Gast 4AM 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. 45-200SS Rev C

STAINLESS SERIES LUBRICATED AIR MOTORS

OPERATION & MAINTENANCE MANUAL

1AM

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 and you will receive years of trouble free service.

IMPO RTANT: 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.

General information

Operating Pressure Limits:Model Pressure

1AM 100 PSI / 7 bar
4AM 100 PSI / 7 bar
6AM 100 PSI / 7 bar

4AM

6AM

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 packed with food grade grease.

• Use Gast #AS117 food grade oil, #AD220 pneumatic

lubricating oil, 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

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

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.

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

xample:

E
Model designation: 1UP-NRV-10
Year manufactured: 2003

Gast Mfg. Corp.
II 2GD c + 1ºC Ta +40ºC*
Benton Harbor, MI USA
Telephone: [phone]

* Legend:
II Equipment group II
2 Equipment category 2
G Gas atmospheres
D Dust atmospheres
c Constructional safety
+1CTa +40ºC Max. surface temp. 275ºF/135ºC
Ambient range +1ºC to +40ºC (34ºF/104ºF)

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.

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.

INSTALLATION

Correct installation is your responsibility. Make sure you

have the proper installation conditions.

Injury Hazard

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.

Wear eye protection when installing this product.

Failure to follow these instructions can result in
serious injury or property damage.

2

Mounting

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

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,

ouplings and pinions on the motor shaft. Check

c
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.

Accessories

Consult your Gast representative for filter
recommendations. Install a moisture trap and filter in
the air line ahead of the motor. For the most efficient
output and control of speed use air lines that are the
same size or the next pipe size larger than the motor
intake.

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
storage.

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
#AS117 food grade oil, #AD220 pneumatic lubricating
oil, or a detergent SAE#10W automotive engine oil.
Adjust lubricator to feed 1 drop of oil for every 50-75
cubic feet of air while the unit is running. 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. To press a component onto
the shaft, remove the end cap and support the rear end
of the shaft

An automatic air line lubricator should be installed 18”
or as close as possible in the air line just ahead of the
motor. Adjust the lubricator to feed one drop oil for
every 50-75 cubic feet of air moving through the motor.
Air consumption at various speeds and pressures are
available from your local Gast representative, online at
www.gastmfg.com

Air consumption data at various speeds and pressures
are available from your Gast Distributor/Representative
or the factory.

or from the factory 269/926-6171.

OPERATION

Injury Hazard

Air stream from product may contain solid or liquid
material that can result in eye or skin damage.

Do Not use combustible gases to drive this motor.

Wear hearing protection. Sound level from motor
may exceed 87db(A).

Failure to follow these instructions can result in eye
injury or other serious injury.

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.

3

Use a pressure regulator and/or simple shut-off valve to
regulate the motorʼs 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.

3

per

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

igh speed or continuous duty usage. Do Not overfeed

h
oil or exhaust air may become contaminated.

Operate the motor for approximately 2 hours at
the maximum desired load. Measure the

surface temperature of the motor on the body
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 203ºF / 95ºC. 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

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.

It is your responsibility to regularly inspect and make
necessary repairs to this product in order to maintain
proper operation.

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 motorʼs 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.

Use Gast recommended Flushing Solvents.
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 spray solvent, spray
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. Slowly apply pressure until there is no trace
of solvent in the exhaust air.

5. Listen for changes in the sound of the motor. If
motor runs smooth, you are finished. If the
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.

Lubrication

For applications requiring food grade lubrication, Gast
#AS117 food grade oil is available. Gast #AD220 or a
detergent SAE #10 automotive engine oil is
recommended for other applications. Lubricating is
necessary to prevent rapid wear of internal components
on lubricated models. Excessive moisture in air line
may cause 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.

4

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.

SERVICE KIT INSTALLATION

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 vanes, end cap
gasket, body gasket, bearings and a muffler element or
felt.

Rebuilds
Tool kits which include a more in-depth rebuild manual

re available through your Gast

a
Distributor/Representative. These kits include the tools

required to remove and reassemble end plates,
bearings and shaft seals, and to set the proper end
clearance. The rebuild manual also includes step by
step instructions, including illustrations, to help achieve
a successful rebuild. Gast highly recommends using
the air motor rebuild manual and tool kit when
attempting a minor or major rebuild to your Gast air
motor.

Minor Rebuild:

1. Remove the end cap.

2. Remove dead end plate bolts.

3. Remove dead end plate using factory issued tool,
(do NOT use screwdriver to remove the end plate).

4. Remove vanes.

5. Clean parts. Check for scoring on the end plate
and rotor assembly. If scoring exists, send unit to
a Gast authorized service facility.

7. Place the dead end plate on the body.

8. Place the bearing onto the shaft using a factory
supplied bearing pusher.

9. Install end plate bolts. Check to make sure the end
plate does not bind - it should allow a small amount
of movement. Tighten bolts to 60-80 in-lbs.

10. Use the bearing tapper from kit to lightly tap on the
inner race of the dead end bearing to free up and
center the rotor in the body; the rotor should not rub
on either end plate when pushed or pulled.

11. Reattach the end cap.

12. Lubricated models only: add a few drops of oil
into the ports and rotate shaft by hand for a few
rotations.

Major Rebuild:

For major repairs, it is recommended that the unit be sent
to a Gast authorized service facility.

Disposal (Please note current regulations)

Parts of the air motor may be recycled as scrap
metal.

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4

3

2

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2

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1

1

EXPLODED PRODUCT VIEW, PARTS & ORDERIN G INFORMATION 1AM SERIES

1AM SERIES

REF# DESCRIPTION QTY Face Mount Hub Mount NEMA 42C Flange Mount

1 ∆ SEAL 1 AC190 AC190C AC190C

2 ∆ BEARING 2 AG549A AG549A AG549A

3 DRIVE END PLATE 1 AS111A AS111 AS111A

4 O-RING, BODY 2 AK945A AK945A AK945A

5 ∆∆ BODY 1 AS110 AS110 AS110

6 CAM RING 2 AC195 AC195 AC195

7 ROTOR ASSEMBLY 1 AS114 AS114 AS114

8 VANE 4 AC259A AC259A AC259A

9 ∆ DEAD END PLATE 1 AS112 AS112 AS112

10 O RING END CAP 1 AS116 AS116 AS116

11 ∆ END CAP 1 AS113 AS113 AS113

FLANGE (NOT SHOWN) 1 AS115

*** ∆ MUFFLER 1

*** FOAM 1

*** SERVICE KIT 1 K201SS K201SS K201SS

*** Items not shown

∆ Denotes parts in the service kit

To avoid injury, exhaust air should be
plumbed away or appropriate muffler
should be used

AM-NRV-7SS 1AM-NRV-39SS 1AM-NRV-105SS

1

6

1

2

3

4

5

6

7

77

8

7

8

9

1

0

1

1

EXPLODED PRODUCT VIEW, PARTS & ORDERIN G INFORMATION 4AM SERIES

4AM SERIES

EF# DESCRIPTION QTY HUB MOUNT FLANGE MOUNT

R

1 FLANGE 1 AS128

2 ∆ SEAL 1 AS132 AS132

3 BEARING 2 AS131 AS131

4 DRIVE END PLATE 1 AS121 AS121

5 ∆ O-RING, BODY 2 AS130 AS130

6 BODY 1 AS120 AS120

7 ROTOR ASSEMBLY 2 AS124 AS124

8∆ VANE 4 AB876 AB876

9 DEAD END PLATE 1 AS122 AS122

10∆ O RING END CAP 1 VG2145 VG2145

11 END CAP 1 AS123 AS123

12 PUSH PIN 4 AM467 AM467

13 SPRING 2 AM466 AM466

*** ∆ SERVICE KIT 1 K205SS K205SS

*** Items not shown

∆ Denotes parts in the service kit

To avoid injury, exhaust air should be
plumbed away or appropriate muffler
should be used

4AM-NRV-200SS 4AM-NRV-201SS

7

1

2

3

A

4

5

6

7

8

9

1

0

1

1

3

B

1

2

1

3

EXPLODED PRODUCT VIEW, PARTS & ORDERIN G INFORMATION 6AM SERIES

6AM SERIES

REF# DESCRIPTION QTY FACE MOUNT NEMA56C FLANGE MOUNT

1 FLANGE 1 AS128

2 ∆ SEAL 1 AS132 AS132

3A DRIVE END BEARING 1 AD638C AD638C

3B DEAD END BEARING 1 AS131 AS131

4 DRIVE END PLATE 1 AS139 AS139

5 ∆ O-RING, BODY 2 AS130 AS130

6 BODY 1 AS134 AS134

7 ROTOR ASSEMBLY 2 AS135 AS135

8∆ VANE 4 AS137 AS137

9 DEAD END PLATE 1 AS122 AS122

10∆ O RING END CAP 1 VG2145 VG2145

11 END CAP 1 AS123 AS123

12 PUSH PIN 8 AM467 AM467

13 SPRING 4 AM466 AM466

*** ∆ SERVICE KIT 1 K281SS K281SS

*** Items not shown

∆ Denotes parts in the service kit

To avoid injury, exhaust air should be
plumbed away or appropriate muffler
should be used

6AM-NRV-200SS 6AM-NRV-201SS

8

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
C

enter (unless specifically agreed upon in writing signed by both parties or specified in writing as part of a Gast OEM

Q

uotation). 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.

MAINTENANCE RECORD

DATE PROCEDURE PERFORMED

9

TROU BLESHOOTING CHART

www.gastmfg.com

ISO 9001 & 14001 CERTIFIED

Problem

ow Low Wonʼt Run Runs Hot Runs Well Reason & Remedy

L

Torque Speed Then Slows For Problem.

Down

•• • Dirt or foreign material present.

Inspect and clean.

•• • • •Vanes misaligned. Realign vanes.

•• Low air pressure. Increase pressure.

• Air line too small. Install larger line(s).

••Restricted exhaust. Inspect and repair.

•• • •Motor is jammed. Disassemble and repair.

••Air source inadequate. Inspect and repair.

••Air source too far from motor.

Reconfigure setup.

For the name of your nearest Gast Certified Service Center, please contact one of the sales offices below:

Gast Manufacturing, Inc.

2300 S. M139
Benton Harbor, MI 49022
Ph: 269/926-6171
FAX: [phone]
www.gastmfg.com

Gast Hong Kong

Unit 12, 21/F, Block B
New Trade Plaza
6, On Ping Street, Shatin
N. T. Hong Kong
Ph: (852) 2690 1066
Fax: [phone]
www.gasthk.com

Gast Group Ltd

A Unit of Idex Corporation
Unit 11, The 10 Centre Nash Rd
Redditich, B 98 7AS
United Kingdom
Ph: [phone]

Fax: [phone]

10