SERVICE MANUAL

AIR STARTER A-45

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ARRANCADOR MODELO: ________________________________
Nº DE SERIE: _________________________________________
CONTROL DE CALIDAD: ______________ FECHA: ___________
DISTRIBUIDOR: _____________________ FECHA: ___________

GARANTIA: GALI garantiza el producto contra vicios y defectos del material y fabricación por UN AÑO desde la fecha de
su venta al usuario. Esta garantía cubre única y exclusivamente la sustitución gratuita de las piezas defectuosas,
excluyendo toda prestación o mano de obra en material ajeno.
Condiciones:
1.- Haber remitido debidamente cumplimentada la tarjeta adjunta.
2.- No haber hecho uso, mantenimiento o almacenaje inadecuados.
3.- No haber efectuado modificación alguna en el producto.
4.- Haber seguido las instrucciones de instalación del Manual de Servicio.
GALI rehúsa toda responsabilidad por daños y perjuicios que puedan producirse durante la instalación y funcionamiento de
sus productos.

GUARANTEE: Within a period of ONE YEAR after purchase date, GALI will be liable for faulty material or manufacturing
defects of its products. The guarantee only covers free replacement of faulty parts and excludes any other indemnity or
reimbursement of labour costs involved in alien material.
The guarantee in valid only if:
1.- The attached card has been duly filled-in and mailed.
2.- The product is always being subject to proper use, maintenance and storage.
3.- No modification whatsover has been introduced in the product.
4.- The installation follow the instructions of the User Handbook.
GALI will not be liable for damage, injury or loss of any kind whatsoever, caused by or in connection with the installation or
use of its products.

GARANTIE: GALI garantit le produit contre vices et défauts de matière et de fabrication pendant UN AN à partir de la date
de vente à partir de la date de vente à l’utilisateur. Cette garantie couvre uniquement et exclusivement le remplacement
gratuir des pieces défectueuses, excluant toute autre prestation ou main d’ oeuvre sur de matériel autre que le démarreur.
Conditions:
1.- Avoir retourné, dûment completée, la carte jointe.
2.- Ne pas avoir fait un usage, entretien ou emmagainage inadaptés.
3.- N’avoir effectué aucune modification sur le produit.
4.- Avoir suivi len instrucions d’assemblage du Manuel de Service.
GALI décline toute responsabilité en ce qui concerne les dommages ou préjudices survenus lors de l’installation ou du
fonctionnement de ses produits.

GARANTIE: GALI Während EINES JAHRES nach Kaufdatum leisten wir Gewähr für Material-und Fabrikationsfehler
unserer Erzeugnisse. Unsere Garantie deckt ausschliesslich den kostenfreien Austausch schadhafter Teile Jegliche
anderen Gewährleistungsansprüche sowie Ersatz von Lohnkosten für Arbeiten an fremdem Material sind ausgeschlossen.
Unsere Garantie ist nur gültig wenn:
1.- Die beigefügte Karte ausgefüllt un pünktlich eingesandt wird.
2.- Unsere Anweisungen bezüglich Behandlung, Wartung und Lagerung genau befolgt werden.
3.- Vom Kunden keine Anderungen an unseren Produkten vorgenommen werden.
4.- Haber seguido las instrucciones de instalación del presente manual.
Für Beschandigung oder Verlust an Eigentum oder Personen beim Einbau oder Gebrauch der GALI-Geräte wird keine
Haftung übernommen.

GARANZIA: Durante UN ANNO dopo la data d’acquisito, GALI offre garanzia per i difetti di materiale o fabbricazione dei
suoi prodotti. La garanzia comprende unicamente la sostituzione gratuita dei pezzi difettosi, ed esclude ogni altra
prestazione.
Perche la garanzia sia valida, bisogna che:
1.- La cartolina allegata sia compilata e spedita puntualmente.
2.- Le instruzioni d’impiego, immagazzinaggio e manutenzione di GALI vengano sempre rigorosamente osservate.
3.- Il cliente non introduca delle modifiche sui prodotti di GALI.
4.- Haber seguido las instrucciones de instalación del presente manual.
Rifiutasi ogni responsabilitá per dan materiali o corporali eventuali che possano prodursi durante l’installazione o
funzionamento dei prodotti GALI.

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CONTENT :

1.- INTRODUCIION

2.- AIR STARTER SERIE A

2.1.- CE – CONFORMITY OF STARTERS GALI

2.2.- DESCRIPTION OF ELEMENTS
2.3.- IDENTIFICATION PLATE
2.4.- STARTER DATA
2.4.1.- TECHNICAL DATA
2.4.2.- TORQUE/SPEED-POWER DIAGRAM and AIR FLOW DIAGRAM
2.4.3.- EXTERNAL DIMENSIONS

3.- TRANSPORT AND INFORMATION FOR ASSEMBLY

3.1.- STATE DELIVERY

3.2.- TRANSPORT
3.3.- UNPACKING
3.4.- STORAGE

4.- ASSEMBLY

4.1.- INSTALATION
4.2 - FITTING OF CONTROL INSTRUMENTS AND SERVOLUBRICATOR
4.3.- SUPPLY OF COMPRESSED AIR
4.4.- SUPPLY OF ELECTRIC POWER

5.- FIRST START-UP

5.1.- AIR FEEDING CIRCUIT

5.2.- CHECKING ASSEMBLY
5.3.- PUTTING INTO SERVICE
5.3.1.- PRIMING OF THE OIL INJECTION SYSTEM
5.3.2.- LUBRICANTING OILS

6.- OPERATION

6.1.- START-UP AND ENGAGEMENT

6.2.- START UP
6.3.- SHUTDOWN
6.4.- DESENGAGEMENT
6.5.- RESTART

7.- SAFETY INDICATORS

8.- MAINTENANCE

8.1.- GENERAL PRECAUTIONS

8.2.- MAINTENANCE PROGRAM
8.2.1.- MONTHLY REVISION
8.2.2.- ANNUAL REVISION

9.- CORRECTION OF POSSIBLE FAULTS

10.- EXTERNAL DIMENSIONS

11.- ACCESSORIES FOR THE INSTALLATION

12.- SPARE PARTS

12.1.- PARTS OF STARTER A45

12.2.- PARTS OF KIT
12.3.- OTHER ELEMENTS

13.- DISTRIBUTION AND SERVICES

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SAFETY INSTRUCTIONS

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.

WARNING: IF THECORRECTIVE ACTIONS DON’T TAKE, MAY OCCUR INJURY OR

DAMAGE.

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

REGULATIONS IN FORCE HAVE BEEN RESPECTED.

STARTER ASSEMBLY OF THE ENGINE MUST BE DONE BY QUALIFIED PERSONNEL. IN THIS REGARD,
THE QUALIFIED PERSONNEL MUST BE TRAINED, INSTRUCTED AND FAMILIAR WITH THE SYSTEM.

IN THE EVENT OF INJURY OR DAMAGE CAUSED BY FAILURE TO FOLLOW THE SAFETY

INSTRUCTIONS OR PROCEDURES FOR IMPOPER CONDUCT, OR USING THE STARTER FOR OTHER
PURPOSES, THE MANUFACTURER IS NOT RESPONSIBLE.

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1.- INTRODUCTION

These instructions are for installing GALI starters in the correspondent motor safely. If you read and respected
the following information, the team will have a proper operation and have a long service life.

The starters GALI operate safely, when they are properly selected, installed and maintained.

To ensure the safety of the starters have to take preventive measures. It is therefore absolutely necessary to
fully read, understand and observe the dangers that may arise.

These instructions are made especially for people involved in installation, dismantling, operation and
maintenance.

Respect the information in these instructions will ensure trouble-free operation techniques. If a failure to follow
instructions, especially the chapter "Security", the starter could represent a mortal danger to the operation and
maintenance personnel.

2. - 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.

2.1.- CE –CONFORMITY OF STARTERS GALI

The starters GALI are built, designed and tested according to Machinery Directive 98/37/CE and 2006/42/CE.

In addition to the directives and European standards are also considered security policies and regulations for
accident prevention.

All GALI starters are supplied with the “Declaration of incorporation of a quasi-machine”, according to Directive
2006/42/CE (Annex II B)

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2.2. - 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:
- Exhaust silencer: limits the sound level of start-up.

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

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2.3.- IDENTIFICATION PLATE

In the plate is included the GALI reference assembly, the serial number and the year of manufacture. The plate
is situated in a visible place and accessible.

The plate don’t have the market of the CE, because the GALI starters are considered “quasi-machines”,
according to the Machinery Directive 2006/42/CE (annex II B)

Besides of the plate, all starters have the following data marked on the body:

GALI
30 BAR MAX G A45 X (X: turning direction: R (right -CW) or L (left -CCW) )
NUMBER OF BASE
ROTATION (indicated by an arrow, according to turning direction)

In the identification plate includes the following data:

SERIAL NUMBER / YEAR OF MANUFACTURE -------

SET REFERENCE------------------------------------------------

MANUFACTURER'S ADDRESS ---------------------------

2.4.- STARTER DATA

2.4.1.- TECHNICAL DATA

A45
MAXIMUM POWER 66 KW

MAXIMUM TORQUE 540 Nm

MAXIMUM WORKING PRESSURE 30 bar

NET WEIGHT 25.5 Kg

SPEED AT MAXIMUM POWER 2300rpm

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2.4.2.- TORQUE/SPEED-POWER DIAGRAM and AIR FLOW DIAGRAM

2.4.3.- EXTERNAL DIMENSIONS

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3.- TRANSPORT AND INFORMATION FOR ASSEMBLY

3.1.- ESTATE DELIVERY

Before delivery, GALI starters have been examined and tested under various operating conditions. The results
of these tests are recorded in a protocol.

All the starters are factory ready for service.

3.2.- TRANSPORT

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 geometry of the starter is such that it is easy to located fastening elements which allow its transport or
lifting.

Heavy objects. May cause muscle damage or back pain.

Always use an adequate and proper lifting technique.

Some heavy objects may fall and cause serious injury.

Personnel should wear safety shoes.

3.3.- UNPACKING

Remove fully the packaging. Remove the plastics plugs that clog the holes for the inlet nozzle and air outlets for
accessories. These plugs are to prevent dirt from inside the starter before final assembly.

3.4.- STORAGE

To prevent damage, the starters have to be stored in a place closed, protected against weather impact, dirt,
dust, moisture, chemicals, extreme temperatures and mechanical damage.

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.

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.

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.

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4.- ASSEMBLY

4.1.- INSTALATION

Not allowed to modify the starter when the security and performance can be adversely
affected. In this case, the CE shall be void.

The assembly has to done only by qualified personnel. Qualified means that the personnel are
formed, trained and familiar with the system.

The personnel must have read and understood the instruction and safety regulations before
starting work.

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

To secure the starter to the flange are used quality screws 8.8 and tightened with a torque determined (see
picture below):

SPECIAL NUT M16x1,50

TIGHTENING TORQUE 98

8 SECURING SCREWS M12

TIGHTENING TORQUE 84 Nm.

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.

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

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 Independently of the assembly positions of the starter as a whole with respect to the motor, 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:

4 SCREWS M12
TIGHTENING TORQUE 84 Nm

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 70 Nm.

After fixed the starter to the engine:

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
3.5 15º 0.7 - 1

Jn 2.117 (12)
12º
0.3 – 0.5

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.

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4.2.- FITTING OF CONTROL INSTRUMENTS AND SERVOLUBRICATOR

Connect control instruments as per installation scheme. Fit the push-button valve “V” at a maximum distance o
5 metre from the starter and use flexible pipe of 2.5 mm inner diameter for connection. If the control pipe has to
be longer, fit a solenoid valve near the starter and connect same with an electrical remote control valve. In this
case it is recommended using a starter equipped with a GALI starting limiter.

In installation comprising automatic starting and engine control equipment, the push-button valve “V” can be
replace by a solenoid valve.

Fit the servolubricator “S” vertically in a well visible and practicable place to allow for easy priming, control and
refilling.

4.3. - 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 A45 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.

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 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 45 mm or 1 ¾ 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.

4.4. - SUPPLY OF ELECTRIC POWER

In the cases where the control system incorporates an electro valve directly mounted on the starter, 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.

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5.- FIRST START UP

5.1. - 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.

5.2. - 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 4.3.

Test for leaks and check that the control circuit is not choked.

Check that the air receiver is charged and that the flow valve is opened

5.3. – PUTTING INTO SERVICE

ALWAYS RESPECT THE SAFETY INSTRUCTIONS 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.

Check the adjustment of the auto-start device (if installed), to ensure:

-the speed of the starter shaft never exceeds the value of 2500 r/min for type A45
-the starter stops working, once the engine has attained a speed 1 to 1.5 times its ignition
speed.

Check for correct meshing of the driving pinion with the flywheel gear ring by jeans of several
short starter impulses.

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 Do not operate the starter at pressures higher than those indicated in the
characteristics of the equipment.

The installation of a gauge connected to the pipe at the entrance of air to the starter allows
you to ensure there is no air remaining in the circuit and when the starter work may
determine the effective pressure of the supply

5.3.1.- PRIMING OF THE OIL INJECTION SYSTEM

The priming operation should always be carried out before the first start. Never operate the starter if the
lubrication system does not work properly.

The servolubricator is an auto-priming unit. Before its first operation, we advise, however, to proced as follows:
Adjust the injection volume to its maximum. Actuate 2-3 times the push-button and then adjust again the oil
injection to the volume as per detailed below:

Duration press A45

<2 3
2-6 4
6 - 10 6

Never operate the starter if the lubrication system does not work properly.

5.3.2.- LUBRICANTING OILS

We strongly recommend employing for the servolubricator oil of low viscosity index, low freezeing point (less
than -25ºC= 13ºF), with good antirust properties and compatible with air humidity. Such oils are generally used
for pneumatic tools.
A type SAE 10 motor oil can be employed as well. In case of extremely low temperature (less than -20ºC= -4ºF),
special (Turbo Oil) oil should be used, however.

The servolubricator is lubricated with oil: TELLUS 32 oil.

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6. - OPERATION

6.1. - 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.

6.2. - 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.

6.3. - SHUTDOWN

The shutdown can take place for different reasons:

- 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.

- 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.

6.4. – 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.

6.5. - 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.

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7. – 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 F 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.

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8. - MAINTENANCE

8.1. - GENERAL PRECAUTIONS

ALWAYS RESPECT SAFETY INDICATIONS DESCRIBED IN 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.

8.2. - 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).

Periodically check the oil level which should always be servolubricator between MAX. and
MIN..

If the oil has to be replaced by other low temperature must be completely disassembled the starter, be carefully
cleaned, ensuring that no residual oil before the lock could cause the starter.

Then lubricate all parts with the new oil and re-assemble the starter.

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

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8.2.1. - MONTHLY REVISION

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 (point 4.1)
Observe cracks or marks of the drive Visual Remove lock nut, fit new pinion and
5 pinion replace the nut with the corresponding
torque (point 4.1)
6 Rotate the pinion manually Carry out starter internal inspection
Verify tightness of front securing screws Torque Set torque as per point 4.1
7
wrench
Verify tightness of pinion securing nut Torque Set torque as per point 4.1
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

8.2.2. - ANNUAL REVISION

-GENERAL REVISION: CHANGE OF SETS OF GASKETS

Be sure to have at hand a set of seals ref. 5290401

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 6 Change the gasket 04
4 Withdraw main valve unit 05 Manual
Remove special nut 06 Set key 8 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 plug 11 Set key 12
8
Loosen membrane 12 Manual Change membrane 12
9 Mount plug 11 with sealant Set key 12
Remove screw 15 Allen key 4 Change gaskets 16, 17 and 18
10
Remove subassembly
11 Connect feeding sleeve

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-20-
-GENERAL REVISION: REVISION OF ROTORS AND LUBRICATION

Be sure to have at hand a repair kit ref. 5290780

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 and washer 02 Allen key
3 Remove head Manual
4 Withdraw main rotor 04 and secondary 03 Manual
Examine state of rotors Visual Replace with new rotors
5
(wear, cracks, etc.)

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9. – CORRECTION OF POSSIBLE FAULTS

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 flow
seems to exist in control  Control circuit blocked.  Disconnect and clean out
1
circuit.  There is not signal for the electro  Control signal
valve

On pressing push-  Leak in control duct. .  Repair or replace.

button, starter does not
 Insufficient air pressure  Increase pressure in receiver
respond, although air
flows through control  Piston 7 and valve 8 sticking in  Remove and check both, smoothen
2 closed position guides or change parts.
circuit
 Electro valve or filter choked.  Remove and clean the same
 Excessive length of main air  Approach push-button to starter or
pipework install a solenoid valve near the starter
Pinion revolves and  Ring gear and/or pinion have burrs  Clean burrs or replace if necessary.
advances, but does not or are damaged Replace pinion by a more adequate
3 engage the ring gear. one.
 Lack of clearance between pinion  Check by distortion of ring gear.
and ring gear
Pinion revolves but does  Push-rod 11 inoperative  Disassemble, check, smoothen
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 and
5
bearing.
 Check valve 13 stuck of blocked.  Disassemble, clean, oil and
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
upon opening the flow pipes. installations instructions.
valve of the feed line,
7
although electro valve  Main valve 26 blocked and open,  Disassemble, clean oil and replace
are not actuated.. valves 8 and 9 blocked or broken. joint if needed.

Lack of starter power..  Main pipe work chocked or its bore  Revisar toda la tubería,
is less than stipulated for the starter. cambiándola si su diámetro interior no
8 es el adecuado.
 Insufficient air pressure.  Increase pressure in receiver.
 Badly worn rotors.  Replace.

-22-
 After starting the engine,  Incorrect bore of main pipe work.  Check entire pipe work for correct
pinion tries to-reengage bore and replace if incorrect.
and hits the ring gear
 Idling of main valve 26.  Disassemble, clean, oil and
9 which results in damage
resemble.
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.
10  Valve 13 does not close properly  Disassemble, check for correct
closing of the ball and the plug, press
the valve against its seat.
 Splined shaft 19 blocked.  Disassemble, clean., check spring
22

-23-
10. – EXTERNAL DIMENSION

10.1.- KIT REF. (SEGUN KIT)

-24-
11.- ACCESSORIES FOR THE 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:

11.1. – PUSH-BUTTON AND ELECTRO VALVES

In the case of control by push-button , this can be installed up to a maximum distance of 5 metres from the
starter, using for its connection flexible pipe with an inside diameter of 2.5 mm prepared for a nominal pressure
of 30 bar. For longer distances an electro valve will be fitted near the starter, wired to an electric push switch.

In the facilities with automatic starting control, the manual push-button can be replaced with an electro valve.

When the starter is served with the electro valve included, only the wiring of the latter will be necessary, since
the starter incorporates the necessary conduits for the air signal.

GALI can serve different types of electro valves and pushers. Specific GALI references exist if it is wished to
have the starter with electro valve incorporated. In this case, only the electric connection thereof is necessary
and the main air pipe.

11.2. – DRIVE PINIONS

Besides a great number of standard pinions, GALI can provide specific drive pinions for any application of its
starters.

All the pinions that GALI supplies have the reference number indicated and direction of rotation on the face
opposite the entry of the teeth.

X X
X

REFERENCIA
REFERENCE
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.

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.

-25-
11.3. – 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

01

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.

11.4. – INTAKE FILTER AND INLET ELBOWS

Filters can be supplied to prevent dirt entering the starter. These filters have a mesh diameter of 0.6 mm, and
they come with a purging device. They can be supplied with or without coupling sleeves to the intake pipe.

Any type of elbow or pipe can be designed for specific applications.

5804045

-26-
11.5. - 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.

11.6. – SERVOLUBRICATOR SL6

This servolubricator has been especially designed to be used with the GALI air starters. Yet it may also be
employed for the lubrication of any kind of pneumatic circuit operating intermittently.
Upon reception of a pneumatic signal, the pump of the servolubricator injects a certain quantity of oil into the
corresponding inlet, which is normally the feed air inlet of the equipment to be lubricated.

The oil reservoir; not being pressurized, can be refilled without isolating from the air main.
When actuating the servolubricator several times, the pump will be primed automatically. To ensure the oil
enters the starter motor from its first operation, we recommend performing 4-5 feint starts at maximum injection
volume allowing the lube-pipe to fill-up. Thereafter, the injection volume has to be adjusted again to the desired
volume.
The necessary oil quantity depends upon the starting frequency and duration and on the condition of the feed
air (degree of humidity, salinity and pollution). For a starting duration of 0,5 to 2 seconds, we would advise:
-Type A15 starter: 0,4 cm3

In case of infrequently used starting equipment or unfavourable starting conditions, the lubrication has to be
intensified, however.
The sevolubricator may be installed in any desired position, although we recommend its installation in a higher
place than the starter and possibly near to same.

Adjustment:
This servolubricator has an adjusting screw and an external indicator showing the oil volume injected for each
operating cycle. When turning the adjusting screw to the right, the infection volume will be increased, and when
turning it to the left, the volume will be reduced.

* Measurements in mm

-27-
12.- SPARE PARTS

12.1.- PARTS OF STARTER A45 R-L

POS. REF. Nº DESIGNATION QUANT. OBSERV.

1 5145001 FRONTAL COVER 1
2 5145002 BEARING OUTER RING 1
4 0926025 NEEDLE BEARING 1
5 0387208 RETAINER 1 SET OF SEALS
6 0277625 TENSIÓN WASHER 1
7* 5145007* HAULING CROWN RIGHT 1
5145507** HAULING CROWN LEFT 1
8 0821111 BEARING ROLLER 23
9 5145009 SPECIAL JOINT 1 SET OF SEALS
10 5145010 BEARING DISC 1
11* 5145011* SPLINED SHAFT RIGHT 1
5145511** SPLINED SHAFT LEFT 1
13* 5145013* SPRING RIGHT 1
5145513** SPRING LEFT 1
14 0071235 ALLEN SCREW 4
18 0383804 CLOSURE RING 1 SET OF SEALS
76 1251201 WASHER 4

-28-
POS. REF. Nº DESIGNATION QUANT. OBSERV.
19* 5145019* MOTOR BODY RIGHT 1
5145519** MOTOR BODY LEFT 1
26 5145026 STUD 4
27 5145027 RING CHARGE 1
28 5145028 LOCK RING 1
29 0923020 NEEDLE BEARING 2 REPAIR KIT
30 5145030 DISC 1
31 0922520 NEEDLE BEARING 2 REPAIR KIT
32 5290705 ASSEMBLY PUSHER 1
36 0070520 ALLEN SCREW 2
37 1250506 WASHER 2
38 5145038 SECUNDARY ROTOR 1 REPAIR KIT
40 5145040 MAIN ROTOR 1 REPAIR KIT
42 0423002 BEARING DISC 2 REPAIR KIT
43 0423203 SUPPORT DISC 4 REPAIR KIT
44 0422502 BEARING DISC 2 REPAIR KIT
45 0422603 SUPPORT DISC 4 REPAIR KIT
50 5145050 DISC 1
52 5145052 DISC 1

-29-
POS. REF. Nº DESIGNATION QUANT. OBSERV.
49 5145049 STUD M8 4
51 0150816 WASHER 4
53 0100865 NUT M8 4
64 0121012.30 NUT 1
77 0151002 WASHER 1
79 5290721 CHECK VALVE 1
82 0502147 SILENCER 1
83 5145083 SHORT FLEXIBLE PIPE 1
84 5145084 LONG FLEXIBLE PIPE 1
85 5147147 MEMBRANE 1
86 6205005 PLUG 1
87 5145087 ELBOW 1
88 5306180 SILENCER A45 1
91 0151425 WASHER 4
92 0101411 NUT 4
93 1411315 GUARD RING 8 SET OF SEALS
94 5145094 SCREW 4
99 0070545 ALLEN SCREW 2
103 0501321 SILENCER 1
104* 5145114* HEAD RIGHT 1
5145614** HEAD LEFT 1
112 5202075 SERVO-INTERLOCK 1

-30-
POS. REF. Nº DESIGNATION QUANT. OBSERV.
55 0306004 O-RING 1 SET OF SEALS
56 5145056 MAIN VALVE 1
57 5145057 SPECIAL NUT 1
58 5145058 LIP SEAL 1 SET OF SEALS
61 0301002 O-RING 1 SET OF SEALS
63 1251001 WASHER 1
64 0121012.30 NUT 1
65 5145065 SPRING 1
66 0200312 PIN 1
67 0308045 O-RING 1 SET OF SEALS
68 5145068 INLET NOZZLE 1
75 0071245 ALLEN SCREW 4
76 1251201 WASHER 4
84 5145084 LONG FLEXIBLE PIPE 1
93 1411315 GUARD RING 8 SET OF SEALS
94 5145094 SCREW 4
102 0304435 O-RING 1 SET OF SEALS
105 5145105 DISTRIBUTOR 1
106 5145106 BUSHING 1
107 5145107 JOINT SHELL 1

* To starter A45 R
** To starter A45 L

REPAIR KIT
5290780
(Includes Set of Seals)
SET OF SEALS 5290401

-31-
12.2 KIT PARTS

12.2.1 KIT PARTS REF. (SEGUN KIT)

POS. REF. DESIGNATION QUANT. OBS.

1
2
3
4
5
6
7
8

-32-
12.3.- OTHER ELEMENTS

-SERVO-INTERLOCK: Ref. 5202075

POS. REF. DESIGNATION QUANT. OBS.

1 5202076 CILINDER BODY 1
2 5202077 INTERMEDIATE BODY 1
3 5202078 COVER BODY 1
4 5202079 PLUNGER WITH GUIDE 1
5 5202080 PLUNGER 1
6 5202081 SPRING 1
7 0301302 O-RING 1 SET OF SEALS
8 0070425 ALLEN SCREW 4
9 0070430 ALLEN SCREW 4
10 5202112 SEAL “U” 1 SET OF SEALS

-33-
-FILTER: Ref. 5804045

POS. REF. Nº DESIGNATION QUANT. OBSERV.

1 5804041 FILTER BODY 1
2 5804044 FILTER 1
3 0151002 WASHER 4
4 0011030 HEXAGONAL SCREW 4
5 5804051 COVER FASTENING 1
6 5804033 DRAINING SCREW 1
7 0307803 O-RING 1
8 0305704 O-RING 2 SET OF SEALS
10 5145069 STUD 4

-34-
-SERVOLUBRICATOR SL6: Ref. 5205500

POS. REF. Nº DESIGNATION QUANT. OBSERV.

1 5205501 CENTRAL BODY 1
2 5205502 REGULATOR BODY 1
3 5205503 SMALL WINDOW 1
4 5205504 UNION BOARD 1
5 5205505 SPRIND GUIDE 1
6 5205506 DISK PISTON 1
7 5205507 DISC ADJUSTMENT 1
8 5205508 REGULATION SCREW 1
9 5205509 ASPIRATION SCREW 1
10 5205510 SPRING 1
11 0510820 RACORD 1
12 5205512 BASE 1
13 5205513 TOP COVER 1
14 5205514 VALVE 1
19 0301704 O-RING 2
20 0261201 ELASTIC RING 1
21 0311804 GASKET “U” 1
22 0305116 O-RING 1
23 0220336 PIN 1
24 0300802 O-RING 1
25 0300615 O-RING 1
26 0800600 BALL Ø6 1
27 0070615 ALLEN SCREW 8
28 1250607 WASHER 8
30 5205034 COLUMN 4

-35-
31 0070430 ALLEN SCREW 4
32 0070415 ALLEN SCREW 6
33 5205002 FILTER 1
34 5205001 TANK CAP 1
35 5205007 TANK 1
36 0306602 O-RING 2
37 0070625 ALLEN SCREW 2
38 0302215 O-RING 1
39 0161015 WASHER 2
40 5701053 VALVE 1
41 0550445 DOUBLE CONE PIPE NYLON 2
42 0520414 RACORD 2

SET OF SEALS SERVOLUBRICATOR SL6 5290630

-36-
-REPAIR KIT: Ref. 5290780 (includes set of seals)

-37-
-SET OF SEALS: Ref. 5290401

-38-
13.- DISTRIBUTION AND SERVICE

GALI GROUP

ESPAÑA:

GALI INTERNACIONAL, S.A.

Polígono Industrial Mas d’en Cisa
C/ Josep Tura, 5
08181-Sentmenat - BARCELONA
Apartado 11
Tel. 93 715 31 11
Fax 93 726 43 85 / 715 07 51

FRANCE: DEUTSCHLAND (D): ITALIA: CHINA:

GALI FRANCE, S.A. GALI DEUTSCHLAND GmbH GALI ITALIA, s.r.l. GALI (CHINA) TRADING COMPANY
66200 ELNE 55411 BINGEN 22070 SENNA COMASCO (CO) LIMITED
Rue B. Thimonnier – Z.I. Am Ockenheimer Graben 32 Via Canturina Vecchia, 19 JIN HAI ROAD, 6, BUILDING 12, 2F
Tel. 468 22 20 05 Tel. 0049-6721-10026/10027 Tel. 31 461 224 – 461 230 PUDONG DISTRICT, SHANGAI,
Fax 468 22 47 44 Fax 0049-6721-13144 Fax 31 461 245 CHINA, PC 201206
Tel. 00-86-21-58991830
Fax. 00-86-21-58991860

OTHER COMPANIES
DISTRIMAR, S.L.
ESPAÑA COMERCIAL DIESEL, S.L. ARDORA, S.A.
35009 LAS PALMAS GRAN
TANAJET, S.L. 20110 PASAJE SAN PEDRO 36208 VIGO
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
LES BRUYERES ETS. LEPETIT
GASCOGNE ENERGELEC D’APPLICATIONS 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 B.V SEA-TEK A/S ATLAS MARIN & INDUSTRI
20537 HAMBURG De Roysloot, 10 1820 SPYDEBERG 41502 GOTEBORG
Wendenstrasse 252 NL 2231 NZ RIJNSBURG Villaveien 1 U Marielholmsgatan 40
Tel. 0049-40-251 55-119 Tel. 71 402 92 10 Tel. 69 83 80 80 Tel. 31 84 45 50
Fax 0049-40-251 55-150 Fax 71 402 18 19 Fax 69 83 83 66 Fax 31 25 65 09
USA:
PORTUGAL:
C.S. CONTROLS
JAMECOR PRODUCTOS QUÍMICOS
Houma LA (USA)
4200 PORTO
101 Dickson Road, LA 707363
D. Eduardo Santos Silva, 261
Tel. +1 985 876 6040
Tel. 2 540 07 65
Fax +1 985 876 0751
Fax 2 540 20 78

KOREA: SINGAPORE: NEW ZEALAND: JAPAN:

SAMSAWON, INC. ADEX ZONEX PTE. LTD. VM DIESELS (NZ) LIMITED BOLLFILTER JAPAN LTD.
110-607 SEOUL 628623 SINGAPORE 118-120 NELSON STREET 4-2-14, Hachiman-dori, Chuo-ku,
CHONGO-KU 1 LOK YANG WAY NO.19B, PETONE Kobe 651-0085
Tel. 2 395 34 00 JURON Tel. 4 568 88 43 Tel. +81-(0)78-242-8550
Fax 2 396 03 40 Tel. 261 56 11 Fax 4 568 56 43 Fax. +81-(0)78-242-8515
Fax 266 53 32

-39-