4. You must wear eye protection for this step.
Cover exhaust with a cloth and reconnect the air
line.
5. Restart the motor at a low pressure of
approximately 10 PSI / 0.7 bar until there is no
trace of solvent in the exhaust air.
6. Listen for changes in the sound of the motor. If
motor sounds smooth, you are finished. If motor
does not sound like it is running smoothly,
installing a service kit will be required
(See “Service Kit Installation”).
Check that all external accessories such as relief valves
or gauges are attached and are not damaged before
operating product.
Cleaning sound absorber
1. Remove the sound absorber.
2. Clean the felt filter.
3. You must wear eye protection for this step.
Lubricate motor with 3-4 drops of oil.
4. Check the air compressor.
5. Listen for changes in the sound of the motor. If
motor sounds smooth, you are finished. If motor
does not sound like it running smoothly, installing
a service kit will be required (See “Service Kit
Installation”).
Shutdown
It is your responsibility to follow proper shutdown
procedures to prevent product damage.
1. Turn off air intake supply.
2. Disconnect air supply and vent all air lines.
3. Disconnect air lines.
4. Remove air motor from connecting machinery.
5. Remove the muffler.
6. Wear eye protection. Keep away
from air stream. Use clean, dry air
to remove condensation from the inlet port of the
motor.
7. Lubricate motor with a small amount of oil into the
intake port. Rotate shaft by hand several times to
distribute oil.
8. Plug or cap each port.
9. Coat output shaft with oil or grease.
10. Store motor in a dry environment.
Disposal (Please note current regulations)
Parts of the air motor or air powered gear motor,
shafts, cast iron or aluminum castings, gear
wheels as well as rolling contact bearings may be
recycled as scrap metal.
Estimated Ball Bearing Life of Lubricated Air Motors
Air Motor Model Shaft speed in RP Ball Bearing Life
hours L
1AM 10,000 28,000
1UP 6,000 14,000
2AM 3,000 30,000
4AM 3,000 14,000
6AM 3,000 6,500
8AM 2,500 8,000
16AM 2,000 15,000
Based on running pressure of 60 PSI and coupling connection to motor load. The direction,
magnitude and location of applied loads to the motor shaft will change expected bearing life.
Driving the motor with wet dirty compressed air can reduce expected bearing life. The above are
life estimates not warrantied minimum values.
SPUR & WORM GEAR REDUCERS - OPERATING AND MAINTENANCE INSTRUCTIONS
General Information:
The product nameplate specifies all information required
when ordering parts or requests for information. The
type of lubricant required for unit is also specified on the
nameplate.
10
Product Use Criteria:
• All worm gear reducers require that the air motor be
mounted so that the inlet and exhaust ports are at a
90º angle to the centerline of the reducer output shaft.
• Gear reducers are NOT self-locking. If a brake is
required for safety, as in the case of air pressure failure,
etc., contact your Gast Distributor/Representative.
• Some worm gear reducers may be shipped with a plug
in the top pipe plug. The plug must be removed and the
breather plug installed for proper operation.
• Check the oil level in spur gear reducers which have
been stored or not operated for a period of time.
• Gear motors require proper lubrication. Insufficient oil
level can cause loss of performance, damage or failure
of the gear reducer.
Spur Gear Reducer Specifications
Model GR11 GR20 GR25
Speed Range 33.3 to 400 RPM 30 to 300 RPM 20 to 200 RPM
(Reducer Output Shaft)
Gear Reduction 15:1 10:1 15:1
Maximum Allowable 100 lbs/45,4 kg 200 lbs/90,8 kg @300 250 lbs/113,5 kg at 200
End Thrust With RPM to 800 lbs/363,2 kg RPM to 800 lbs/363,2 kg
Zero Overhung Load. at 30 RPM at 20 RPM
(Reducer Output Shaft)
Maximum Allowable 100 lbs/45,4 kg at 333 200 lbs/90,8 kg at 300 200 lbs/90,8 kg at 200
Overhung Load With RPM to 200 lbs/90,8 kg RPM to 600 lbs/272,4 kg RPM to 600 lbs/272,4 kg
Zero End Thrust. at 33.3 RPM at 30 RPM at 20 RPM
(Reducer Output Shaft)
Lubrication Use a 300 ssu at 100˚F/38˚C turbine quality lubricant – Gast #AG292A, Gulf
Harmony 53, Shell Tellus 33, Socony DTE heavy medium or Humble Nuto 53.
For horizontal operation, remove both plugs and add oil to top hole until
other hole overflows.
For vertical operation, fill to overflow point of upper most hole.
5
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