Idex Gast 4AM Series User manual

® Registered Trademark/™ Trademark of Gast Manufacturing Inc. ©Copyright 2019 Gast Manufacturing Inc. All Rights Reserved.
www
.gastmfg.com
ISO 9001 CERTIFIED
Model 2AM Shown Model 4AM Shown Model 6AM Shown Model 16AM Shown
AM SERIES AIR MOTORS
Operation and Maintenance Manual
Part No. 45-200 D170 (Rev. T)
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.
WARNING
PLEASE READ THIS MANUAL COMPLETELY BEFORE INSTALLING AND USING
THIS PRODUCT. SAVE THIS MANUAL FOR FUTURE REFERENCE AND
KEEP IN THE VICINITY OF THE PRODUCT.
General Information:
Operating Pressure Limits
Lubricated Models Pressure
1AM 100 psi / 7 bar
1UP 80 psi / 5.6 bar
2AM 100 psi / 7 bar
4AM 100 psi / 7 bar
6AM 100 psi / 7 bar
8AM 100 psi / 7 bar
16AM 100 psi / 7 bar
LL and NLP Models Pressure
1AM 80 psi / 5.5 bar
1UP 65 psi / 4.9 bar
2AM 80 psi / 5.5 bar
4AM 80 psi / 5.5 bar
6AM 80 psi / 5.5 bar
8AM 80 psi / 5.5 bar
16AM 80 psi / 5.5 bar
Product Use Criteria:
• Non-hazardous conditions: Operate at ambient temperatures up
to 250ºF (121ºC).
• Hazardous conditions: Operate at ambient 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 efcient output and speed con-
trol.
• 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 Directive 2014/34/EU. 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.

© 2019, Gast Manufacturing
We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA
2
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 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 preceed all safety messages.
These words mean:
mDANGER
You will be killed or seriously injured if you don’t follow
instructions.
mWARNING
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.
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
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 conguration documents, startup instructions and
circuit diagrams.
• The system specic legal regulations and requirements.
• The current applicable national and regional specications
regarding explosion protection, safety and accident prevention.
Complete the following checklist prior to starting
installation in a hazardous area. All actions must be
completed in accordance with Directive 2014/34/EU.
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
II 2GD
Ex h IIC T4 Gb
Ex IIIC T135°C Db
Benton Harbor, MI USA
Telephone: [phone]
* Legend:
II: Equipment group II
2: Equipment category 2
G: Gas atmospheres
D: Dust atmospheres
b: EPL b.
Max. surface temp. 275ºF/135ºC
Ambient range (Ta) +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:
Non-hazardous 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.
m WARNING
Injury Hazard
Install proper guards around output shaft as needed.
Air stream from product may contain solid or liquid materi-
als 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.

© 2019, Gast Manufacturing
We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA
3
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
Check the direction of the motor airow. 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 lter in the air line before the connection to the
motor. Next install an air pressure regulator to control motor speed
and torque.
For lubricated operation: Air motors with an “LL” or “NLP”
designation in the model number can operate with or without
lubrication. For optimal service and life, lubrication is recommended.
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, use an FDA-approved, food-grade lubricant. 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 efcient 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
manufacturer’s 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 < 109 electrical leakage
resistance to prevent static electrical problems.
Ground the motor.
Accessories
A mufer is shipped with the air motor (except 16AM) but is not
installed. Consult your Gast Distributor/Representative for additional
lter recommendations. Install a moisture trap and 5 micron lter 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
m WARNING
Injury Hazard
Air stream from product may contain solid or liquid materi-
al 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.
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 ow rate to the required speed or torque. Adjust the
lubricator to feed one drop of oil for every 50-75 CFM (1.5-2 M3per
minute) of air moving through motor. Check the oil level daily. The
gear reducer does not need lubrication.

© 2019, Gast Manufacturing
We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA
4
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 275ºF/135ºC. 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
m 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 materi-
al 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.
For Lubricated Operation
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 mufer 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 lters after rst
500 hours of operation. Clean lters and determine how frequently
lters 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 inefciently.
Use only Gast #AH255B Flushing Solvent. DO NOT use
kerosene or ANY other combustible solvents to flush this
product.
1. Disconnect air line and mufer.
2. Add ushing solvent directly into motor. If using liquid solvent,
pour several tablespoons directly into the intake port. If using
Gast #AH255B, 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 nished. 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 the sound absorber.
1. Remove the sound absorber (for non-lubricated operation,
inspect mufer every 90 days. To avoid excessive clogging of
mufer element, change frequently).
2. Clean the felt lter.
3. You must wear eye protection for this step. For lubricated
operation, add 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 nished. 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 mufer.
6. Wear eye protection. Keep away from air
stream. Use clean, dry air to remove condensation from the
inlet port of the motor.
7. For lubricated operation, add 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.

© 2019, Gast Manufacturing
We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA
5
Estimated Ball Bearing Life of Air Motors
Air Model Model Shaft Speed in RP Ball Bearing Life Hours L10
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 2,000 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 AND WORM REDUCERS - OPERATING AND MAINTENANCE INSTRUCTIONS
General Information:
The product nameplate species all information required when
ordering parts or requests for information. The type of lubricant
required for unit is also specied on the nameplate.
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.
Spur Gear Reducer Specifications
Model GR11 GR20 GR25
Speed Range (Reducer Output
Shaft) 33.3 to 400 RPM 30 to 300 RPM 20 to 200 RPM
Gear Reduction 15:1 10:1 15:1
Maximum Allowable End Thrust
With Zero Overhung Load. (Re-
ducer Output Shaft)
100 lbs/45,4 kg 200 lbs/90,8 kg @300 RPM to
800 lbs/363,2 kg at 30 RPM
250 lbs/113,5 kg @200 RPM to
800 lbs/363,2 kg at 20 RPM
Maximum Allowable Overhung
Load With Zero End Thrust.
(Reducer Output Shaft)
100 lbs/45,4 kg @ 333 RPM to
200 lbs/90,8 kg at 33.3 RPM
200 lbs/90,8 kg @ 300 RPM to
600 lbs/272,4 kg at 30 RPM
200 lbs/90,8 kg @ 200 RPM to
600 lbs/272,4 kg at 20 RPM
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 overows.
For vertical operation, ll to overow point of upper most hole.
• 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. Insufcient oil level
can cause loss of performance, damage or failure of the gear
reducer.

© 2019, Gast Manufacturing
We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA
6
Change output shaft direction of worm gear reducers
1. Remove drain plug and drain oil from unit.
2. Remove end cover and seal cage cap screws. While supporting
output shaft, remove end cover and shims from unit. Keep
shims with cover.
3. Remove output shaft and seal cage together from extension
side. Keep shims with seal cage.
4. Insert seal cage, shims and sub-assembly into housing from
the side opposite from which they were removed.
5. Insert seal cage cap screws and tighten with light pressure.
6. Assemble end cover with shims. Insert end cover cap screws
and tighten with light pressure.
7. Turn high speed shaft in both directions to check that gear train
is running freely.
8. Cross-tighten seal cage and end cover cap screws.
Worm Gear Reducer Series A-F
Gear Reducer Specifications
All output shafts are in the standard location.
Model Air Motor Ratio
AG803 4AM 20:1
AG805 4AM 40:1
AG807 4AM 60:1
AG809 6AM 10:1
AG811 6AM 20:1
AG816 8AM 20:1
Service, Parts, or Repair
For service, parts or repair of the worm gear reducer, contact the
manufacturer listed on the nameplate.
Part No. 45-200 D170PL (Rev. S)
TROUBLESHOOTING GUIDE
Problem
Reason and Remedy for Problem
Low Torque Low Speed Won’t Run Runs Hot
Runs Well
Then Slows
Down
••• Dirt or foreign material present. Inspect and ush.
••• Internal rust. Inspect and ush.
• • Low air pressure. Increase pressure.
•Air line too small. Install larger line(s).
• • Restricted exhaust. Inspect and repair.
• • • • Motor is jammed. Have motor serviced.
• • Air source inadequate. Inspect and repair.
• • Air source too far from motor. Recongure setup.

© 2019, Gast Manufacturing
We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA
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 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 Quota-
tion). 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 RE-
PLACEMENT.
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 MANUFAC-
TURES.
This warranty can be modified only by authorized Gast personnel by signing a specific, written description of any modifications.

Gast Manufacturing
2300 M-139 Highway
Benton Harbor, MI 49023
Ph: 269-926-6171
Fax: [phone]
Gast Group Limited
Room 3502-3505
No. 1027 Chang Ning Road,
Zhaofeng Plaza
Shanghai, China 200050
Phone [phone]
Fax [phone]
Gast Group Ltd.
Unit 11, The I O Centre
Nash Road
Redditch, B98 7AS
United Kingdom
Phone [phone]
Fax [phone]
® Registered Trademark/™ Trademark of Gast Manufacturing Inc. ©Copyright 2019 Gast Manufacturing Inc. All Rights Reserved.
www
.gastmfg.com
ISO 9001 CERTIFIED
MAINTENANCE RECORD
Date Procedure Performed
For repair parts ordering information and exploded product view, visit our website or call us at the number listed below.
We have Gast Authorized Repair Facilities throughout the world. For the most up-to-date listing, contact one of our sales
offices below: