5130-SM (Rev.

D – Jul 2019)

o SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINTS SAFETY INFORMATION

o READ AND UNDERSTAND THIS MANUAL BEFORE USING AND INSTALLING THIS DEVICE

o A NOT PROPER USE OF THE DEVICE COULD RESULT IN INJURY

SERVICE MANUAL
AIR STARTER FOR DIESEL AND GAS INTERNAL
COMBUSTION ENGINES
Type S30

S30 service manual

 5130-SM (Rev. D – Jul 2019)

CONTENT

1. GUARANTEE INFORMATION............................................................................................3

2. GENERAL INFORMATION.................................................................................................3

3. SAFETY INFORMATION ....................................................................................................4

4. PRODUCT IDENTIFICATION .............................................................................................4

5. PERFORMANCE DATA .....................................................................................................7

6. INSTALLATION ON ENGINE .............................................................................................8

7. COMPRESSED AIR INSTALLATION REQUIREMENTS ..................................................11

8. STARTER OPERATION RECOMMENDATIONS .............................................................13

9. ELECTRIC POWER SUPPLY...........................................................................................14

10. MAINTENANCE ...............................................................................................................15

11. TROUBLESHOOTING ......................................................................................................17

12. SPARE PARTS ................................................................................................................18

13. DISTRIBUTORS AND SERVICE ......................................................................................34

14. APPENDIX .......................................................................................................................35

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1. GUARANTEE INFORMATION
GUARANTEE: Within a period of ONE YEAR after the 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 is valid only if:

1. The product has always been subjected to proper use, maintenance and storage.
2. No modification whatsoever has been introduced in the product.
3. The installation follows the instructions on this manual.

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.
GALI refuses all the responsibility for damage and losses caused by an incorrect use or maintenance of its products.

2. GENERAL INFORMATION
The purpose of this manual is to provide the required information for a correct use and installation of the
air starter type S30.

The S30 Gali air starter is a lubrication free starting and cranking device and it is intended for its
installation on main and auxiliary reciprocating diesel or gas engines of an approximate range of 750-
3200 kW (1020-4350 HP), although the suitability depends, in practice, on the engine total displacement
and the gear ratio between the starter’s driving pinion and the engine’s flywheel ring gear.

The S30 is suitable to operate directly at the high pressure of 3 MPa so no external equipment or
additional control air piping is required to reduce the air pressure of stored in the air reservoirs. The
engine characteristics, (the compressed air conditions and the ambience temperature, among others)
will determine the exact minimum starting pressure. The starter will be able to start within the range from
the maxim installation air pressure (3 MPa max. in case of S30 starter), to the minimum starting pressure.

The S30 air starter is designed to operate with compressed air, nitrogen or natural gas (ask Gali for
natural gas application). Refer to chapter 7 for the required air quality (the word “air” will be used in this
manual to refer to the previously mentioned gases). Its operation principle is based on an engaged gear
pair (rotors) that, thanks to air pressure, are able to rotate. The torque generated by the rotors is
multiplied by an internal reduction mechanism connected to the output shaft. A driving pinion assembled
to the output shaft will engage the ring gear transmitting the required torque to accelerate the engine
until the required speed.

The S30 air starter is equipped with an internal mechanism to assure a correct engagement and to avoid
premature disengagement before the engine is started up. Additionally, a safety mechanism avoids the
starter to reengage the ring gear in case of non-interrupted starting signal, and starter’s overspeed. The
S30 air starter can also be used as a gas turbine cranking system.

Gali Internacional strongly recommends reading carefully this manual before the use and installation of
the S30 air starter. For further information, feel free to contact one of our dealers or distributors, or directly
with Gali Internacional (refer to Chapter 13 “Distributors and Service”).

3. SAFETY INFORMATION
Some safety indications are detailed along this manual. For a correct interpretation, the following symbol
criteria should be considered:

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▪ Essential requirement: all starter installation that is not according to the corresponding
requirement will be considered as “no conforming”.

▪ Recommendation: to obtain the maximum lifetime and best operation of the starter.

▪ Warning: if the corrective actions are not taken into account injury or damage could occur.

Gali recommends using always PPE when manipulating the air starter.

Symbol meanings established by the regulations have been respected for the indications corresponding
to safety. Starter assembly to the engine must be carried out by qualified personnel. On this regard, the
qualified personnel must be trained, instructed and familiar with the system. In the event of injury or
damage caused by failure on following the safety instructions or procedures for inappropriate conduct, or
using the starter for other purposes, the manufacturer is not responsible.

4. PRODUCT IDENTIFICATION
The product can be identified of two ways:
1) By means of the starter’s nameplate, which is located on the back of starter’s main valve housing (on
left side for counter clockwise starters, figure 5130M7800SM, and on right side for clockwise ones, figure
5130M6800.05SM, viewed from behind), that provides the following information: model, type, max. power,
max. starter’s allowable pressure, rotation, serial number, manufacturing year, part number and
manufacturer’s address (figures 5130001SM and 5130002SM).

2) By means of the inscription on starter’s rotor housing placed at right side (for clockwise and for counter
clockwise starters), that provides the following information: maximum starter’s allowable pressure, model,
sense of rotation (R = right, L = left), serial number and an arrow that informs about the rotation sense
(figures 5130001SM and 5130002SM).

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Do not operate this starter at pressures greater than those indicated in the product identification.

1. Conformity mark (validation test).

2. Body inscription.
3. Identification plate.

1. Identification plate
2. Starter’s body.
3. Maximum working pressure (30 bar)
4. Sense of rotation (R=CW, L=CCW).
5. Serial number.
6. Sense of rotation arrows (viewed from
pinion end).
CCW
CW
7. Conformity mark (validation test).
8. Reduction body.

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Right rotation means that the starter will

turn clockwise (CW) viewed from its pinion
end. Left rotation means that the starter
will turn counterclockwise (CCW) viewed
from its pinion end (see figure
5130003SM).

Depending on the starter’s placement side on the engine, the latter will turn CW or CCW (see figure 1).

Figure 1. Starter’s sense of rotation

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5. PERFORMANCE DATA
Figure 2 shows the typical output torque and power versus speed (measured at starter’s output shaft) at
different air pressures at air starter’s inlet. Figure 3 shows the typical air consumption at different air
pressures at air starter’s inlet. Air consumption is referred to FAD conditions (1.013 bar, 20º C).

Figure 2. Torque and power diagram Figure 3. Air consumption diagram

The following table shows the main performance data of S30 air starter:

S30
Maximum working pressure 3 MPa (435.1 psig)
Maximum power 41.5 kW (55.6 HP)
Maximum torque (0 rpm) 305 Nm (225 lbf·ft)
Minimum pressure operating Normal Engagement: 0,6 MPa (87 psig) / Soft Engagement: 1 MPa (145 psig)
Net weight 21 kg (46.3 lb)
Speed at maximum power 2500 min-1
Maximum speed 3500 min-1
Sound level 120 dB(A)
Working temperature range -20 to +80º C
Table 1. Air starter technical data

▪ Do not operate this starter unless it is installed on an engine (do not operate it free of load).

▪ Do not exceed the air starter maximum speed. Adjust the air starter declutching speed and
pinion – ring gear transmission ratio to avoid over speed. Over speed may reduce air starter’s
lifetime. Ask Gali for technical guidance.

▪ Always follow the engine maker instructions for the engine start up.

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6. INSTALLATION ON ENGINE

6.1. SECURING ON ENGINE

The starter can be coupled to the engine by different ways:

1) By means of a flange (that assures the
connection dimensions, almost always
according to SAE J542B).
2) By bracket, in case the engine is not equipped
with flywheel housing (big size engines
mainly).
3) By cradle, where the starter is assembled by
its body diameter to the engine block (very
unusual system).

To get a secure coupling of the starter to the engine, it is recommended to use 8.8 quality screws tightened
with a proper torque (see picture 5130004SM):

1. Pinion nut: use a torque wrench to tighten it to the specified torque. Two types of pinion nut may be used. (See chapter 12 spare
parts).

Case Item Size Type Additive Value/Standard

M14 x 1.5 76 Nm (Nut)
TYPE 1 Nut + Counternut Tightening torque Loctite 243
(fine pitch) 63 Nm (Counternut)

SINGLE NUT DIN 980V M14 x 1.5

TYPE 2 Tightening torque Loctite 243 100 Nm
8.8 (fine pitch)

2. Driving pinion.
3. SAE J542B (or another standard) coupling flange or bracket.
4. Starter’s front cover; maximum available threaded length: 27 mm

5. Coupling flange screws: use a torque wrench to tighten them to the specified torque:

Item Size Type Additive Value/Standard

4÷8 Screws 8.8 M12 Tightening torque Loctite 243 59 Nm

For the pinion nut (1) tightening, apply Loctite 243 or equivalent product to the starter’s output shaft thread
to increase the union resistance against loosening due to vibrations. Let the union get dried for 24 hours.
Do the same for the bracket or coupling flange securing screws (5).

In case of pinion replacement or dismantling, a new tightening nut (1) and washer must be used
for pinion reassembly. The washer is not a standard market component as it is the nut. See spare
parts kit 5290999.

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6.2. DISTANCE TO ENGINE’S RING GEAR

The distance between the pinion front and engine’s

ring gear front must be 6 mm with an allowable
tolerance of 1 mm.

1. Engine’s ring gear.

2. Driving pinion.

▪ In order to assure a correct engagement between ring gear and pinion and high lifetime,
both elements must be correctly aligned.

▪ In order to assure a correct engagement between ring gear and pinion, engine’s ring gear
teeth must be heat treated. For a hardness value recommendation, please contact Gali.

▪ In order to obtain a suitable geometry of the ring gear to get the best functionality, please
contact Gali to assistance with the design.

▪ Ring gear and pinion lubrication with grease is recommended.

6.3. BACKLASH ADJUSTMENT

To assure a correct mating and smooth operation between pinion and ring gear, the following normal
backlash (jn) values must be adopted depending on the teeth module or DP, and on the pressure angle.
The normal backlash is the gap between engine’s ring gear and starter’s pinion teeth flanks.

α jn (normal backlash,
Module DP
(press. angle) mm)
10
2.54 0.3 ÷ 0.6
10/12
2.75 -
3 -
8
3.175
8/10 20º
3.5 -
4 -
0.7 ÷ 1.0
6
4.233
6/8
5 - 1. Pinion.
3 - 2. Ring gear.
3.5 -
14.5 – 15º
4 -
12
2.117 0.3 ÷ 0.5
12/14 12°
Table 2. Backlash adjustment.

A normal backlash greater than that recommended above could provoke overstress on starter’s
driving pinion and so premature failure. A normal backlash smaller than that recommended
above could provoke engagement failure. Ask Gali in case of doubt.

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6.4. AIR STARTER POSITION

The air starter can be placed at any position on the engine, but the most recommendable is the one with
exhaust below the output shaft level (270º), or at 0º or 180º. In order to avoid the possible condensates
to get inside the starter’s body.

Intermediate positions are also possible (45º, 60º, etc), depending on the bolt pattern of the
engine’s flywheel housing and/or the starter’s coupling flange (usually according to SAE
J542B). Ask Gali in case of doubt.

Do not lift the starter by the exhaust silencer.

In case of installation by bracket, the air starter needs to be directly assured by 8 x M12 bolts class 8.8
on the 8 threaded holes on the starter’s front cover. This will allow a positioning angle range of 8 positions,
one per 45º degrees rotation. The required tightening torque for front cover’s bolts is 59 Nm. Use of Loctite
243.

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With regard to the air inlet, it can also be positioned

at 2 different positions to allow the adaptation with
the starting air supply piping system of the engine.

1. Use a torque wrench to tighten the screws of inlet bend (1) to the specified torque (be sure that there is a washer type AET
for screws DIN 912, size M8, for every screw).

Item Size Type Additive Value/Standard

4 screws 8.8 DIN 912 M8x80 Tightening torque Loctite 243 14 Nm

2. Inlet bend.

The most recommendable position for the air inlet is one with the orifice facing down in order to let the
possible condensates inside the piping system flow downstream just before the air enters inside the starter.

▪ Please, ask Gali to deliver the starter with the suitable inlet bend position in order to permit a
correct installation to the air starting pipe. If not specified otherwise, position 0º is delivered
as standard for CCW and CW starters.
▪ Exhaust silencer position can also be adapted according to customer’s requirements (0º or
180º). Please, ask Gali to implement those modifications.

7. COMPRESSED AIR INSTALLATION REQUIREMENTS

7.1. COMPRESSED AIR QUALITY

The starter is designed to deliver its maximum torque at 3 MPa (435.1 psig), although this pressure will
not always be necessary to carry out the start-up. The minimum pressure necessary to start the engine
will depend on each specific application.

In no case the starter should be submitted to pressures greater than 30 bar (435.1 psig).

The air should arrive to the starter as clean and dry as it is possible. The air starter operation and lifetime
will be optimum if the compressed air has got a minimum quality. Condensates are not allowed to get into
the starter. A minimum particle filtering degree of 600 microns is required.

Air condensates (mixed with oils or not) inside the starter may cause parts damage and
corrosion and/or malfunctioning.

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7.2. COMPRESSED AIR INSTALLATION CONNECTION TO STARTER

Unless specifically recommended otherwise, the inner diameter of the air starting pipe should not be at
any point smaller than 36 mm or 1 3/8” inches. In case of long pipes, the inner diameter should be greater
than the minimum recommended to avoid excessive pressure drop and assure the maximum air pressure
at air starter’s inlet. The compressed air pipe between the air receiver and the starter should have the
less changes of direction (tee, elbows) and reductions as possible.

The starter’s inlet is provided with a ⅛” BSPP female threaded connection port on the inlet bend ready to
install a pressure transmitter or a pressure gauge.

▪ To guarantee the safety during the starter maintenance, it is necessary to install an isolation
valve which assures a main starting air pipe free of pressure.
▪ Before air starter operation, check that all unions are correctly tightened, and no air
leakages exist.
▪ Respect and follow always the local or applicable regulations with regard to pressure
equipment and piping.
▪ In case of new installations, it is recommended to blow up the air piping system before
assembling the starter to avoid that dirt and welding burrs get inside the starter.
▪ Overload on air starter’s inlet bend may cause damages on the part.

Different inlet air connections can be supplied under

request; flanged (DIN, SAE, JIS…), threaded
(BSPP/T, UNF, NPT…), male or female compression
type DIN 2353, etc. The S30 air starter is delivered
with a flange type connection as standard, with the
following dimensions (see picture 5130010SM):

1. Threaded port BSPP ⅛” female auxiliary connection.

2. Inlet bend.
3. M8 stud or bolts: use a torque wrench to tighten the nuts (5) or bolts to the inlet bend (2) to the specified torque:

Item Size Type Additive Value/Standard

4 x nuts (5) (in case of deliver nuts)
M8 Tightening torque Loctite 243 14 Nm
4 x bolts + 4 x washers (in case of deliver bolts)

4. Suitable O-ring can be supplied with the starter (size 47.2x3.5, NBR 72).
5. M8 nut (recommended types: “prevailing nut” BN 80175 or “self-locking nut” DIN 985).

▪ The air starter is delivered without studs+nuts or bolts on the inlet bend, although it is possible
to supply them together with the starter under request.

▪ Installing a suitable flexible hose pipe between the air starter’s inlet and the air starting pipe
is recommended to avoid transmission of vibration from the engine to the starter. The
minimum recommended length is 300 mm.

See the diagram on chapter 14.3 of this manual for the recommended air installation sketch.

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8. STARTER OPERATION RECOMMENDATIONS

8.1. NORMAL OPERATION

The starter declutching speed should be as lower as possible in order to increase as maximum the
starter’s lifetime and in order to reduce the air consumption. The less the engine firing speed can be, the
less the starter declutching speed will be.

Galí air starter engages and declutches automatically when the start signal is ON and OFF; respectively
the starter can be activated by a solenoid valve (integrated on the starter or external), or by a manual
start valve. When the starter stops, it will remain immobile until the control air pressure disappears
(solenoid valve or plunger is switched all), for which reason, in order to operate the starter again, it is
necessary to cease acting on the plunger or to disable the solenoid valve briefly. This operation prevents
the starter from insisting on another engagement action while the person in charge of controlling the
same is not sure that the engine is totally stopped, preventing the drive pinion from attempting to engage
if the crown wheel of the engine is still in motion, which could lead to serious damage.

The following starting sequences are commonly used to start an engine:

NORMAL START SEQUENCE START SEQUENCE WITH CRANKING (OR SLOW TURN)

STARTER SIGNAL ON
1 1 - START SIGNAL ON 1
Air starter start BUTTERFLY VALVE ON
solenoid valve
0 - START SIGNAL OFF STARTER SIGNAL OFF
0 0

ENGINE IDLE SPEED ENGINE IDLE SPEED

ENGINE SPEED ENGINE SPEED

STARTER DECLUTCHING SPEED STARTER DECLUTCHING SPEED

CRANKING TIME
ENGINE FIRING SPEED
ENGINE FIRING SPEED
1

STARTING TIME TIME

STARTING TIME TIME

The air starter engages the ring gear and accelerates the engine Curve 1: the air starter engages the ring gear and turns the engine
until the firing speed. The engine declutching signal can be during a defined time for cranking process. After this time the starter
materialized just an instant after. will accelerate the engine until the firing speed and will get
declutched just after.

Curve 2: the air starter engages the ring gear. The butterfly valve or
the slow turning system (which can be equipped on the air starter
under request) are also activated at the same time. The starter turns
the engine during a defined time for cranking process at a lower
speed than in curve 1 thanks to one of the previously mentioned
systems. Then, the butterfly valve or the slow turning system is
deactivated and then the starter is able to accelerate the engine until
the firing speed and just an instant after, the starter can be
declutched.

It is strongly recommended the use of Gali butterfly valve, or the

slow turn system in case of requiring a long cranking process. By
this way, the cranking speed can be adjusted to avoid air starter
overspeed or excessive air consumption. The slow turning system
is also used as a safety starting system, especially for engines that
require a gradual and accurate starting sequence (mainly DF and
gas engines to check condensates inside the cylinder heads –
“water stroke” - or for unburned fuel removal). Ask Gali commercial
dept. for more information about these applications.
Figures 3 and 4. Start sequence.

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▪ Other starting sequences are possible according to each particular application (double
starter system, etc). Ask Gali or one of our distributors and representatives for technical
support. Gali offers the attendance to the starting tests in order to get the most efficient start
sequence.

▪ Do not activate the starter while the engine is running.

8.2. MANUAL OPERATION

The starters provided with a solenoid valve can be

activated by means of the manual start button which is
located on the solenoid valve body as shown in figure
5130011SM.

1. Manual start button.

2. Solenoid valve.

Whatever the type of solenoid valve that is provided

with a Gali starter, those will be always equipped with
an emergency manual start button (if not specified
otherwise)

Several models of solenoid valve can be delivered with the starter under request.

9. ELECTRIC POWER SUPPLY

In the cases where the engine control system is ready to electrically activate the starter, it will be
necessary to connect a voltage supply to the starter’s solenoid valve according to the indications for the
same. Gali starters can be delivered with a start solenoid valve according to customers’ needs and
completely integrated on the starter. In case that an electric activation of the starter is required, and no
further requirements are specified on this regard, the solenoid valve delivered will be 24 V DC (6 W) with
connector DIN EN 175301-803 and with manual emergency start button.

▪ The electrical installation must comply with the local applicable electro technical regulations.

▪ In case of solenoid valve maintenance, it is recommended to replace it completely. See spare

parts chapter of each specific starter kit manual (PM – Parts Manual).

▪ Do not try to dismantle the components of the solenoid valve.

▪ The connection cable to the solenoid valve must not be strained to avoid overload on the valve.

▪ The valve’s coil must not be loaded by the cable weight. Cable clamping is recommended to
avoid vibration transmission from the engine.

▪ Do not try to lose the nuts or screws of the valve itself (except those for disassembling it from
the air starter servo-locker and base plate screws.

Cable

Coil Nut

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10. MAINTENANCE

▪ Close always the compressed air pipe isolation valve with a blocking element when carrying
out any kind of maintenance task on the installation. Release the air remaining in the pipe by
manual or electrical activation of the starter’s solenoid valve (the starter will try to work, pay
attention to the movements that take place), or allow this air to discharge smoothly by slowly
loosening any plug or actuating an automatic or manual discharge valve. If there is a pressure
gauge, use it to check the absence of pressure.

▪ Always use original GALI spare parts to assure continued and reliable performance for many
years. The spare parts that are not GALI originals can generate hazards or malfunctioning of
the starter.

▪ In order to achieve the maximum lifetime and reliability of the starter, preventive maintenance
schedule should be suited as is detailed next.

Always use the greases and oils shown below (see also chapter 12.4):

▪ OILS:
SHELL OMALA S4 GX (or equivalent).
O-rings (oil or teflon lube)
▪ TEFLON LUBE:
BARDAHL SUPER TEFLUBE LDS (or equivalent).

Splined shaft, servo-locker parts,

pusher and main valve parts (teflon BARDAHL SUPER TEFLUBE LDS (or equivalent).
lube)

▪ MOBIL MOBILITH SHC 100 GREASE (included on spare

parts kit ref. 5290827).
Bearings and rollers (grease)
▪ KLUBERPLEX BEM 34-132 GREASE (alternative grease).

▪ MOBIL MOBILITH SHC 1500 GREASE (included on spare

parts kits ref. 5290827).
Main rotor and crown teeth (grease)
▪ KRAFFT KL COMPLEX GREASE (alternative grease)

Table 3. Lubrication.

See the following pages for a detailed explanation of the maintenance works and regularity.

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10.1. PREVENTIVE MAINTENANCE

Preventive maintenance is the best way to assure correct air starter operation and longer lifetime. It is
recommended to carry out the following actions to take advantage of completely air starter performance.
30 BAR
Total starting Action *Time (h)
Action description Regularity
time Id Staff
Check general condition of the starter (external visual inspection). Check that there are no visually detectable damaged 0.25
N1 Monthly 1
external parts. Replace affected parts if necessary.
0.50
N2 Check air leakages on the starter and on the air installation. Replace affected parts if necessary. Monthly 1
0.10
N3 Grease the pinion and ring gear with the suitable grease. Monthly 1
1) Verify that rotation is normal, not very smooth, not very hard. Check for abnormal sounds (this check can be done by 1) 0.10
rotating the mechanism by the splined pinion shaft). 1
2) Clean and re-grease all the bearings with grease Mobil Mobilith SHC 100 (or Klueber Kluberplex BEM 34-132). See 2) 3.00
chapter 12.4 for reference. 18 months or 1
N4
-Front crown bearing. every 3000 starts.
-Main rotor bearings.
-Secondary rotor bearings.
-Crown teeth and main rotor metallic teeth
18 months or 0.25
N5 Relubricate all the servolocker internal parts with Teflon Lube oil, except those ones specifically indicated on chapter 12.4.
every 3000 starts. 1
Normal 18 months or 0.10
N6 Regrease the pusher with Teflon Lube oil. Check the pusher condition.
every 3000 starts. 1
≤ 5 sec
18 months or 0.10
N7 Regrease the splined shaft with Teflon Lube oil.
every 3000 starts. 1
Every 3 years or 1.00
N8 Replace all the gaskets of the starter (servolocker and starter)
6000 starts 1
Replace the following parts if action #4 has NOT been carried out at the due period:
-Main rotor and main rotor bearings.
2.00
N9 -Secondary rotor and secondary rotor bearings. Every 4500 starts
1
-Crown
-Crown rollers.
Replace the following parts if action #4 has been carried out at the due period:
-Main rotor and main rotor bearings.
2.00
N10 -Secondary rotor and secondary rotor bearings. Every 6000 starts
1
-Crown
-Crown rollers.
0.25
N11 Check the driving pinion conditions (cracks, hits, etc). Monthly
1
Every 10000 0.5
N12 Only for soft engagement starter version: replace pusher assembly (ref. 5290706) and lubricate with Teflon Lube oil
starts 1
Check general condition of the starter (external visual inspection). Check that there are no visually detectable damaged 0.25
L1 Monthly 1
external parts. Replace affected parts if necessary.
0.50
L2 Check air leakages on the starter and on the air installation. Replace affected parts if necessary. Monthly 1
0.10
L3 Grease the pinion and ring gear with the suitable grease. Monthly 1
1) Verify that rotation is normal, not very smooth, not very hard. Check for abnormal sounds (this check can be done by 1) 0.10
rotating the mechanism by the splined pinion shaft). 1
2) Clean and re-grease all the bearings with grease Mobil Mobilith SHC 100 (or Klueber Kluberplex BEM 34-132). See 2) 3.00
chapter 12.4 for reference. 18 months or 1
L4
-Front crown bearing. every 1500 starts.
-Main rotor bearings.
-Secondary rotor bearings.
-Crown teeth and main rotor metallic teeth
18 months or 0.25
L5 Relubricate all the servolocker internal parts with Teflon Lube oil, except those ones specifically indicated on chapter 12.4.
every 1500 starts. 1
18 months or 0.10
Long L6 Regrease the pusher with Teflon Lube oil. Check the pusher condition.
every 1500 starts. 1
6-10 sec 18 months or 0.10
L7 Regrease the splined shaft with Teflon Lube oil.
every 1500 starts. 1
Every 3 years or 1.00
L8 Replace all the gaskets of the starter (servolocker and starter)
3000 starts 1
Replace the following parts if action #4 has NOT been carried out at the due period:
-Main rotor and main rotor bearings.
2.00
L9 -Secondary rotor and secondary rotor bearings. Every 2250 starts
1
-Crown
-Crown rollers.
Replace the following parts if action #4 has been carried out at the due period:
-Main rotor and main rotor bearings.
2.00
L10 -Secondary rotor and secondary rotor bearings. Every 3000 starts
1
-Crown
-Crown rollers.
0.25
L11 Check the driving pinion conditions (cracks, hits, etc). Monthly
1
0.5
L12 Only for soft engagement starter version: replace pusher assembly (ref. 5290874) and lubricate with Teflon Lube oil Every 5000 starts
1
Table 4. Preventive maintenance (*proposal).

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▪ It is not correct to only replace one rotor of the pair (main or secondary), or only one size of
bearing (main or secondary rotor one). To assure a proper operation of the starter and long
lifetime the complete rotor set needs to be replaced at the same time (main and secondary
rotor and their bearings). For example, a new main rotor cannot operate with a used secondary
rotor and vice versa. The same happens with the rotor bearings.

▪ In case of air starter overspeed (>3500 rpm, ask Gali for a special maintenance program)

▪ Use the table attached on appendix documentation for preventive maintenance control.

▪ For long time of no operation of the air starter, it is recommended to use oil in order to lubricate
the internal parts. Long-time no operation means less than 30 starts per month approximately.
The lubrication will be done automatically by the starter during the last engine start by
incorporating a Gali servo-lubricator SL6. The oil to be used is Shell Omala S4 GX. Ask Gali
for more information.

10.2. CORRECTIVE MAINTENANCE.

See chapter 11.

11. TROUBLESHOOTING
See appendix chapter 14.2.

Please, send the failure checklist report to Gali in case technical assistance is required.

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12. SPARE PARTS

12.1. MAIN SPARE PARTS

DESCRIPTION REFERENCE CONTENT LOCATION ON STARTER

Front cover 5290848 (Ø92)

assembly 5290849 (Ø89)

Crown 5290938 (CW)

assembly 5290939 (CCW)

Roller 0820808 (x28)

Splined shaft 51306106 (CW)

spring 51307106 (CCW)

l = 157 / e = 18 mm
51306254 (CW)
51307254(CCW)
(Soft engagement)

l = 159,5 / e = 20,5 mm
Splined shaft 51306110 (CW)
51307110 (CCW)
(Std engaement)

l = 167 / e = 28 mm
51306109 (CW)
51307109 (CCW)
(Std engagement)

Pinion nut
5290999
and washer

Type 1 Type 2

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Reduction 5290306 (CW)

body 5290307 (CCW)

Starter body
5290349
assembly

Internal components are not included (bearings, rotors, etc)

Main rotor
5290940
assembly

Be aware of the thread sense for each retainer when assembling (CW
or CCW)
Tools ref. 5905810 and 5905812 are required for assembling (included
on spare part ref. 5290827)

Pusher
assembly
5290704
(Standard
engagement)

Pusher
assembly
5290713
(Soft
engagement)

Pusher
(Standard
51306205
engagement)

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Pusher
(Soft
5290706
engagement)

Exhaust
51306600
silencer

Head
(version 51306247 (CW)
without 51307247 (CCW)
speed limiter)

Head
51306249 (CW)
(version with
51307249 (CCW)
speed limiter)

Check valve 5290726

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5290039 (CW)
Servolocker
5290040 (CCW)
assembly

Servolocker 51206413
pipes
(x1) without speed limiter
(x5) with speed limiter

Main valve 5290941 (CW)

assembly 5290942 (CCW)

Quick
exhaust
5290943 (CW)
valve
5290944 (CCW)
(version with
speed limiter)

Quick
exhaust
valve 5290945 (CW)
(version 5290946 (CCW)
without
speed limiter)

Speed limiter
51206300
assembly

Table 5. Main spare parts (images only for illustrative purposes, the real spare parts may differ from the pictures).

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Some of the spare parts may be delivered non-lubricated condition (only anticorrosion lubricant).
Do not forget to lubricate the parts before assembling them on the starter. Refer to chapter 12.4
for the lubrication requirements.

▪ Request the spare part drawing in case of needing detailed assembly instructions.
▪ Some spare parts may require the application of Loctite 542, 648 or 243 on some fittings or
screws. In case of application of these additives, it is recommended to let them cure during a
minimum time of 24 hours before operating the starter.
▪ Some O-rings or gaskets may not be included on the previously mentioned spare parts. For
this, refer to chapters 12.2 and 12.3.
▪ Some components may lose a certain amount of lubrication during transportation. Gali
recommends checking the condition of the received spare parts before assembling them on the
starters and relubricate the required parts if necessary (see chapter 12.4).
▪ If main rotor or bearing is replaced, secondary rotor or bearing has also to be replaced (and
vice versa). Only rotor or bearing pairs assembled at the same time can operate together (do
not mix new rotor or bearings with old ones).

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12.2. SPARE PARTS KITS

DESCRIPTION REFERENCE CONTENT

It includes all the seals that air starter should have:

- 0305803 - 0303404 - 0309524 x2 - 0384204 - 0121412

- 0305125 - 0303402 - 0300703 - 51206404 - 0311503
- 0304735 - 0302603 - 0300815 x2 - 51306414 - 51206413.1 x5
- 0304802 x2 - 0302502 - 0300602 - 51306111 - 51206413.2 x5
- 0303802 x2 - 0302102 - 0300415 x2 - 51306112 - 0302802
- 0303602 - 0302015 x3 - 0385005 - 51306107 - 51206306

0305803 0305125 0304735 0304802 0303802 0303602 0303404

Starter seal kit 5290036

0303402 0302603 0302102 0302015 0309524 0300703 0300815 0300602 0300415 0302802 0302502

0384204 51306111 51306107 0121412 51206306

0385005 51206404 51306414 51306112 0311503 51206413.1

51206413.2

Simple set for air starter repair:

- 51306225
- 51306227
- 5290036

51306225 51306227

Starter repair
5290826
kit

5290036

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Complete set for air starter repair:

- 51306225
- 51306227
- 5290557
- 5290558
- 5905810
- 5905812
- 51306229 51306225 51306227 5290557 5290558

- 51306230
- 51306231
- 51306232
5905810 5905812 51306229 51306230 51306231 51306232
Starter repair 5290827
kit

5290036

Table 6. Spare parts kits (images only for illustrative purposes, the real spare parts may differ from the pictures).

Pipes, fittings, flexible hoses and special spare parts depend on each particular starting kit. Refer
to the specific manual for each application. (Parts manual “PM”).

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12.3. LOCATION OF SEALS

The location of the seals belonging to seal kit reference 5290036 is shown in the following pictures:

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The following picture shows the seals for starters with limiter:

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The following picture shows a detail of the servo locker assembly:

Spare parts kit Spare parts kit

Id Reference QTY Id Reference QTY
reference reference

01 0121412 1 5290036 16 0305125 1 5290036

02 51306111 1 5290036 17 51206404 1 5290036

03 51306112 1 5290036 18 0302502 1 5290036

04 0384204 1 5290036 19 0302802 1 5290036

05 0385005 1 5290036 20 0300815 2 5290036

06 0302015 3 5290036 21 51206413.2 5 5290036

07 0303802 2 5290036 22 51206413.1 5 5290036

08 0304802 2 5290036 23 51206306 1 5290036

09 0304735 1 5290036 24 0302102 1 5290036

10 0305803 1 5290036 25 0300703 1 5290036

11 0309524 2 5290036 26 0302603 1 5290036

12 0303404 1 5290036 27 0311503 1 5290036

13 0300602 1 5290036 28 0303402 1 5290036

14 0300412 2 5290036 29 0303602 (*) 1 5290036

15 51306414 1 5290036 - - - -

(*) O-ring valid only for old version (prior to January 2011).

Table 7. Seals list.

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12.4. LUBRICATION AREAS

For lubrication, always use

the greases and oils
indicated in table 3 and
apply according to the
following instructions:

1. Front bearing

Lubricant Lubrication condition Spare references Qty

MOBIL MOBILITH SHC 100 GREASE

5290848 (Ø92)
1
5290849 (Ø89)
KLUBERPLEX BEM 34-132 GREASE

2. Crown rollers

Lubricant Lubrication condition Spare references Qty

0820808 28

MOBIL MOBILITH SHC 100 GREASE

KLUBERPLEX BEM 34-132 GREASE 5290938 (CW)

1
5290939 (CCW)

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3. Crown teeth.

Designation / Use Lubrication condition Spare references Qty

MOBIL MOBILITH SHC 1500 GREASE

5290938 (CW)
1
5290939 (CCW)
KRAFFT KL COMPLEX GREASE

4. Main rotor teeth.

Designation / Use Lubrication condition Spare references Qty

MOBIL MOBILITH SHC 1500 GREASE 5290826

5290827 1
KRAFFT KL COMPLEX GREASE 5290940

5. Main and secondary rotor bearings.

Designation / Use Lubrication condition Spare references Qty

MOBIL MOBILITH SHC 100 GREASE 5290940

5290826 2+2
KLUBERPLEX BEM 34-132 GREASE 5290827

6. Main valve’s membrane (red colour).

Do not lubricate this seal.

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7. Main valve.
Designation / Use Lubrication condition Spare references Qty

BARDAHL SUPER TEFLUBE LDS or an 5290941 (CW)

Lubricate all the parts (shaft, valve seat, etc) 1
equivalent one 5290942 (CCW)

8. Pusher and pusher’s guide.

Designation / Use Lubrication condition Spare references Qty
5290704
BARDAHL SUPER TEFLUBE LDS or an 51306205
Lubricate pusher and pusher guide completely 1
equivalent one 5290713
5290706

9. Servo-locker parts
Designation / Use Lubrication condition Spare references Qty
BARDAHL SUPER TEFLUBE LDS or an Lubricate the coloured parts (green, yellow, blue), 5290039
1
equivalent one and springs. Do not lubricate the not coloured piston. 5290040

10. Membrane (brown colour on the real starter).

Do not lubricate this seal.

• For all O-rings, apply oil BARDAHL SUPER TEFLUBE LDS or an equivalent one.
• For metal parts conservation, apply oil BARDAHL SUPER TEFLUBE LDS or an equivalent one.

Do not lubricate the seals and parts previously indicated which don’t need lubrication.
Premature wear may occur.

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12.5. TIGHTENING TORQUES

Use a torque wrench to

tighten the screws to the
specified torque indicated
below:

1. Front cover screws. (Be sure that there is a washer “for screw DIN 912 AET” M12, in every screw).

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M12x55 Tightening torque Loctite 243 59 Nm 4

2. Silencer’s plate screws. (Be sure that there is a washer “for screw DIN 912 AET” M10, between the screw and the
washer DIN 9021 M10).

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M10x30 Tightening torque Loctite 243 35 Nm 1

3. Inlet bend’s screws. (Be sure that there is a washer “for screw DIN 912 AET” M8, in every screw).

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M8x80 Tightening torque Loctite 243 14 Nm 4

4. Main valve housing’s screws. (Be sure that there is a washer “for screw DIN 912 AET” M8, in every screw)

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M8x80 Tightening torque Loctite 243 14 Nm 4

5. Silencer support screws. (Be sure that there is a washer “for screw DIN 912 AET” M8, in every screw).

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M8x100 Tightening torque Loctite 243 14 Nm 4

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Use a torque wrench to tighten

the screws to the specified
torque indicated below:

1. Motor body’s nuts. (Be sure that there is a washer DIN 125 M12, in every screw).

Item Size Type Additive Value/Standard Qty

Self-blocking nut DIN
M12 Tightening torque Loctite 243 59 Nm 4
985

2. Servolocker screws. (Be sure that there is a washer “for screw DIN 912 AET” M5, in every screw).

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M5x14 Tightening torque Loctite 243 5 Nm 4

3. Servolocker screws. (Be sure that there is a washer “for screw DIN 912 AET” M6, in every screw).

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M6x50 Tightening torque Loctite 243 7 Nm 4

4. Fast unloading housing’s screws. (Be sure that there is a washer “for screw DIN 912 AET” M8, in every screw).

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M8x45 Tightening torque Loctite 243 14 Nm 4

5. Silencer’s plate screws. (Be sure that there is a washer “for screw DIN 912 AET” M10, between the screw and the
washer DIN 9021 M10).

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M10x30 Tightening torque Loctite 243 35 Nm 1

6. Fittings.

Item Size Type Additive Value/Standard Qty

Banjo fitting G1/8’’ Tightening torque Oil 12 Nm 2

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Use torque wrench to tighten the pusher

guide’s (2) screws to the specified torque:

1. Pusher guide’s screws. (Be sure that there is a washer “for screw DIN 912 AET” M4, in every screw).

Item Size Type Additive Value/Standard Qty

Screw DIN 912 8.8 M4x20 Tightening torque Loctite 243 3 Nm 4

Use torque wrench to tighten the main

valve’s (2) nut to the specified torque:

1. Main valve’s nut. (Be sure that there is a washer DIN 125 M10, in the nut).

Item Size Type Additive Value/Standard Qty

Self-locking nut DIN 985 M10 Tightening torque Loctite 243 35 Nm 1

Gali doesn’t recommend applying Loctite 542 for extra sealing purposes to fittings whose
tightness is guaranteed by the own fitting design (i.e., fitting equipped with rubber seal or with
metallic washer). Loctite 542 is only recommended for thread sealing without any other sealing
method between the connected parts. In case of Loctite 542 application, it is mandatory to let it
cure during 24 h minimum before operating the starter.

In order to loosen threaded parts with Loctite applied, it is possible that it is necessary to apply
heat to the union in order to melt the Loctite and avoid the breakage of the part at the moment
of unscrewing. A heat blower can be used. Try not to damage other parts because of excessive
heat application.

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13. DISTRIBUTORS AND SERVICE

GALI GROUP
SPAIN JAPAN
GALI INTERNACIONAL, SA GALI JAPAN
C/ Josep Tura, 5 Polígono Industrial Mas d’en Cisa 3A 3F Ishi blldg, 3-8-4
08181 Sentmenat (Barcelona) Sakae-cho, Kawaguchi
+34 93 715 31 11 332-0017 Saitama
+34 93 715 07 51 +81 807 498 4710
gali@galigrup.com t.nagano@galigrup.com
www.galigrup.com
FRANCE GERMANY ITALY CHINA MALAYSIA
GALI FRANCE, SA GALI DEUTSCHLAND, GmbH GALI ITALIA, Srl ZHENJIANG GALI INT. GALI MALAYSIA
1, Rue Barthélémy Thimonnier Am Ockenheimer Graben, 32 Via Dante snc TRADING CO, Ltd. Unit F-13-5, Mentari Court
66200 Elne 55411 Bingen 22070 Cirimido (CO) Runzhou Industrial Park SS 10, 46150 Petaling Jaya
+33 468 22 20 05 +49 672 11 00 26 +39 031 46 12 24 212004 Zhenjiang Selangor
+33 468 22 47 44 +49 672 11 31 44 +39 031 46 12 45 +86 051185725611 +60 (0) 16 2777 602
comexp@gali-france.fr info@gali.de gali@gali-italia.it china@galigrup.com r.sowald@galigrup.com
OTHER COMPANIES
EUROPE
SPAIN SPAIN SPAIN GERMANY GREECE
COMERCIAL DIESEL, S.L. DISTRIMAR, S.L. ARDORA, S.A. CARL BAGUHN, GmbH INJEGOV S.A.
Arrandegi, 2 Bloque 6 bajos Tomás A. Alonso, 150-152 Wewndenstrasse, 252-254 VIPA Shistou, Road 2
Pasaje San Pedro Urbanización Nueva Isleta Teles 83206 20537 Hamburg 18863 OT3 Perama (Piraeus)
20110 Guipúzcoa 35009 Palmas de Gran Canaria 36208 Vigo +49 40 251 55-0 +30 210 43.23.600/1-2
+34 94 340 11 12 +34 92 846 61 55 +34 98 621 32 38 +49 40 251 55-150 (-151) +30 210 43.12.770
+34 94 339 13 72 +34 92 846 72 07 +34 98 621 45 77 info@carlbaguhn.de info@injegov.gr
FRANCE FRANCE FRANCE THE NETHERLANDS ENGLAND
LEPETIT S.A. POSITIF S.A.D. – SOCIETE ELECTRA BRANDT B.V SIMPLEX-TURBULO Co. Ltd.
Avenue Marcelle Lemignot Lot 114 6 Rue Anne Gacon D’APPLICATIONS DIESEL De Roysloot, 10 Wherwell Priory , Wherwell,
76700 Gonfreville l’Orcher Village d'entreprises de St. Henri 50, Rue de da Digue NL 2231 NZ Rijnsburg Andover Hampshire SP11 7JH
+33 232 74 98 40 13016 Marseille 57105 THIONVILLE +71 402 92 10 +44 1264 86 01 86
+33 232 74 98 49 +33 495 06 13 20 +33 382 88 62 62 +71 402 18 19 +44 1264 86 01 80
+33 491 69 58 05 +33 382 88 58 36 sales@electrabrandt.nl spares@simplexturbulo.com
RUSSIA, KAZAKHSTAN AND RUSSIA, KAZAKHSTAN AND NORWAY SWEDEN
BALTIC COUNTRIES BALTIC COUNTRIES SEA-TEK A/S MAJNABBE MOTOR DIESEL
LSP TRANSIT LTD DMLieferant (PROMIMPORT,LLC) Elgtrekket, 1 SERVICE AB
Kännu 64/4, Initsiativnaya,7-Building 3-Flat IV – 1820 Spydeberg Signalgatan,1
13418 Tallinn Offices 1-9 +47 69 83 33 50 442 40 Kungälv
+372 6 077 007 121357 Moscow mail@sea-tek.no +46 303 20 60 56
+372 6 477 007 +7 (499) 990 05 50 sales@majnabbemotor.com
lsp@lsp.ee +7 (800) 775 29 59
info@dmliefer.ru
ASIA
BANGLADESH KOREA INDIA TURKEY SINGAPORE
TECHNOSOL Limited SAMSAWON, INC. TURBO MOT INDIA PVT.LTD. ENTECH & SEMAR Inc. Co. ARK VISION SPARE &
Paramount Height 411 World Meridian Biz (Only for Marine Sector) Aydintepe Mah. Sahil Bulvari ENGINEERING PTE LTD
8 th Floor (Suir # 8-B) Center, 15-1, 9, Sreevatsa Dwaraka, Kovai Cad, 126 Denizciler Ticaret (Only for Marine Sector)
65/2/1 Box Culvert Road Yangpyeond-dong 150-103 Pudur Coimbatore Merkezi 51 Tuas Ave 1 Tuas Lot, Jurong
Purana Paltan, Dhaka-1000 Yeongdeungpo-Gu, Seoul K:2 No:57 Tuzla / Istanbul, TR 639501 Singapore
641 042 Tamilnadu
+88 02 9551724 +82 02 6340 3402 +90 216 330 74 80 +65 6862 3379
+91 422 2606 338
+88 02 8402584 +82 02 6340 3409 +90 216 330 74 06 +65 6863 0930
+91 422 2606 339
service@technosol-group.com samsawon@samsawon.co.kr spare@semarmarine.com arkvision@singnet.com.sg
info@turbomotindia.com
IRAN IRAN INDONESIA UNITED ARAB EMIRATES JAPAN
PARANG MES SAHANI KHAS KIAN KARA PARSA ARK VISI TEKNIK OIL TECH INTERNATIONAL KOUN KOGYO INC
Shahid Atefi St., 119 (Only for Marine Sector) (Only for Marine Sector) PO BOX 108513 2225-1
Opp. Mellat Park Nº 16, 5th floor – Flat 10 Jl. Raya Pejuangan Abu Dhabi Nagoya Aichi, Japan.
Vai Asr Ave. Northern Razan-Madar Kebon Jeruk Square Blok E 12A +971 2 633 29 75 +81 052 795 3370
Tehran 1967945133 11530 Jakarta +971 2 633 29 76 +81 052 791 3383
Eastern 4º Alley, Teherán
+ 98 21 22053398 +62 21 5365 4927 www.kuk-inc.com
+98 21 22910263
+ 98 21 22050489 +62 21 5366 0342
+98 21 22910334
+ 98 21 22050162 sales@arkvisi-teknik.com
+98 21 22915023
info@parangmes.com
info@kiankara.net
AMERICA
USA USA BRASIL
C.S. CONTROLS CALIFORNIA OFFICE MACH CONTROLS
Louisiana Office and Fact. 1820 N. Lincoln Street Rua Isa, 164
101 Dickson Road Orange, CA 92865 36240-000, Santos Dumont
Houma LA 707363 +1 714 974 5684 +55 (32) 3251-1086
+1 985 876 6040 pbs@cscontrols.com
+1 985 876 0751 +55 (32) 99800-0612
info@cscontrols.com contato@machcontrols.com.br

OCEANIA
AUSTRALIA NEW ZEALAND
DEERING AUTONICS BEST POWER SYSTEMS
9/65 Solomon Rd ENGINEERING LTD
Jandakot 12 Sylvia Way
6164 Western Australia Te Horo Beack
+ 818 9417 2488 Kapiti Coast 5581
+818 9417 2977 + 64 4 939 8586
sales@deering.com.au + 64 4 939 8588
gus@dieselpower.co.nz

More updated information at Gali website www.galigrup.com

34
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14. APPENDIX

14.1. PREVENTIVE MAINTENANCE CONTROL SHEET

14.2. TROUBLESHOOTING CHECKLIST
14.3. AIR INSTALLATION SKETCH
14.4. ELECTRICAL CONNECTION OF AIR STARTER
14.5. DECLARATION OF INCORPORATION
14.6. MAIN DIMENSIONS OF AIR STARTER

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14.1. PREVENTIVE MAINTENANCE CONTROL SHEET

□Normal (<5 sec).

Start sequence
used □Long cranking cycle (> 5 sec) or slow turn.
15.
□Air starter over speed (> 3500 rpm). Ask Gali for maintenance program.
1st preventive maintenance 2nd preventive maintenance 3rd preventive maintenance 4rd preventive maintenance
Action Id Date: Date: Date: Date:
(refer to table 4) No of starts: No of starts: No of starts: No of starts:
Done Not done Done Not done Done Not done Done Not done

N1 / L1

N2 / L2

N3 / L3

N4 / L4

N5 / L5

N6 / L6

N7 / L7

N8 / L8

N9 / L9

N10 / L10

N11 / L11

N12 / L12

Table 8. Preventive maintenance control sheet

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14.2. TROUBLESHOOTING CHECKLIST (refer to picture 5130021SM on page 39)

AIR STARTER STATE FAILURE POSSIBLE CAUSE ACTIONS TO SOLVE THE PROBLEM WHAT HAPPENED
(mark as it happened) (Mark which is the problem appeared on the starter) (Mark actions carried out to solve the problem) (Mark actions carried out to solve the problem. Start again after each action) AFTER THE ACTION?

Not enough air pressure at starter’s inlet (empty air reservoir(s) or no air at starting system). □
Increase system air pressure until 30 bar

Air installation isolation valve closed. □

Open air isolation valve of air installation.

Starter’s air control circuit completely blocked. □

□ Check starter’s control pipes and clean out.
On activating solenoid valve or pushing manual start button, starter
does not respond and not air flow seems to exist in the control circuit. No electrical signal for solenoid valve (position 03 on picture 5130021SM). There is no “click” sound on activating it. □
Provide electrical signal to solenoid valve.
Damaged solenoid valve (position 03 on picture 5130021SM), damaged connector or damaged push button. In case of solenoid valve, there
is no “click” sound on activating it.
□
Replace by new one.

Solenoid valve filter installed on servolocker is blocked (position 02 on picture 5130021SM). □

Remove and clean filter.

Air leakage from rigid or flexible control pipes. □

Fix or replace them.

Not enough air pressure at starter’s inlet (at air reservoir(s) or at starting system). □
□
Increase system air pressure until 30 bar

On activating solenoid valve or pushing manual start button, starter Piston ref. 51306555 or ref. 51306558 blocked (positions 05 and 06 on picture 5130021SM). □
does not respond although air flows through control circuit (air Remove and check both. Smoothen guides or replace parts.
escaping by servolocker’s holes can be heard).
□
PINION NOT ENGAGED TO THE RING GEAR

Solenoid valve (position 03 on picture 5130021SM) or starting air pipe strainer chocked.
Remove and clean or replace.

Solenoid valve filter installed on servolocker is blocked (position 02 on picture 5130021SM). □

Remove and clean filter.

Engine’s ring gear and/or starter’s pinion have burrs or are damaged. □
Clean burrs or replace if necessary. Refer to chapter 6.
□

Lack of normal backlash between starter’s pinion and engine’s ring gear. □
Check and correct. Increase the normal backlash if the problem persists. Refer to table 2

□ Lack of frontal gap between starter’s pinion and engine’s ring gear. □
Check and correct. Refer to chapter 6.2.
Pinion revolves and advances, but does not engage the ring gear.

Not enough hardness of engine’s ring gear teeth profile and front surface (≈ <40 HRc).
□
Gali soft engagement system is required → Ref. 5290713 + ref. 51306254 (CW starter)
or ref. 5290905 + ref. 51307254 (CCW starter).

Bad alignment between starter’s pinion and engine’s ring gear. □

Check and correct.

Pusher ref. 51306205 or 5290706 inoperative (position 10 on picture 5130021SM).

□
Disassemble, check, smooth guide diameter, remove tip burrs if any, clean or replace if
necessary.

□ Not enough air pressure at starter’s inlet (at air reservoir(s) or at starting system). □
Pinion rotates but does not advance. Increase system air pressure until 30 bar.

Splined shaft ref. 51306254 / 51306110 / 51306109 (CW) or 51307254 / 51307110 / 51307109 (CCW) stuck (position 11 on picture □
5130021SM). Disassemble or pull it out and clean the Ø32 surface, check spring ref. 51306106 (CW)
or 51307106 (CCW). Lubricate shaft with Teflon lube oil. Reassemble.

Air starter inoperative.

□
Disassemble. Inspect rotors for foreign elements between polymer teeth and possible
□ wear of gears, spindles and bearings.
Pinion advances but does not rotate.
Check valve ref. 5290726 stuck or blocked (position 07 on picture 5130021SM).
□
Check that valve ball is not stuck or some foreign particle is not allowing its free
movement. Clean, lubricate with Teflon oil spray and reassemble. Replace if required.

□ Main valve ref. 5290941 (CW) or 5290942 (CCW) (position 01 on picture 5130021SM) stuck or blocked at opened position, or one of its O- □
Starter starts to operate upon opening the flow valve of air pipe line,
rings is damaged. Check that valve is not stuck at opened position and check O-ring condition. Replace if
although solenoid valve is not activated (starter operates by itself).
necessary.

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□ Air starting pipe restricted, air strainer saturated or not enough diameter of air starting pipe.
Pinion engages ring gear but will not crank the engine.
PINION ENGAGED TO THE RING GEAR
□
□
Starter starts to operate upon opening the flow valve of air pipe line,
although solenoid valve is not activated (starter operates by itself).
□ movement. Clean, lubricate with Teflon oil spray and reassemble. Replace if required.
Starter starts to operate upon opening the flow valve of air pipe line,
although solenoid valve is not activated (starter operates by itself).
□ Check and replace or modify. Refer to chapter 7.1 and 7.2 for pipe requirements.
Lack of starter power. The starter rotates the engine during a time but
declutches before the electrical signal is OFF (not cranked engine),
or the starter operates intermittently.
□
After starting the engine and when the electrical signal is OFF, pinion
tries to reengage and hits the ring gear.
AFTER ENGINE GOT STARTED UP
□
□
The starter doesn’t stop.
□ □
After diesel engine starting, pinion disengages from the flywheel and
continues rotating for a period of time.
Table 9. Troubleshooting checklist.
S30 service manual
5130-SM (Rev. D – Jul 2019)
Main valve ref. 5290941 (CW) or 5290942 (CCW) stuck or blocked (position 01 on picture 5130021SM). □
Disassemble, clean, lubricate with Teflon oil spray and reassemble or replace.
Rotors worn, cracked or blocked (position 08 / 09 on picture 5130021SM).
□
Disassemble, clean, lubricate with Teflon oil spray and reassemble or replace by new
ones.
Not enough air pressure at starter’s inlet (at air reservoir(s) or at starting system). In this situation, air pressure may be below minimum
starting pressure.
□
Increase system air pressure until 30 bar.
□
Check and replace or modify. Refer to chapter 7.1 and 7.2. for pipe requirements.
Membrane ref. 51206404 broken (position 04 on picture 5130021SM). □
Replace.
Pusher ref. 51306205 or 5290706 dirty or stuck, not fully stroke is allowed so main valve cannot open to crank the engine (position 10 on
picture 5130021SM).
□
Disassemble, check, smooth guide diameter, remove tip burrs if any, clean or replace.
Starter’s air control circuit partially blocked. □
Check starter’s control pipes and clean out.
□
Lack of normal backlash between pinion and ring gear.
Check and correct. Refer to chapter 6 table 2.
□
Incorrect connection of starter control pipes.
Connect control pipes correctly. Refer to starter manuals.
□
Check valve ref. 5290726 stuck or blocked (position 07 on picture 5130021SM).
Check that check valve’s ball is not stuck or some foreign particle is not allowing its free
Main valve ref. 5290941 (CW) or 5290942 (CCW) (position 01 on picture 5130021SM) stuck or blocked at opened position, or one of its o- □
rings is damaged. Check that valve is not stuck at opened position and check o-ring condition. Fix or replace
if necessary.
Air starting pipe restricted, air strainer saturated or not enough diameter of air starting pipe. □
Not enough air pressure at starter’s inlet (at air reservoir(s) or at starting system). In this situation, air pressure may be below minimum
starting pressure.
□
Increase system air pressure until 30 bar
Highly worn or cracked rotors (position 08 / 09 on picture 5130021SM). □
Replace.
□
Piston ref. 51306555 blocked or stuck (position 05 on picture 5130021SM).
Disassemble, check, smooth guide diameter, remove tip burrs if any, clean or replace.
Piston ref. 51306558 (position 06 on picture 5130021SM). □
Remove and check or replace parts.
Main valve ref. 5290941 (CW) or 5290942 (CCW) stuck or blocked (position 01 on picture 5130021SM). □
Disassemble, clean, lubricate with Teflon oil spray and reassemble or replace.
Piston ref. 51306555 blocked (position 05 on picture 5130021SM). □
Remove and check both. Smooth guides or replace parts.
Check valve ref. 5290726 stuck or blocked. (does not close properly) (position 07 on picture 5130021SM).
□
Check that valve ball is not stuck or some foreign particle is not allowing its free
movement. Clean, lubricate with Teflon oil spray and reassemble. Replace if required.
Splined shaft ref. 51306254 / 51306110 / 51306109 (CW) or 51307254 / 51307110 / 51307109 (CCW) stuck (position 11 on picture □
5130021SM). Disassemble and clean, check spring ref. 51306106 (CW) or 51307106 (CCW).
Lubricate shaft with Teflon lube oil. Reassemble.
Piston ref. 51306555 blocked or stuck (position 05 on picture 5130021SM). □
Disassemble, check, smooth guide diameter, remove tip burrs if any, clean or replace.
Membrane ref. 51206404 broken (position 04 on picture 5130021SM). □
Replace.
Particle filter obstructed (position 02 on picture 5130021SM)
Remove, clean and reassemble.
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 5130-SM (Rev. D – Jul 2019)

Id Name Location Spare part reference Delivery / Observations

01 Main valve assy. Starter’s head 5290941 (CW) / 5290942 (CCW) Pre-assembled
Main valve Individual part. To be assembled on
02 Particle filter 772002401
housing main valve housing.
Gali standard models. Other types
03 Solenoid valve Base plate 0721524 / 0721024 under request. To be assembled on top
of base plate.
To be assembled inside quick exhaust
5290036 / 5290826 / 5290827
Quick exhaust valve
04 Membrane
valve 5290943 (CW) / 5290944 (CCW) → With speed limiter Pre-assembled. To be assembled into
5290945 (CW) / 5290946 (CCW) → Without speed limiter main valve housing.
05 Piston Servolocker 5290039 (CW) / 5290040 (CCW) Already assembled inside servolocker

06 Piston Servolocker 5290039 (CW) / 5290040 (CCW) Already assembled inside servolocker
Pre-assembled. To be assembled
07 Check valve Starter’s head 5290726
inside starter’s head.
Pre-assembled. To be assembled
08 / 09 Rotors Starter’s body 5290940 / 5290826 / 5290827
inside starter’s body.
Individual part. To be assembled inside
Pusher assy. 51306205 (Std engagement) / 5290706 (Soft engagement)
pusher assy.
10 Pusher
Pre-assembled. To be assembled
Reducing body 5290704 (Std engagement) / 5290713 (Soft engagement)
inside reducing body.
51306110 (CW) / 51307110 (CCW) → Std engagement & short shaft
Individual part. To be assembled inside
11 Splined shaft Front cover 51306109 (CW) / 51307109 (CCW) → Std engagement & long shaft
starter’s front cover.
51306254 (CW) / 51307254 (CCW) → Soft engagement
Individual part. To be assembled inside
12 Spring Front cover 51306106 (CW) / 51307106 (CCW)
starter’s front cover.
Table 10. Troubleshooting spare list.

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 5130-SM (Rev. D – Jul 2019)

14.3. AIR INSTALLATION SKETCH

Galí recommends, as minimum, a pneumatic installation according to the following schema:

Inlet main starting air pipe recommended
minimum inner diameters:
-A17: 25 mm
2 3 -A27: 30 mm
-S30: 36 mm
-S38: 36 mm
1 -A47: 45 mm
-A48: 45 mm
-2 x A47: 63 mm
5

30 bar
4

Starting air main shut 300 mm flexible hose

valve (safety) is recommended
6
M
6

TO CONDENSATES MANIFOLD

It is recommendable to drain the installation frequently to avoid condensates to enter to air starters
1. COMPRESSOR SET
GALI COMPRESSOR SETS INCLUDE
-RELIEF VALVE
-PRESSURE SWITCH (LOAD/IDLE)
-AUTOMATIC DRAIN
2. RELIEF VALVE
3. PRESSURE GAUGE
4. AIR STARTER STRAINER
(0,6 mm mesh)
5. AIR STARTER
6. DRAIN (MANUAL OR AUTOMATIC)

Otherwise, if possible, the better choice is a pneumatic installation according to the following schema:

Inlet main starting air pipe recommended

9 8 minimum inner diameters:
-A17: 25 mm
Air pressure dew -A27: 30 mm
1 point: 3-7º C
-S30: 36 mm
-S38: 36 mm
30 bar -A47: 45 mm
-A48: 45 mm
7 2 4 5 -2 x A47: 63 mm

30 bar
10

3
Starting air main shut
valve (safety)
M
300 mm flexible hose 11
is recommended

TO CONDENSATES MANIFOLD

1. COMPRESSOR SET
GALI COMPRESSOR SETS INCLUDE
-RELIEF VALVE
-PRESSURE SWITCH (LOAD/IDLE)
-AUTOMATIC DRAIN
2. OIL SEPARATOR
3. CAPACITIVE DRAIN
4. PRE-FILTER (ISO 8573-1:2001 CLASS 4)
5. REFRIGERATION AIR DRYER
6. AIR RESERVOIR
7. MANUAL SHUT VALVE
8. PRESSURE GAUGE
9. RELIEF VALVE
10. AIR STARTER STRAINER
(0,6 mm mesh)
11. AIR STARTER

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14.4. ELECTRICAL CONNECTION OF AIR STARTER

14.4.1. AIR STARTER WITHOUT BUTTERFLY VALVE

While supply voltage is not present, the starting solenoid valve will remain switched off and the air starter
won't turn. If supply voltage is applied by means of closing the -S1 contact, the starting solenoid valve
will switch on and the air starter will start to turn. See schema CMD-002, on page 42.

14.4.2. AIR STARTER WITH BUTTERFLY VALVE

While supply voltage is not present, the starting solenoid valve will remain switched off and the air starter
won't turn. If supply voltage is applied by means of closing the -S1 contact, the starting solenoid valve
will switch on and the air starter will start to turn. If the optional exhaust butterfly solenoid valve is
assembled, it can be operated by means of closing the -S2 contact. While exhaust butterfly is activated,
the air start will turn at a lower speed. See schema CMD-001, on page 43.

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 5130-SM (Rev. D – Jul 2019)

CMD-002:

Schema CMD-002:

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 5130-SM (Rev. D – Jul 2019)

CMD-001:

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14.5. DECLARATION OF INCORPORATION

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 5130-SM (Rev. D – Jul 2019)

14.6. MAIN DIMENSIONS OF AIR STARTER

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S30 service manual