SERVICE MANUAL

AIR STARTER
A27.G01

Mca-1-

ARRANCADOR MODELO: ________________________________

N DE SERIE: _________________________________________
CONTROL DE CALIDAD: ______________ FECHA: ___________
DISTRIBUIDOR: _____________________
FECHA: ___________

GARANTIA: GALI garantiza el producto contra vicios y defectos del material y fabricacin por UN AO desde la fecha de su venta al
usuario. Esta garanta cubre nica y exclusivamente la sustitucin gratuita de las piezas defectuosas, excluyendo toda prestacin o mano
de obra en material ajeno.
Condiciones:
1.- Haber remitido debidamente cumplimentada la tarjeta adjunta.
2.- No haber hecho uso, mantenimiento o almacenaje inadecuados.
3.- No haber efectuado modificacin alguna en el producto.
4.- Haber seguido las instrucciones de instalacin del Manual de Servicio.
GALI rehsa toda responsabilidad por daos y perjuicios que puedan producirse durante la instalacin y funcionamiento de
sus productos.
GUARANTEE: Within a period of ONE YEAR after purchase date, GALI will be liable for faulty material or manufacturing defects of
its products. The guarantee only covers free replacement of faulty parts and excludes any other indemnity or reimbursement of labour
costs involved in alien material.
The guarantee in valid only if:
1.- The attached card has been duly filled-in and mailed.
2.- The product is always being subject to proper use, maintenance and storage.
3.- No modification whatsover has been introduced in the product.
4.- The installation follow the instructions of the User Handbook.
GALI will not be liable for damage, injury or loss of any kind whatsoever, caused by or in connection with the installation or
use of its products.
GARANTIE: GALI garantit le produit contre vices et dfauts de matire et de fabrication pendant UN AN partir de la date de vente
partir de la date de vente lutilisateur. Cette garantie couvre uniquement et exclusivement le remplacement gratuir des pieces
dfectueuses, excluant toute autre prestation ou main d oeuvre sur de matriel autre que le dmarreur.
Conditions:
1.- Avoir retourn, dment complete, la carte jointe.
2.- Ne pas avoir fait un usage, entretien ou emmagainage inadapts.
3.- Navoir effectu aucune modification sur le produit.
4.- Avoir suivi len instrucions dassemblage du Manuel de Service.
GALI dcline toute responsabilit en ce qui concerne les dommages ou prjudices survenus lors de linstallation ou du
fonctionnement de ses produits.
GARANTIE: GALI Whrend EINES JAHRES nach Kaufdatum leisten wir Gewhr fr Material-und Fabrikationsfehler unserer
Erzeugnisse. Unsere Garantie deckt ausschliesslich den kostenfreien Austausch schadhafter Teile Jegliche anderen
Gewhrleistungsansprche sowie Ersatz von Lohnkosten fr Arbeiten an fremdem Material sind ausgeschlossen.
Unsere Garantie ist nur gltig wenn:
1.- Die beigefgte Karte ausgefllt un pnktlich eingesandt wird.
2.- Unsere Anweisungen bezglich Behandlung, Wartung und Lagerung genau befolgt werden.
3.- Vom Kunden keine Anderungen an unseren Produkten vorgenommen werden.
4.- Haber seguido las instrucciones de instalacin del presente manual.
Fr Beschandigung oder Verlust an Eigentum oder Personen beim Einbau oder Gebrauch der GALI-Gerte wird keine
Haftung bernommen.
GARANZIA: Durante UN ANNO dopo la data dacquisito, GALI offre garanzia per i difetti di materiale o fabbricazione dei suoi
prodotti. La garanzia comprende unicamente la sostituzione gratuita dei pezzi difettosi, ed esclude ogni altra prestazione.
Perche la garanzia sia valida, bisogna che:
1.- La cartolina allegata sia compilata e spedita puntualmente.
2.- Le instruzioni dimpiego, immagazzinaggio e manutenzione di GALI vengano sempre rigorosamente osservate.
3.- Il cliente non introduca delle modifiche sui prodotti di GALI.
4.- Haber seguido las instrucciones de instalacin del presente manual.
Rifiutasi ogni responsabilit per dan materiali o corporali eventuali che possano prodursi durante linstallazione o
funzionamento dei prodotti GALI.

Mca-2-

POR FAVOR, ENVIAR HOY MISMO / PLEASE MAIL TODAY / SVP EXPEDIER AUJOURDHUI MEME
BITTE SOFORT EINSENDEN / PREGASI DI SPEDIRE OGGI STESSO

GALI INTERNACIONAL, S.A.

Ctra. Molins de Rei a Vic, Km.32.7
Apartado 11
08181 SENTMENAT (Barcelona)
ESPAA

REFERENCIA: ______________________________________________

N SERIE: ___________________________________________________

CLIENTE / CUSTOMER / CLIENT / KUNDE:

_________________________________________________________________________________________________________

DISTRIBUIDOR / DEALER / DISTRIBUTEUR / VERTRAGSHNDLER / DISTRIBUTORE:

_________________________________________________________________________________________________________

FECHA/DATE/DATUM/DATA:
_________________________________________________________________________________________________________

Mca-3-

CONTENT :

HOW TO USE THIS MANUAL

1. - PRESENTATION OF AIR STARTER SERIES A
1.1. - EXTERNAL DIMENSIONS AND TECHNICAL DATA
1.2. - DESIGNATION
1.3. - DECLARATION OF THE MANUFACTURER
2. - TRANSPORT AND STORAGE, ASSEMBLY AND DISMANTLING
2.1. - TRANSPORT AND STORAGE
2.2. - ASSEMBLY
2.3. - DISMANTLING
3. - INSTALLATION
3.1. - POSITIONING AND ALIGNMENT
3.2. - SUPPLY OF COMPRESSED AIR
3.3. - PRESSURE READINGS
3.4. - SUPPLY OF ELECTRIC POWER
3.5. - POSSIBILITIES OF ASSEMBLY
3.5.1. INLET NOZZLE
4. - FIRST START-UP
4.1. - AIR FEEDING CIRCUIT
4.2. - CHECKING ASSEMBLY
4.3. PUTTING INTO SERVICE
5. - OPERATION
5.1. - DESCRIPTION OF ELEMENTS
5.2. - START-UP AND ENGAGEMENT
5.3. - START UP
5.4. - SHUTDOWN
5.4.1. - FOR ABSENCE OF SIGNAL
5.4.2. - FOR BACKWARD MOTION OF DRIVE PINION
5.5. - DESENGAGEMENT
5.6. - RESTART
6. SAFETY INDICATORS
7. - MAINTENANCE
7.1. - GENERAL PRECAUTIONS
7.2. - MAINTENANCE PROGRAM
7.2.1. - MONTHLY REVISION
7.2.2. - ANNUAL REVISION
8. - CORRECTION OF POSSIBLE FAULTS
9. - ACCESSORIES FOR THE INSTALLATION
9.1. DRIVE PINIONS
9.2. INLET NOZZLE
9.3. - FRONT SECURING FLANGE
10. SPARE PARTS

12. - DISTRIBUTION AND SERVICES

Mca-4-

HOW TO USE THIS MANUAL.

YOU ARE ASKED TO READ THIS MANUAL CAREFULLY IN ORDER TO ASSURE:

INSTALLATION, USE, MANIPULATION OR DISMANTLING OF THE STARTER IN A SAFE

MANNER.
MAXIMUM STARTER LIFE.
CORRECT OPERATION OF THE STARTER THROUGHOUT ITS USEFUL LIFE.

IN THE COURSE OF THE TEXT, VARIOUS INDICATIONS APPEAR. FOR THEIR CORRECT
INTERPRETATION THE FOLLOWING MEANINGS OF THE SYMBOLS SHOULD BE KEPT IN MIND:

MANDATORY REQUIREMENT: ANY INSTALLATION OF THE STARTER THAT DOES

NOT COMPLY WITH THIS REQUIREMENT, SHALL BE CONSIDERED NONCONFORMING.

RECOMMENDATION: TO OBTAIN MAXIMUM LIFETIME AND BEST OPERATION OF

THE STARTER.

IN THE INDICATIONS CORRESPONDING TO SAFETY THE SYMBOL MEANINGS ESTABLISHED BY THE

REGULATIONS IN FORCE HAVE BEEN RESPECTED.

Mca-5-

1. - PRESENTATION OF AIR STARTER SERIES A

The GALI air starters are devices generally installed as auxiliary units of thermal motors or turbines, for their
start-up.
These starters are based on the principle of two geared rotors which are turned through the action of air
pressure. This movement is subjected to the appropriate reduction to obtain a determined torque on the output
shaft. To this shaft the appropriate pinion is fitted and the movement thereof pulls the motor it is desired to start.
This pulling action is achieved by meshing the pinion of the starter with a crown wheel usually fitted on the
flywheel of the motor.
The starters have internal mechanisms to achieve the meshing and avoid their start-up until it has been carried
out successfully. They are also provided with a device that avoids reengagement.
1.1. EXTERNAL DIMENSIONS AND TECHNICAL DATA

A27
MAXIMUM POWER

25 KW

MAXIMUM TORQUE

133 Nm

MAXIMUM WORKING PRESSURE

30 bar

NET WEIGHT

13 kg

SPEED AT MAXIMUM POWER

3500 rpm

FRECUENCIA MAXIMA

4000rpm

Mca-6-

EXTERNAL DIMENSIONS
All GALI starters may be delivered for right or left turning.
Figure for right or left turning:

Mca-7-

1.2.- DESIGNATION
All starters have the following data marked on the body:
GALI
30 BAR MAX G A27 X
NUMBER OF BASE
ROTATION

(turning direction X: R - right / L - left)

(indicated by an arrow, according to turning direction)

The following diagram represents the criterion selected to determine the turning direction of the starter,
according to the relative positions of this with respect to the motor.

According to the graphic, its possible to provide the next references:

Turning

Reference

R (derecha)

5127000.G01

L (izquierda)

5127500.G01

Mca-8-

2.- TRANSPORT AND STORAGE, ASSEMBLY AND DISMANTLING

2.1. - TRANSPORT AND STORAGE

The reduced weight of the GALI starters allows their handling by a single operative for the jobs of maintenance,
assembly and dismantling.
The geometry of the starter is such that it is easy to located fastening elements which allow its transport or
lifting.
The packing which they are provided with for delivery facilitates transport and storage, at the same time as it
protects the starter from possible blows or surface damages.

The starters leave the factory with anti-rust grease that protects the internal mechanisms.
Nevertheless, it is recommended to store them in a dry place.

2.2. - ASSEMBLY
Completely remove the packing material. Remove the plastic caps that plug the holes corresponding to the inlet
nozzle and to the air outlets for accessories. The sole function of these plugs is to avoid dirt penetrating to the
interior of the starter before its final assembly.

In case any of the holes foreseen for reading the pressure (see point 3.3) are not used for this
purpose, close them in a secure manner by means of the corresponding threaded caps and
gaskets.

2.3. - DISMANTLING

Cover the access holes to the interior of the starter appropriately, avoiding the possible entry of
dirt or particles of any type. Take particular care with the caps themselves, which could
introduce or release loose particles into the interior.

In the event of the starter incorporating an electro valve, protect this particularly from impact. If
the starter will remain dismantled a long time, protect the pinion and output shaft of the starter
by means of oil or grease to prevent rusting.

Mca-9-

3.- INSTALLATION

3.1. - POSITIONING AND ALIGNMENT

It is recommended the starter be coupled to the motor by means of a front flange.

GALI can supply standard flanges, or tailored according to order requirements.

The starter can be mounted on any position on the motor, the most recommendable being to
locate the silencer below the drive pinion shaft.

If the coupling has to be made unavoidably by cylindrical cradle, it is necessary to check that
this adapts perfectly without producing local stress, assisting it if necessary with an annular
clamp.

It should be verified that there is adequate play between drive pinion and crown wheel, and that
it is constant over the length of the tooth edge. Check if the front distance of the gearing is that
indicated. Also respect the screw tightening torques of the following diagram.

m (DP)

Jn

2.540 (10)
2.75
3
3.175 (8)
3.5
4.233 (6)
3
3.5
2.117 (12)

alfa

Jn (mm)

0.3 0.6
20
0.4 0.7
15
12

0.7 - 1
0.3 0.5

Mca-10-

The starter has to be firmly joined to the motor body (not to the bed or other attached
elements). To avoid vibrations between the starter and the connection pipe, the installation is
recommended near the starter of a straight length of flexible pipe of at least 300 mm, which
complies with the regulations relative to pipes under pressure (97/23/EC).

If it is not possible to secure the starter to the body of the motor, make sure that in the
operation thereof no vibrations are produced which affect the distance between the drive pinion
and the crown wheel of the motor flywheel.

Mca-11-

3.2. - SUPPLY OF COMPRESSED AIR

The starter is designed to deliver its maximum torque at 30 bar, although this pressure will not always be
necessary to carry out start-up. The minimum pressure necessary to achieve motor start-up will depend on each
specific application. GALI guarantees that all A17 starters carry out the meshing movement and main valve
opening at least up to 8 bar.

In no case should the starter be subjected to pressures greater than 30 bar.

The air should arrive at the starter clean and dry. It is recommended an automatic purge be
fitted in the tank and a GALI air filter be connected immediately before the starter. The
installation should foresee a horizontal stretch for installation of the filter.

Unless expressly recommended otherwise, the inside diameter of the feeding pipe should not
at any point be less than 25 mm or 1 inches.

In the case of long pipes, the inside diameter should be greater than the minimum
recommended. The feeding conduit should have as short a run as possible and a minimum of
changes of direction.

To guarantee safety in starter maintenance, it is necessary to incorporate a lockable and

airtight shutoff valve which assures the isolation against pressure in the access line to
the starter when the valve is closed.

3.3. - PRESSURE TAKE-OFF

As can be seen in schematic 1.1, the starters comes with a air inlet pressure of 1 /4 threaded in the inlet
nozzle. When the starter is delivered, these sockets are plugged with the corresponding airtight cap.

It is recommended to use the free pressure socket to fit a pressure gauge, 0-40 bar.

Mca-12-

3.4. - SUPPLY OF ELECTRIC POWER

The control system incorporates a solenoid valve directly mounted on the starter, so it will be necessary to
connect the supply voltage, according to the indications for the same.

The electrical installation has to comply with the requirements of the Low Voltage
Electrotechnical Regulations.

3.5. - POSSIBILITIES OF ASSEMBLY

3.5.1. INTAKE NOZZLE
Independently of the assembly positions of the starter as a whole with respect to the motor (see point 3.1), both
the intake nozzle and the exhaust silencer are directional, to facilitate their adaptation to the motor.
Four positions are possible, at 90 to each other, as indicated in the following figure:

01

02

If not specified otherwise, the position A is that delivered as standard.

To change from one position to another, it is necessary to remove the four screws 01 and rotate the intake
nozzle 02, taking care not to damage the O-ring that joins the two pieces and situate the flexible pipe in the
most favourable position. Be careful to avoid the entry of dirt to the interior of the starter. Replace the screws,
applying a torque of 48 Nm.

Mca-13-

4- FIRST START UP
4.1. - AIR FEEDING CIRCUIT

The tube should be cleaned with pressurised air before being coupled to the starter, taking
particular care to prevent loose particles reaching the interior, due to welding the pipes or for
any other reason.

4.2. - CHECKING ASSEMBLY

Carry out all the installation checks without pressure in the line.

Check that the installation has been carried out in accordance with the general instructions provided above. In
particular, verify that the line has no passing restrictions, with regard to that indicated in point 3.2.
Check the fastening of all elements and the installation of the necessary gaskets to guarantee air-tightness in
the unions between elements.
4.3. PUTTING INTO SERVICE
ALWAYS RESPECT THE SAFETY INSTRUCTIONS OF POINT 6 OF THIS MANUAL

Before connecting the starter to an installation that is in service, the air should always
be discharged from it.

When the installation is completed, open the air feed valve carefully, observing if there is any leak; in such a
case, close it again, empty the pipe slowly and clear the problem.
Apply short low-pressure bursts manually. Ensure the meshing between the pinion and crown wheel of the
motor is correct.

Do not make the starter work at pressures greater than those indicated in the
characteristics of the unit.

The installation of a pressure gauge connected to the pipe in the air intake to the starter allows
you to make sure that there is no air remaining in the circuit and, when the starter is working, it
will be possible to determine the effective air feed pressure.

Mca-14-

5. - OPERATION

5.1. - DESCRIPTION OF THE ELEMENTS

The starter is made up of the following major blocks:
-

Main valve: it serves for opening the air passage to the interior of the starter.
Head: distribution of air to the various elements.
Motor: it includes the pair of rotors and the casing inside which the rotation takes place.
Reducer and output shaft: transmission necessary to deliver the appropriate torque and speed to the
output pinion and produce the meshing and unmeshing movements thereof.
Servo-interlock: includes the air signal valve to begin the start-up and meshing movement, as well as to
prevent re-meshing.
Exhaust silencer: limits the sound level of start-up.
Electrovalve: receives the electrical signal and converts it in a pneumatic signal

The following diagram offers a view in cross section of the main components of the starter:

MAIN VALVE

HEAD

MOTOR

REDUCER AND OUTPUT SHAFT

SERVOINTERLOCK
EXHAUST SILENCER

ELECTRO-VALVULA

Mca-15-

5.2. - START-UP AND MESHING

The starter has two successive operations:
-

First action: in which the pinion carries out an approach movement to the crown wheel and
simultaneously a double turn that favours the meshing of both elements. Only when the meshing has
been completed successfully is it possible to proceed to the second movement.
Second movement: the main valve is opened, giving the motor body the possibility to develop its
maximum power.

5.3. - START UP
Once the second movement has been carried out, the starter accelerates the motor very quickly, thereby
reducing losses in the cylinders to the maximum until the compression is achieved under appropriate conditions
for producing ignition if the fuel feed is correct.
5.4. - SHUTDOWN
The shutdown can take place for different reasons:
5.4.1. - FOR ABSENCE OF SIGNAL
If the signal fed by the electro valve or the air plunger is cut off, the starter is stopped and disengages.

Control of the signal time can contribute to reducing the consumption of start-up air and
lengthening the useful life of the starter.

5.4.2. - FOR BACKWARD MOTION OF THE DRIVE PINION

At the moment when the motor comes into operation on its own, the greater torque generated by the latter
causes disengagement and an internal mechanism produces shutdown of the starter.

5.5. DISENGAGEMENT
When shutdown takes place for any of the reasons indicated in point 5.4, the drive pinion is automatically
withdrawn to the idle position.

5.6. - RESTART
When the starter has been stopped, it will remain immobile until the control air pressure disappears (electro
valve or plunger), for which reason, in order to operate the starter again, it is necessary to cease acting on the
plunger or to disable the electro valve briefly.
Since the actual starter mechanisms are incapable of detecting whether the motor is rotating or has stopped
after a start-up intent, this operation prevents the starter from insisting on another meshing action while the
person in charge of controlling the same is not sure that the motor is totally at rest, preventing the drive pinion
from attempting to engage if the crown wheel of the motor is still in motion, which could lead to serious damage.
Before attempting a new start-up always make sure that the crown wheel of the motor has
stopped.

Mca-16-

6. SAFETY INDICATIONS

Always pay the maximum attention to possible air leaks. Always wear ear protection
when this starter is tested or compressed air discharges are made in the installation.
In the exhaust high sonic energy levels can be produced.

Always wear suitable eye protection for any maintenance operation of the starter.

For any operation on the starter, you should always close the supply and empty the
air feed pipe, by acting on the plunger when the installation is air and the electrically
controlled valve button when the installation is electric.
Disconnect, by means of a lockable shutoff valve, the air supply hose before
installing, dismantling or adjusting any accessory of this starter. The lock should
remain in place until operations on the starter are completed.
Before connecting the starter to an installation that is in service, you should always
discharge the air pressure in the same. If there is a pressure gauge at the inlet to the
starter, use it check for absence of pressure.

To avoid the risk of explosion, refrain from using air hoses or couplings in the
installation which are damaged or have not been accepted by the competent
inspection.
Never make the equipment work above the maximum useable pressure (30 bar). If
there is a pressure gauge at the inlet to the starter, use it check for absence of
pressure.
Hands or other body parts should be kept clear of the drive pinion of the starter or the
crown wheel of the motor when air pressure is present in the start-up installation.
Risk of impact and entrapment.

Do not position yourself in the discharge area of compressed air (within

approximately 3m from the exhaust silencer) during start-up, nor leave loose objects
there that could be displaced by the same.

Mca-17-

7. - MAINTENANCE

7.1. - GENERAL PRECAUTIONS

ALWAYS RESPECT SAFETY INDICATIONS DESCRIBED IN POINT 6 OF THIS MANUAL

Always close the shutoff valve with a padlock when carrying out any kind of maintenance task on the
installation. Discharge the air remaining in the pipe by activating the electrically controlled valve (the starter will
try to work, pay attention to the movements that take place), or else allow this air to discharge smoothly by
slowly loosening any plug. If there is a pressure gauge at the inlet to the starter, use it check for absence
of pressure.

Always use original GALI spare parts. The spare parts that are not GALI originals can generate
hazards or malfunctioning of the starter.

7.2. - MAINTENANCE PROGRAM

The preventive maintenance of the GALI starters greatly depends on the use that the corresponding user makes
thereof, both for the frequency of start-ups and for the type of motor. Indeed, a starter that never works
deteriorates more quickly than one which does so with a certain frequency (for example, once a week).

To achieve maximum duration and reliability in the operation of the GALI starter, the
maintenance program should be carried out which is detailed next.

Mca-18-

7.2.1. - MONTHLY REVISION

M01

GENERAL REVISION OF INSTALLATION

Action to carry out
Tools
Observe if there are leaks in the
installation.
Observe if there are cracks in flexible pipe

Visual

Close the general shutoff valve with

padlock and empty the pipe slowly.
Observe wear in flanks of the drive pinion

Visual

2
3
4

Observe cracks or marks of the drive

pinion

Rotate the pinion manually

7
8
9
10
11

Verify tightness of front securing screws

Verify tightness of pinion securing nut
Verify state of wiring
Verify electrically controlled valve securing
Open general shutoff valve

Visual

Torque
wrench
Torque
wrench
Visual
Visual

In the event of defect

Close the corresponding general shutoff
valve, empty the pipe and replace
deteriorated element.
Close the corresponding general shutoff
valve, empty the pipe and replace flexible
pipe.

Remove lock nut, fit new pinion and

replace the nut with the corresponding
torque (9.2)
Remove lock nut, fit new pinion and
replace the nut with the corresponding
torque (9.2)
Carry out starter internal inspection M05.
Set torque as per table 3.1
Set torque as per table 9.2
Replace wiring and protect it
appropriately
Retighten screws

Mca-19-

7.2.2. - ANNUAL REVISION

M04
1
2
3
4
5
6
7
8
9
10
11
12
13
14

GENERAL REVISION: CHANGE OF SETS OF GASKETS

Action to carry out
Tools
Close the general shutoff valve with
padlock and empty the pipe.
Loosen the 4 nuts 01.
Set key 10
Loosen the 4 screws 03.
Allen key 10
Withdraw main valve unit 05
Manual
Remove special nut 06
Tool 08
Remove nut 09
Set key 7
Mount nut 09 and washer
key 08 and 07
Place main valve in its housing and
Manual
position with the pin
Loosen the 2 screws 11
Allen key 03
Loosen the 4 screws 13
key T20
Dismantle tube 15
Set key 13
Remove cap 16
Set key 12
Withdraw membrane 17
Manual
Mount plug 16 with sealant
Set key 12
Remove screw 18
Allen key 4
Remove tube 19
Set key 11
Remove 4 screw 20
Allen key 3
Remove filter 23
Mount the 4 screws 03 with washer
Connect feeding sleeve with the 4 nuts 01

Screwdriver
Allen key 6
Set key 10

In the event of defect

Change the gasket 02

Change the gasket 04
Change cup-shaped gasket 07
Change gasket 08,09,10,24

Change gasket 12
Change gasket 14

Change membrane 17
Change gaskets 21 and valve 22

Change filter 23

13

18

22

21

11

12
14
23
20
01
02

15
19
08

16

09

17

07

10

05

24

04

03

06

Mca-20-

M05
1
2
3
4
5
6
7
8
9
10
11
12
13

GENERAL REVISION: REVISION OF ROTORS AND LUBRICATION

Action to carry out
Tools
In the event of defect
Close the general shutoff valve with
padlock and empty the pipe.
Loosen the four nuts 01
Flat star key 11
Remove head and 4 washers 02
Manual
Withdraw main rotor 03 and secondary 04 Manual
Examine state of rotors (wear, cracks,
Visual
Replace with new rotors
etc.)
Dismantle reten 05-06-07-08 according
key 09
Replace with new
instructions - see page 21
5907123
Key Facon U-49AD5-1 and u-49AD-1
Grease bearings
Grease
KLUBERPLEX
BEM 34-132
Loosen the four screws 10
Allen key 6
Grease crown teeth
Krafft KL
COMPLEX
Grease bearings
Grease
KLUBERPLEX
BEM 34-132
Replace the head with the four nuts 01
Flat star key 11
and washers 02
Replace the crown wheel and front cover Allen key 06
with the four screws and their washers
Open general shutoff valve

Grease
KRAFFT KL COMPLEX
Grease
KLUBERPLEX BEM 34-132
03

Grease
KLUBERPLEX BEM 34-132

10

04
Grease
KLUBERPLEX BEM 34-132
Grease
KLUBERPLEX BEM 34-132

02

01

Grease
KLUBERPLEX BEM 34-132

Grease
KLUBERPLEX BEM 34-132

Mca-21-

For lubrication always use the grease and oil indicated below:
O-rings: TELLUS 32 oil.
Bearings and rollers: KLUBERPLEX BEM 34-132 grease.
Main rotor and crown teeth: KRAFFT KL COMPLEX grease

Right turning starter:

pos. 05=ref. 5127141
pos. 06=ref. 5127127
pos. 09=ref. 5907188

pos. 07=ref.5127140
pos. 08=ref.5127137

09

05

e/c =10

07

06

08

R
21
lock

lock

lock

lock

21

Mca-22-

Left turning starter:

pos. 05=ref. 5127140
pos. 06=ref. 5127137
pos. 09=ref. 5907188

pos. 07=ref.5127141
pos. 08=ref.5127127

09

e/c =10

05

06

07

26

lock
lock

08

lock

26

lock

Mca-23-

8. CORRECTION OF POSSIBLE FAULTS (See figure page.25)

ALWAYS RESPECT THE SAFETY INSTRUCTIONS OF POINT 6 OF THIS MANUAL

FAILURE
On pressing pushbutton, starter does not
respond and not air
flow seems to exist in
control circuit.

POSIBLE CAUSE
Empty air receiver (s)
Flow valve (s) closed.
Control circuit blocked.
There is not signal for the
electro valve

On pressing pushbutton, starter does not

respond, although air
flows through control
circuit

Leak in control duct. .

Repair or replace.

Insufficient air pressure

Increase pressure in receiver

Piston 7 and valve 8 sticking in

Remove and check both,

closed position
Electro valve or filter choked.
Pinion revolves and
Ring gear and/or pinion have
advances, but does not burrs or are damaged
engage the ring gear.
Lack of clearance between
pinion and ring gear
Pinion revolves but
Push-rod 11 inoperative
does not advance

Insufficient air pressure

Splined shaft 19 sticking

Pinion advances but

does not rotate.
5

Pneumatic motor inoperative

CORRECTION
Charge receiver (s)
Open flow valve (s)
Disconnect and clean out
Control signal

smoothen guides or change parts.

Remove and clean the same
Clean burrs or replace if
necessary. Replace pinion by a
more adequate one.
Check by distortion of ring gear.
Disassemble, check, smoothen
guide diameter, clean or replace if
rusted
Increase pressure in receiver.
Disassemble and clean, check
spring 22 and reassemble.
Disassemble, inspect rotors for

foreign matters between teeth and

for possible wear of gears, spindles
and bearing.
Check valve 13 stuck of
Disassemble, clean, oil and
blocked.
reassemble .
Pinion engages gear
Main valve 26 blocked.
Disassemble, clean, oil and
ring, but will not turn
reassemble or replace main valve.
engine.
Rotors worn or blocked.
Disassemble, clean, oil and
reassemble or replace rotors.
Insufficient air pressure
Increase pressure in receiver.
Main air pipe work restricted or Check all pipe work and replace
insufficient bore.
joint it if necessary.
Membrane 17 broken.
Replace it.
Starter starts working Incorrect connection of control Connect control pipes as per
upon opening the flow pipes.
installations instructions.

Mca-24-

valve of the feed line,

although electro valve
are not actuated..
Lack of starter power..
8

Main valve 26 blocked and

Disassemble, clean oil and

replace joint if needed.

open, valves 8 and 9 blocked or

broken.
Main pipe work chocked or its
bore is less than stipulated for the
starter.
Insufficient air pressure.
Badly worn rotors.
After starting the
Incorrect bore of main pipe
engine, pinion tries to- work.
reengage and hits the Idling of main valve 26.
ring gear which results
in damage to both.
Valve 29 or pilot 28 blocked.
Starter motor will not
stop. .

10

Revisar toda la tubera,

cambindola si su dimetro interior

no es el adecuado.
Increase pressure in receiver.
Replace.
Check entire pipe work for
correct bore and replace if incorrect.
Disassemble, clean, oil and
resemble.
Disassemble, clean, oil and
resemble. replace if needed.
Main valve 26 blocked
Disassemble, clean, oil and
reassemble.
Piston 7 and valve 8 defective. Disassemble, clean, oil and
reassemble. Replace if needed.
Valve 13 does not close
Disassemble, check for correct
properly
closing of the ball and the plug,
press the valve against its seat.
Splined shaft 19 blocked.
Disassemble, clean., check
spring 7

28 29
9

19

22

11

13 17

26

Mca-25-

9. - ACCESSORIES FOR INSTALLATION

Complete installation of any motor can be carried out on order.

GALI can furnish the following accessories to facilitate its assembly when the client prefers to carry out his own
installation:
9.1. DRIVE PINIONS
Besides a great number of standard pinions, GALI can provide specific drive pinions for any application of its
starters.
All the pinions that GALI supplies have the reference number indicated and direction of rotation on the face
opposite the entry of the teeth.

X X
X

REFERENCE
R
EFERENCIA

X X X

X X

ROTATION
R
OTACION
The usual fastening of the drive pinion is implemented by means of a two-part lock nut, with the tightening
torques indicated:
Different fastening methods can be supplied to order.

Mca-26-

Installation of the starter on the motor should assure the assembly of the same so
that the pinion is sufficiently protected to avoid risk of entrapments between the latter
and the crown wheel of the motor, or rubbing against the same. This protection
should be designed such that it catches possible fragments in the event of breakage
of the pinion or crown teeth.

9.3. INTAKE NOZZLE

The starters are delivered fitted with a standard connection nozzle (01) to which the air intake tube (02) can be
welded which connects it with the tank (or with the corresponding intermediate elements, cutoff valve, flexible
pipe, filter or any other piece).

In the event of using it this way, the welding (03) must be airtight and comply with the
corresponding regulations for pressure equipment (97/23/EC).

03

02

01

60

O 35

04
05

The nozzle has to be fixed to the starter with the four self-locking nuts (04) which are supplied untightened. Do
not forget to insert the O-ring (05) which is provided between the nozzle and the starter. Assure the correct
assembly of the same and avoid it being badly positioned, which would damage the same and mean loss of air.
If, during the assembly, this gasket is damaged it will be necessary to replace it with a new identical one.

9.2. - FRONT SECURING FLANGE

As well as a great number of standardized flanges, GALI can deliver specific front securing flanges for any
application of its starters.

Mca-27-

12.- DISTRIBUTION AND SERVICE

GALI GROUP
ESPAA:
GALI INTERNACIONAL, S.A.
08181 SENTMENAT
Ctra. Molins de Rei a Vic, Km.32.7
Apartado 11
Tel. 93 715 31 11
Fax 93 726 43 85 / 715 07 51

FRANCE:
GALI FRANCE, S.A.
66200 ELNE
Rue B. Thimonnier Z.I.
Tel. 468 22 20 05
Fax 468 22 47 44

DEUTSCHLAND (D):
GALI DEUTSCHLAND GmbH
55411 BINGEN
Am Ockenheimer Graben 32
Tel. 0049-6721-10026/10027
Fax 0049-6721-13144

ITALIA:
GALI ITALIA, s.r.l.
22070 SENNA COMASCO (CO)
Via Canturina Vecchia, 19
Tel. 31 461 224 461 230
Fax 31 461 245

OTHER COMPANIES
ESPAA
TANAJET, S.L.
08039 BARCELONA
Muelle Levante, 5
Tel. 93 221 19 48
Fax 93 221 30 78
FRANCE:
GASCOGNE ENERGELEC
32000 AUCH
4 Rue Amiral Bugard
Tel. 562 05 41 31
Fax 562 05 38 78

COMERCIAL DIESEL, S.L.

20110 PASAJE SAN PEDRO
GUIPZCOA
Arrandegi, 2
Tel. 943 40 11 12
Fax 943 39 13 72

ARDORA, S.A.
36208 VIGO
Toms A. Alonso, 150-152
Tel. 986 21 32 38
Fax 986 21 45 77
Teles 83206

DISTRIMAR, S.L.
35009 LAS PALMAS GRAN CANARIA
Urbanizacin Nueva Isleta
Bloque 6 bajos
Tel. 928 46 61 55
Fax 928 46 72 07

LES BRUYERES
F.I.R.E.M.
13011 MARSEILLE
116 Boule de la Pomme
Tel 491 95 25 13
Fax 491 35 29 09

ETS. LEPETIT
76600 LE HAVRE
80-84, R. Aviateur Guerin
Tel. 232 74 98 40
Fax 232 74 98 49

S.A.D. SOCIETE DAPPLICATIONS

DIESEL
57000 THIONVILLE
50, Rue de da Digue
Tel. 382 88 62 62
Fax 382 88 58 36

NEDERLAND:
A D T B.V.
3300 AK DORDRECHT
Buitenkalkhaven 2/6
Tel. 78 613 61 77
Fax 78 614 97 42

NORGE:
SEA-TEK A/S
1820 SPYDEBERG
Villaveien 1 U
Tel. 69 83 80 80
Fax 69 83 83 66

SVERIGE:
ATLAS MARIN & INDUSTRI
41502 GOTEBORG
Marielholmsgatan 40
Tel. 31 84 45 50
Fax 31 25 65 09

SINGAPORE:
ADEX ZONEX PTE. LTD.
628623 SINGAPORE
1 LOK YANG WAY NO.19B,
JURON
Tel. 261 56 11
Fax 266 53 32

NEW ZEALAND:
VM DIESELS (NZ) LIMITED
118-120 NELSON STREET
PETONE
Tel. 4 568 88 43
Fax 4 568 56 43

AES BUEAS
44300 NANTES
38, Rue lOuche Buron
Tel. 251 89 62 62
Fax 240 49 99 67
DEUTSCHLAND (D)
CARL BAGUHN GmbH
20537 HAMBURG
Wendenstrasse 252
Tel. 0049-40-251 55-119
Fax 0049-40-251 55-150
PORTUGAL:
JAMECOR PRODUCTOS QUMICOS
4200 PORTO
D. Eduardo Santos Silva, 261
Tel. 2 540 07 65
Fax 2 540 20 78
KOREA:
SAMSAWON, INC.
110-607 SEOUL
CHONGO-KU
Tel. 2 395 34 00
Fax 2 396 03 40

Mca-32-