SERVICE MANUAL

AIR STARTER
A27.G01

Mca-1-
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-2-
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 NON-
CONFORMING.

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-3-
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-4-
EXTERNAL DIMENSIONS

All GALI starters may be delivered for right or left turning.

Figure for right or left turning:

Mca-5-
1.2.- DESIGNATION

All starters have the following data marked on the body:

GALI
30 BAR MAX G A27 X (turning direction X: R - right / L - left)
NUMBER OF BASE
ROTATION (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, it’s possible to provide the next references:

Turning Reference

R (derecha) 5127000.G01

L (izquierda) 5127500.G01

Mca-6-
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-7-
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) alfa Jn (mm)

2.540 (10)
2.75
0.3 – 0.6
3
20º
3.175 (8)
3.5
4.233 (6) 0.4 – 0.7
3
Jn 3.5
15º
0.7 - 1
2.117 (12) 0.3 – 0.5
12º

Mca-8-
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-9-
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-10-
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 90º to each other, as indicated in the following figure:

01 02

A B C D

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-11-
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-12-
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

SERVO-
INTERLOCK
EXHAUST SILENCER

ELECTRO-VALVULA

Mca-13-
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-14-
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-15-
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-16-
7.2.1. - MONTHLY REVISION

M01 GENERAL REVISION OF INSTALLATION

Action to carry out Tools In the event of defect
Observe if there are leaks in the Close the corresponding general shutoff
1 installation. valve, empty the pipe and replace
deteriorated element.
Observe if there are cracks in flexible pipe Visual Close the corresponding general shutoff
2 valve, empty the pipe and replace flexible
pipe.
Close the general shutoff valve with
3
padlock and empty the pipe slowly.
Observe wear in flanks of the drive pinion Visual Remove lock nut, fit new pinion and
4 replace the nut with the corresponding
torque (9.2)
Observe cracks or marks of the drive Visual Remove lock nut, fit new pinion and
5 pinion replace the nut with the corresponding
torque (9.2)
6 Rotate the pinion manually Carry out starter internal inspection M05.
Verify tightness of front securing screws Torque Set torque as per table 3.1
7
wrench
Verify tightness of pinion securing nut Torque Set torque as per table 9.2
8
wrench
Verify state of wiring Visual Replace wiring and protect it
9
appropriately
10 Verify electrically controlled valve securing Visual Retighten screws
11 Open general shutoff valve

Mca-17-
7.2.2. - ANNUAL REVISION

M04 GENERAL REVISION: CHANGE OF SETS OF GASKETS

Action to carry out Tools In the event of defect
Close the general shutoff valve with
1
padlock and empty the pipe.
2 Loosen the 4 nuts 01. Set key 10 Change the gasket 02
3 Loosen the 4 screws 03. Allen key 10 Change the gasket 04
4 Withdraw main valve unit 05 Manual
Remove special nut 06 Tool 08 Change cup-shaped gasket 07
5
Remove nut 09 Set key 7 Change gasket 08,09,10,24
6 Mount nut 09 and washer key 08 and 07
Place main valve in its housing and Manual
7
position with the pin
Loosen the 2 screws 11 Allen key 03 Change gasket 12
8
Loosen the 4 screws 13 key T20 Change gasket 14
Dismantle tube 15 Set key 13
9 Remove cap 16 Set key 12
Withdraw membrane 17 Manual Change membrane 17
10 Mount plug 16 with sealant Set key 12
Remove screw 18 Allen key 4 Change gaskets 21 and valve 22
Remove tube 19 Set key 11
11
Remove 4 screw 20 Allen key 3

12 Remove filter 23 Screwdriver Change filter 23

13 Mount the 4 screws 03 with washer Allen key 6
14 Connect feeding sleeve with the 4 nuts 01 Set key 10

13 18 22 21 11 12
14

23

20

01

02

15

19
08
16

17 09

07 10 05 24 04 03 06

Mca-18-
M05 GENERAL REVISION: REVISION OF ROTORS AND LUBRICATION
Action to carry out Tools In the event of defect
Close the general shutoff valve with
1
padlock and empty the pipe.
2 Loosen the four nuts 01 Flat star key 11
3 Remove head and 4 washers 02 Manual
4 Withdraw main rotor 03 and secondary 04 Manual
Examine state of rotors (wear, cracks, Visual Replace with new rotors
5
etc.)
Dismantle reten 05-06-07-08 according key 09 Replace with new
6
instructions - see page 21 5907123 Key Facon U-49AD5-1 and u-49AD-1
Grease bearings Grease
7 KLUBERPLEX
BEM 34-132
8 Loosen the four screws 10 Allen key 6
Grease crown teeth Krafft KL
9
COMPLEX
Grease bearings Grease
10 KLUBERPLEX
BEM 34-132
Replace the head with the four nuts 01 Flat star key 11
11
and washers 02
Replace the crown wheel and front cover Allen key 06
12
with the four screws and their washers
13 Open general shutoff valve

Grease
KRAFFT KL COMPLEX
Grease
KLUBERPLEX BEM 34-132
Grease
03 KLUBERPLEX BEM 34-132
10

04 02 01
Grease
KLUBERPLEX BEM 34-132 Grease
KLUBERPLEX BEM 34-132
Grease
KLUBERPLEX BEM 34-132
Grease
KLUBERPLEX BEM 34-132

Mca-19-
 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. 07=ref.5127140
pos. 06=ref. 5127127 pos. 08=ref.5127137
pos. 09=ref. 5907188

09
e/c =10

05 06 07 08
R
21

lock lock lock lock

21
R

Mca-20-
Left turning starter:
pos. 05=ref. 5127140 pos. 07=ref.5127141
pos. 06=ref. 5127137 pos. 08=ref.5127127
pos. 09=ref. 5907188

09
e/c =10

05 06 07 08

26 26
R R
lock
lock lock
lock

Mca-21-
8. – CORRECTION OF POSSIBLE FAULTS (See figure page.25)

ALWAYS RESPECT THE SAFETY INSTRUCTIONS OF POINT 6 OF THIS MANUAL

FAILURE POSIBLE CAUSE CORRECTION

On pressing push- • Empty air receiver (s) • Charge receiver (s)
button, starter does not • Flow valve (s) closed. • Open flow valve (s)
respond and not air • Control circuit blocked. • Disconnect and clean out
1 flow seems to exist in • There is not signal for the • Control signal
control circuit. electro valve

On pressing push- •
Leak in control duct. . • Repair or replace.
button, starter does not
• Insufficient air pressure • Increase pressure in receiver
2 respond, although air
• Piston 7 and valve 8 sticking in • Remove and check both,
flows through control closed position smoothen guides or change parts.
circuit
• Electro valve or filter choked. • Remove and clean the same
Pinion revolves and • Ring gear and/or pinion have • Clean burrs or replace if
advances, but does not burrs or are damaged necessary. Replace pinion by a
3 engage the ring gear. more adequate one.
• Lack of clearance between • Check by distortion of ring gear.
pinion and ring gear
Pinion revolves but • Push-rod 11 inoperative • Disassemble, check, smoothen
does not advance guide diameter, clean or replace if
rusted
4 • Insufficient air pressure • Increase pressure in receiver.
• Splined shaft 19 sticking • Disassemble and clean, check
spring 22 and reassemble.
Pinion advances but • Pneumatic motor inoperative •Disassemble, inspect rotors for
does not rotate. foreign matters between teeth and
for possible wear of gears, spindles
5
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.
6
• 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
7 upon opening the flow pipes. installations instructions.

Mca-22-
 valve of the feed line, • Main valve 26 blocked and • Disassemble, clean oil and
although electro valve open, valves 8 and 9 blocked or replace joint if needed.
are not actuated.. broken.
Lack of starter power.. • Main pipe work chocked or its •
Revisar toda la tubería,
bore is less than stipulated for thecambiándola si su diámetro interior
8 starter. no es el adecuado.
• Insufficient air pressure. • Increase pressure in receiver.
• Badly worn rotors. • Replace.
After starting the • Incorrect bore of main pipe • Check entire pipe work for
engine, pinion tries to- work. correct bore and replace if incorrect.
reengage and hits the • Idling of main valve 26. • Disassemble, clean, oil and
9
ring gear which results resemble.
in damage to both. • Valve 29 or pilot 28 blocked. • Disassemble, clean, oil and
resemble. replace if needed.
Starter motor will not • Main valve 26 blocked • Disassemble, clean, oil and
stop. . reassemble.
• Piston 7 and valve 8 defective. • Disassemble, clean, oil and
reassemble. Replace if needed.
• Valve 13 does not close • Disassemble, check for correct
10
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

7 8

19 22 11 13 17 26

Mca-23-
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
REFERENCE
X

REFERENCIA
X X X

X X

ROTACION
ROTATION

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-24-
 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).

02 03

O 35 01
60

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-25-
10.- SPARE PARTS (See figure pag. 30)

POS. REF. Nº DESIGNATION QTY. NOTES.

01 0275902 TENSION WASHER 1
03 0924520 NEEDLE BEARING 1
04 0071030 ALLEN SCREW 4
06 5127120 FRONT COVER 1
07 5125009 SPECIAL JOINT 1 SET OF SEALS
08 5125002 OUTER RING BEARING 1
09 0820707 ROLLER BEARING 25
10 5125010 DISC BEARING 1
12 0121218 SPECIAL NUT 1
13 0151225 WASHER 1
14 0383504 ANILLO OBTURADOR 1 SET OF SEALS
15 5290101* HAULING CROWN - RIGHT 1
5290102** HAULING CROWN - LEFT 1
16 5125013* SPRING 1
5125513** SPRING 1
17 5125011* SPLINED SHAFT – RIGHT 1
5125511** SPLINED SHAFT - LEFT 1
18 5127130 PLUG 1
19 0301615 O-RING 1 SET OF SEALS
20 5127131 FOLLOWER 1
21 1170585.40 SCREW 2
23 5127124* MOTOR BODY - RIGHT 1
5127624** MOTOR BODY - LEFT 1
24 5127128 MAIN ROTOR 1 REPAIR KIT
25 5127134* VALVE BODY - RIGHT 1
5127634** VALVE BODY - LEFT 1
26 5290525 SILENCER 1
27 5127180 ELBOW 1
28 0120810.40 NUT 1
30 0121011.40 NUT 2
32 5124252 STUD 2
34 5202300 SERVO-LOCKER 1
39 5125084 PIPE 1
40 5290103 SILENCER 1
41 5125026 STUD 4
42 5125091 SPECIAL WASHER 4
43 5125092 SPECIAL NUT 4
44 5127136 SECUNDARY ROTOR 1 REPAIR KIT
45 5290104 CHECK VALVE 1
46 0200208 SLEEVE 1
47 5115085 MEMBRANE 1 SET OF SEALS
48 5127086 PLUG 1
50 5125058 LIP SEAL 1 SET OF SEALS
51 5127170 MAIN VALVE 1
52 0304125 O-RING 1 SET OF SEALS
53 5125105 DISTRIBUTOR 1
54 5127171 BUSHING 1
55 0300615 O-RING 1 SET OF SEALS
56 0302703 O-RING 1 SET OF SEALS
57 5127172 JOIN SHELL 1
58 0150616.30 SPECIL WASHER 1
59 0120606.30 NUT 1
60 5125065 SPRING 1
61 5125069 STUD 4
63 0120810.40 NUT 4
64 0051310 STUD 1
66 0303835 O-RING 1 SET OF SEALS
67 5125068 INLET NOZZLE 1
68 0306625 O-RING 1 SET OF SEALS
69 1251001 SPECIAL WASHER 4
70 0071030 ALLEN SCREW 4
71 5127179 PIPE FOR STOP SIGNAL 1
72 0200616 ELASTIC SPINE 1
73 5125096 PLETINE 1
74 0301102 O-RING 1 SET OF SEALS
75 0300615 O-RING 1 SET OF SEALS
76 0300415 O-RING 1 SET OF SEALS

Mca-26-
 77 5125071 FLANGE 1
78 5106076 SLEEVE 1
79 5127122 LOCKER RING 1 SET OF SEALS
80 5127121 LOCKER RING 1 SET OF SEALS
81 5127139* FRONT LOCKER – RIGHT 1
5127639** FRONT LOCKER - LEFT 1
82 0303715 O-RING 1 SET OF SEALS
83 0922023 NEEDLE BEARING 1
84 0303715 O-RING 1 SET OF SEALS
85 5127127* BIG RETAINER - RIGHT 1
5127137** BIG RETAINER - LEFT 1
86 5127137* BIG RETAINER – RIGHT 1
5127127** BIG RETAINER - LEFT 1
87 0303715 O-RING 1 SET OF SEALS
88 0922023 NEEDLE BEARING 1
89 0303715 O-RING 1 SET OF SEALS
90 0302815 O-RING 1 SET OF SEALS
91 0921518 NEEDLE BEARING 1
92 0302815 O-RING 1 SET OF SEALS
93 5127141* SMALL RETAINER – RIGHT 1
5127140** SMALL RETAINER - LEFT 1
94 0220620 PIN 2
95 5127140* RETAINER – RIGHT 1
5127141** RETAINER - LEFT 1
96 0302815 O-RING 1 SET OF SEALS
97 0921518 NEEDLE BEARING 1
98 0302815 O-RING 1 SET OF SEALS
101 0301202 O-RING 1 SET OF SEALS
102 191544k ELECTROVALVE 1
103 948002407 CONNECTOR 1
104 0301202 O-RING 1 SET OF SEALS
105 772002401 FILTER 1
106 0300412 O-RING 2 SET OF SEALS

REPAIR KIT 5290109

SET OF SEALS 5290108

Note: The repair kit includes a set of seals.

Mca-27-
 4 6 79 3 1 7 8 9 16 17
10 12 15

80
26 27 28 30

32
72
103 106 105
102
101 104
A
34
A
Clean air filter
34 periodically
39
40
71 75

23 86 87 89 25
81 82 84 85 24
76
46
18 19 74

83 92 44 88
47 48 71

21 73 20
90 91 93

45
94 41 42 43 95 96 97 98

77
63
78
61
66

50 51 52 53 54 55 56 57 58 59 60
67
64
69 70

68

Mca-28-
POS. REF. Nº DESIGNACION CANT. OBSERV.
01 0070470 SCREW 4
02 1250405 WASHER 4
03 5202301 BODY 1
04 5290735 PILOT ASSY. 1
05 5202176 LOCKER BODY 1
07 5202175 VALVE 1
08 5202183 SPRING 1
09 5202177 VALVE SUPPORT 1
11 5202178 PISTON 1
12 0301125 O-RING 1 SET OF SEALS
13 5202185 SPRING 1
14 5202186 WASHER 1
15 5202179 VALVE BODY 1
16 0300802 O-RING 1 SET OF SEALS
17 5290723 VALVE ASSY. 1 SET OF SEALS
18 5202184 SPRING 1
19 0070530 SCREW 2
20 1250506 WASHER 2
23 0301702 O-RING 1 SET OF SEALS
24 5202182 CONEXIÓN BODY 1
25 1250405 WASHER 4
26 0070425 SCREW 4
27 1080697 RACOR 1

SET OF SEALS
5290547

1 2 3 4 5 7 8 9

27

12 11 13 14 15 16 17 18

19 20 23 24 25 26

Mca-29-
12.- DISTRIBUTION AND SERVICE

GALI GROUP
ESPAÑA: FRANCE: DEUTSCHLAND (D): ITALIA:
GALI INTERNACIONAL, S.A. GALI FRANCE, S.A. GALI DEUTSCHLAND GmbH GALI ITALIA, s.r.l.
08181 SENTMENAT 66200 ELNE 55411 BINGEN 22070 SENNA COMASCO (CO)
Ctra. Molins de Rei a Vic, Km.32.7 Rue B. Thimonnier – Z.I. Am Ockenheimer Graben 32 Via Canturina Vecchia, 19
Apartado 11 Tel. 468 22 20 05 Tel. 0049-6721-10026/10027 Tel. 31 461 224 – 461 230
Tel. 93 715 31 11 Fax 468 22 47 44 Fax 0049-6721-13144 Fax 31 461 245
Fax 93 726 43 85 / 715 07 51
OTHER COMPANIES
ESPAÑA COMERCIAL DIESEL, S.L. ARDORA, S.A. DISTRIMAR, S.L.
TANAJET, S.L. 20110 PASAJE SAN PEDRO 36208 VIGO 35009 LAS PALMAS GRAN CANARIA
08039 BARCELONA GUIPÚZCOA Tomás A. Alonso, 150-152 Urbanización Nueva Isleta
Muelle Levante, 5 Arrandegi, 2 Tel. 986 21 32 38 Bloque 6 bajos
Tel. 93 221 19 48 Tel. 943 40 11 12 Fax 986 21 45 77 Tel. 928 46 61 55
Fax 93 221 30 78 Fax 943 39 13 72 Teles 83206 Fax 928 46 72 07
FRANCE: S.A.D. – SOCIETE D’APPLICATIONS
LES BRUYERES ETS. LEPETIT
GASCOGNE ENERGELEC DIESEL
F.I.R.E.M. 76600 LE HAVRE
32000 AUCH 57000 THIONVILLE
13011 MARSEILLE 80-84, R. Aviateur Guerin
4 Rue Amiral Bugard 50, Rue de da Digue
116 Boule de la Pomme Tel. 232 74 98 40
Tel. 562 05 41 31 Tel. 382 88 62 62
Tel 491 95 25 13 Fax 232 74 98 49
Fax 562 05 38 78 Fax 382 88 58 36
Fax 491 35 29 09

AES BUEAS
44300 NANTES
38, Rue l’Ouche Buron
Tel. 251 89 62 62
Fax 240 49 99 67

DEUTSCHLAND (D) NEDERLAND: NORGE: SVERIGE:

CARL BAGUHN GmbH Electra Brandt SEA-TEK A/S ATLAS MARIN & INDUSTRI
20537 HAMBURG 2231 NZ Rijnsburg 1820 SPYDEBERG 41502 GOTEBORG
Wendenstrasse 252 De Roysloot 10 Villaveien 1 U Marielholmsgatan 40
Tel. 0049-40-251 55-119 Tel. 71 402 9210 Tel. 69 83 80 80 Tel. 31 84 45 50
Fax 0049-40-251 55-150 Fax 71 402 1819 Fax 69 83 83 66 Fax 31 25 65 09

PORTUGAL:
JAMECOR PRODUCTOS QUÍMICOS
4200 PORTO
D. Eduardo Santos Silva, 261
Tel. 2 540 07 65
Fax 2 540 20 78

KOREA: SINGAPORE: NEW ZEALAND:

SAMSAWON, INC. ADEX ZONEX PTE. LTD. VM DIESELS (NZ) LIMITED
110-607 SEOUL 628623 SINGAPORE 118-120 NELSON STREET
CHONGO-KU 1 LOK YANG WAY NO.19B, PETONE
Tel. 2 395 34 00 JURON Tel. 4 568 88 43
Fax 2 396 03 40 Tel. 261 56 11 Fax 4 568 56 43
Fax 266 53 32

Mca-30-