Gali Air Starter Service Manuel A27!10!08-06

8/16/2019 Gali Air Starter Service Manuel A27!10!08-06

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SERVICE MANUAL AIR STARTER

A27.G01


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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 alusuario. Esta garantía cubre única y exclusivamente la sustitución gratuita de las piezas defectuosas, excluyendo toda prestación o manode 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 desus productos.

GUARANTEE: Within a period of ONE YEAR after purchase date, GALI will be liable for faulty material or manufacturing defects ofits products. The guarantee only covers free replacement of faulty parts and excludes any other indemnity or reimbursement of labourcosts 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 oruse 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 dufonctionnement de ses produits.

GARANTIE: GALI Während EINES JAHRES nach Kaufdatum leisten wir Gewähr für Material-und Fabrikationsfehler unsererErzeugnisse. Unsere Garantie deckt ausschliesslich den kostenfreien Austausch schadhafter Teile Jegliche anderenGewährleistungsansprüche 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 keineHaftung 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 ofunzionamento dei prodotti GALI.


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POR FAVOR, ENVIAR HOY MISMO / PLEASE MAIL TODAY / SVP EXPEDIER AUJOURD’HUI MEMEBITTE SOFORT EINSENDEN / PREGASI DI SPEDIRE OGGI STESSO

GALI INTERNACIONAL, S.A.Ctra. Molins de Rei a Vic, Km.32.7

Apartado 1108181 SENTMENAT (Barcelona)

ESPAÑA

REFERENCIA: ______________________________________________

Nº SERIE: ___________________________________________________

CLIENTE / CUSTOMER / CLIENT / KUNDE:

_________________________________________________________________________________________________________

DISTRIBUIDOR / DEALER / DISTRIBUTEUR / VERTRAGSHÄNDLER / DISTRIBUTORE:

_________________________________________________________________________________________________________

FECHA/DATE/DATUM/DATA:

_________________________________________________________________________________________________________


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CONTENT :

HOW TO USE THIS MANUAL

1. - PRESENTATION OF AIR STARTER SERIES A1.1. - EXTERNAL DIMENSIONS AND TECHNICAL DATA1.2. - DESIGNATION1.3. - DECLARATION OF THE MANUFACTURER

2. - TRANSPORT AND STORAGE, ASSEMBLY AND DISMANTLING2.1. - TRANSPORT AND STORAGE2.2. - ASSEMBLY2.3. - DISMANTLING

3. - INSTALLATION3.1. - POSITIONING AND ALIGNMENT3.2. - SUPPLY OF COMPRESSED AIR3.3. - PRESSURE READINGS3.4. - SUPPLY OF ELECTRIC POWER3.5. - POSSIBILITIES OF ASSEMBLY

3.5.1. – INLET NOZZLE

4. - FIRST START-UP4.1. - AIR FEEDING CIRCUIT4.2. - CHECKING ASSEMBLY4.3. – PUTTING INTO SERVICE

5. - OPERATION5.1. - DESCRIPTION OF ELEMENTS5.2. - START-UP AND ENGAGEMENT5.3. - START UP5.4. - SHUTDOWN5.4.1. - FOR ABSENCE OF SIGNAL5.4.2. - FOR BACKWARD MOTION OF DRIVE PINION5.5. - DESENGAGEMENT5.6. - RESTART

6. – SAFETY INDICATORS

7. - MAINTENANCE7.1. - GENERAL PRECAUTIONS7.2. - MAINTENANCE PROGRAM7.2.1. - MONTHLY REVISION7.2.2. - ANNUAL REVISION

8. - CORRECTION OF POSSIBLE FAULTS

9. - ACCESSORIES FOR THE INSTALLATION

9.1. – DRIVE PINIONS9.2. – INLET NOZZLE9.3. - FRONT SECURING FLANGE

10. – SPARE PARTS

12. - DISTRIBUTION AND SERVICES


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HOW TO USE THIS MANUAL.

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

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

MANNER.• MAXIMUM STARTER LIFE.

• CORRECT OPERATION OF THE STARTER THROUGHOUT ITS USEFUL LIFE.

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

MANDATORY REQUIREMENT: ANY INSTALLATION OF THE STARTER THAT DOESNOT COMPLY WITH THIS REQUIREMENT, SHALL BE CONSIDERED NON-CONFORMING.

RECOMMENDATION: TO OBTAIN MAXIMUM LIFETIME AND BEST OPERATION OFTHE STARTER.

IN THE INDICATIONS CORRESPONDING TO SAFETY THE SYMBOL MEANINGS ESTABLISHED BY THEREGULATIONS IN FORCE HAVE BEEN RESPECTED.


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1. - PRESENTATION OF AIR STARTER SERIES A

The GALI air starters are devices generally installed as auxiliary units of thermal motors or turbines, for theirstart-up.

These starters are based on the principle of two geared rotors which are turned through the action of airpressure. This movement is subjected to the appropriate reduction to obtain a determined torque on the outputshaft. 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 theflywheel of the motor.

The starters have internal mechanisms to achieve the meshing and avoid their start-up until it has been carriedout successfully. They are also provided with a device that avoids reengagement.

1.1. – EXTERNAL DIMENSIONS AND TECHNICAL DATA

A27

MAXIMUM POWER 25 KW

MAXIMUM TORQUE 133 Nm

MAXIMUM WORKING PRESSURE 30 bar

NET WEIGHT 13 kg

SPEED AT MAXIMUM POWER 3500 rpm

FRECUENCIA MAXIMA 4000rpm


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EXTERNAL DIMENSIONS

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

Figure for right or left turning:


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1.2.- DESIGNATION

All starters have the following data marked on the body:

GALI30 BAR MAX G A27 X (turning direction X: R - right / L - left)NUMBER OF BASE

ROTATION (indicated by an arrow, according to turning direction)

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

According to the graphic, it’s possible to provide the next references:

Turning Reference

R (derecha) 5127000.G01

L (izquierda) 5127500.G01


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2.- TRANSPORT AND STORAGE, ASSEMBLY AND DISMANTLING

2.1. - TRANSPORT AND STORAGE

The reduced weight of the GALI starters allows their handling by a single operative for the jobs of maintenance,assembly and dismantling.

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

The packing which they are provided with for delivery facilitates transport and storage, at the same time as itprotects the starter from possible blows or surface damages.

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

2.2. - ASSEMBLY

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

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

2.3. - DISMANTLING

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

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


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3.- INSTALLATION

3.1. - POSITIONING AND ALIGNMENT

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

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

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

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

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

J n

m (DP) alfa Jn (mm)

2.540 (10)2.75

33.175 (8)

0.3 – 0.6

3.54.233 (6)

20º

30.4 – 0.7

3.5 0.7 - 115º

2.117 (12)12º

0.3 – 0.5


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The starter has to be firmly joined to the motor body (not to the bed or other attachedelements). To avoid vibrations between the starter and the connection pipe, the installation isrecommended near the starter of a straight length of flexible pipe of at least 300 mm, whichcomplies 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 theoperation thereof no vibrations are produced which affect the distance between the drive pinionand the crown wheel of the motor flywheel.


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3.2. - SUPPLY OF COMPRESSED AIR

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

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

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

Unless expressly recommended otherwise, the inside diameter of the feeding pipe should notat any point be less than 25 mm or 1 inches.

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

To guarantee safety in starter maintenance, it is necessary to incorporate a lockable andairtight shutoff valve which assures the isolation against pressure in the access line tothe starter when the valve is c losed.

3.3. - PRESSURE TAKE-OFF

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

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


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3.4. - SUPPLY OF ELECTRIC POWER

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

The electrical ins tallation has to comply with the requirements of the Low VoltageElectrotechnical Regulations.

3.5. - POSSIBILITIES OF ASSEMBLY

3.5.1. – INTAKE NOZZLE

Independently of the assembly positions of the starter as a whole with respect to the motor (see point 3.1), boththe 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:

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 themost favourable position. Be careful to avoid the entry of dirt to the interior of the starter. Replace the screws,applying a torque of 48 Nm.

A B C D

01 02


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4- FIRST START UP

4.1. - AIR FEEDING CIRCUIT

The tube should be cleaned with pressurised air before being coupled to the starter, taking

particular care to prevent loose particles reaching the interior, due to welding the pipes or forany other reason.

4.2. - CHECKING ASSEMBLY

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

Check that the installation has been carried out in accordance with the general instructions provided above. Inparticular, verify that the line has no passing restrictions, with regard to that indicated in point 3.2.

Check the fastening of all elements and the installation of the necessary gaskets to guarantee air-tightness inthe unions between elements.

4.3. – PUTTING INTO SERVICE

ALWAYS RESPECT THE SAFETY INSTRUCTIONS OF POINT 6 OF THIS MANUAL

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

When the installation is completed, open the air feed valve carefully, observing if there is any leak; in such acase, close it again, empty the pipe slowly and clear the problem.

Apply short low-pressure bursts manually. Ensure the meshing between the pinion and crown wheel of the

motor is correct.

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

The installation of a pressure gauge connected to the pipe in the air intake to the starter allowsyou to make sure that there is no air remaining in the circuit and, when the starter is working, it

will be possible to determine the effective air feed pressure.


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5. - OPERATION

5.1. - DESCRIPTION OF THE ELEMENTS

The starter is made up of the following major blocks:

- Main valve: it serves for opening the air passage to the interior of the starter.- Head: distribution of air to the various elements.- Motor: it includes the pair of rotors and the casing inside which the rotation takes place.- Reducer and output shaft: transmission necessary to deliver the appropriate torque and speed to the

output pinion and produce the meshing and unmeshing movements thereof.- Servo-interlock: includes the air signal valve to begin the start-up and meshing movement, as well as to

prevent re-meshing.- Exhaust silencer: limits the sound level of start-up.- Electrovalve: receives the electrical signal and converts it in a pneumatic signal

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

REDUCER AND OUTPUT SHAFTMAIN VALVE MOTORHEAD

SERVO-INTERLOCK

EXHAUST SILENCER

ELECTRO-VALVULA


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5.2. - START-UP AND MESHING

The starter has two successive operations:

- First action: in which the pinion carries out an approach movement to the crown wheel andsimultaneously a double turn that favours the meshing of both elements. Only when the meshing hasbeen 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 itsmaximum power.

5.3. - START UP

Once the second movement has been carried out, the starter accelerates the motor very quickly, therebyreducing losses in the cylinders to the maximum until the compression is achieved under appropriate conditionsfor producing ignition if the fuel feed is correct.

5.4. - SHUTDOWN

The shutdown can take place for different reasons:

5.4.1. - FOR ABSENCE OF SIGNAL

If the signal fed by the electro valve or the air plunger is cut off, the starter is stopped and disengages.

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

5.4.2. - FOR BACKWARD MOTION OF THE DRIVE PINION

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

5.5. – DISENGAGEMENT

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

5.6. - RESTART

When the starter has been stopped, it will remain immobile until the control air pressure disappears (electrovalve or plunger), for which reason, in order to operate the starter again, it is necessary to cease acting on theplunger or to disable the electro valve briefly.Since the actual starter mechanisms are incapable of detecting whether the motor is rotating or has stoppedafter a start-up intent, this operation prevents the starter from insisting on another meshing action while theperson in charge of controlling the same is not sure that the motor is totally at rest, preventing the drive pinionfrom 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 hasstopped.


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6. – SAFETY INDICATIONS

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

Always w ear su itable eye protection for any maintenance operation of the starter.

For any operation on the starter, you should always close the supply and empty theair feed pipe, by acting on the plunger when the installation is air and the electricallycontrolled valve button when the installation is electric.

Disconnect, by means of a lockable shutoff valve, the air supply hose beforeinstalling, dismantling or adjusting any accessory of this starter. The lock shouldremain in place until operations on the starter are completed.

Before connecting the starter to an installation that is in service, you should alwaysdischarge the air pressure in the same. If there is a pressure gauge at the inlet to thestarter, use it check for absence of pressure.

To avoid the risk of explosion, refrain from using air hoses or couplings in theinstallation which are damaged or have not been accepted by the competentinspection.

Never make the equipment work above the maximum useable pressure (30 bar). Ifthere is a pressure gauge at the inlet to the starter, use it check for absence ofpressure.

Hands or other body parts should be kept clear of the drive pinion of the starter or thecrown wheel of the motor when air pressure is present in the start-up installation.

Risk of impact and entrapment.

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

approximately 3m f rom the exhaust silencer) during start-up, nor leave loose objectsthere that could be displaced by the same.


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7. - MAINTENANCE

7.1. - GENERAL PRECAUTIONS

ALWAYS RESPECT SAFETY INDICATIONS DESCRIBED IN POINT 6 OF THIS MANUAL

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

Always use original GALI spare parts. The spare parts that are not GALI originals can generate

hazards or malfunctioning of the starter.

7.2. - MAINTENANCE PROGRAM

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

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


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7.2.1. - MONTHLY REVISION

M01 GENERAL REVISION OF INSTALLATION

Action to carry out Tools In the event of defect

1Observe if there are leaks in theinstallation.

Close the corresponding general shutoffvalve, empty the pipe and replacedeteriorated element.

2Observe if there are cracks in flexible pipe Visual Close the corresponding general shutoff

valve, empty the pipe and replace flexiblepipe.

3Close the general shutoff valve withpadlock and empty the pipe slowly.

4Observe wear in flanks of the drive pinion Visual Remove lock nut, fit new pinion and

replace the nut with the correspondingtorque (9.2)

5Observe cracks or marks of the drivepinion

Visual Remove lock nut, fit new pinion andreplace the nut with the correspondingtorque (9.2)

6 Rotate the pinion manually Carry out starter internal inspection M05.

7 Verify tightness of front securing screws Torquewrench Set torque as per table 3.1

8Verify tightness of pinion securing nut Torque

wrenchSet torque as per table 9.2

9Verify state of wiring Visual Replace wiring and protect it

appropriately

10 Verify electrically controlled valve securing Visual Retighten screws

11 Open general shutoff valve


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M05 GENERAL REVISION: REVISION OF ROTORS AND LUBRICATION

Action to carry out Tools In the event o f defect

1Close the general shutoff valve withpadlock and empty the pipe.

2 Loosen the four nuts 01 Flat star key 113 Remove head and 4 washers 02 Manual

4 Withdraw main rotor 03 and secondary 04 Manual

5Examine state of rotors (wear, cracks,etc.)

Visual Replace with new rotors

6Dismantle reten 05-06-07-08 accordinginstructions - see page 21

key 095907123

Replace with newKey Facon U-49AD5-1 and u-49AD-1

7Grease bearings Grease

KLUBERPLEXBEM 34-132

8 Loosen the four screws 10 Allen key 6

9Grease crown teeth Krafft KL

COMPLEX

10Grease bearings Grease

KLUBERPLEXBEM 34-132

11Replace the head with the four nuts 01and washers 02

Flat star key 11

12Replace the crown wheel and front coverwith the four screws and their washers

Allen key 06

13 Open general shutoff valve

Grease KLUBERPLEX BEM 34-132






Grease KRAFFT KL COMPLEX

0102

03

04

10


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

e/c =10

lock lock

lock

lock

09

05 06 07 08

R 2 6

R 2 6


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

ALWAYS RESPECT THE SAFETY INSTRUCTIONS OF POINT 6 OF THIS MANUAL

FAILURE POSIBLE CAUSE CORRECTION• Empty air receiver (s) • Charge receiver (s)• Flow valve (s) closed. • Open flow valve (s)• Control circuit blocked. • Disconnect and clean out• There is not signal for theelectro valve

• Control signal1

On pressing push- button, starter does notrespond and not airflow seems to exist incontrol circuit.

• Leak in control duct. . • Repair or replace.

• Insufficient air pressure • Increase pressure in receiver

• Piston 7 and valve 8 sticking inclosed position

• Remove and check both,smoothen guides or change parts.

2

On pressing push- button, starter does not

respond, although airflows through controlcircuit

• Electro valve or filter choked. • Remove and clean the same• Ring gear and/or pinion have

burrs or are damaged• Clean burrs or replace ifnecessary. Replace pinion by amore adequate one.3

Pinion revolves andadvances, but does notengage the ring gear.

• Lack of clearance between pinion and ring gear

• Check by distortion of ring gear.

• Push-rod 11 inoperative • Disassemble, check, smoothenguide diameter, clean or replace if

rusted• Insufficient air pressure • Increase pressure in receiver.4

Pinion revolves butdoes not advance

• Splined shaft 19 sticking • Disassemble and clean, checkspring 22 and reassemble.

• Pneumatic motor inoperative • Disassemble, inspect rotors forforeign matters between teeth andfor possible wear of gears, spindlesand bearing.

5

Pinion advances butdoes not rotate.

• Check valve 13 stuck of blocked.

• Disassemble, clean, oil andreassemble .

•

Main valve 26 blocked.•

Disassemble, clean, oil andreassemble or replace main valve.• Rotors worn or blocked. • Disassemble, clean, oil and

reassemble or replace rotors.• Insufficient air pressure • Increase pressure in receiver.• Main air pipe work restricted orinsufficient bore.

• Check all pipe work and replace joint it if necessary.

6

Pinion engages gearring, but will not turnengine.

• Membrane 17 broken. • Replace it.

7Starter starts workingupon opening the flow

• Incorrect connection of control pipes.

• Connect control pipes as perinstallations instructions.


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valve of the feed line,although electro valveare not actuated..

• Main valve 26 blocked andopen, valves 8 and 9 blocked or

broken.

• Disassemble, clean oil andreplace joint if needed.

• Main pipe work chocked or its bore is less than stipulated for thestarter.

• Revisar toda la tubería,cambiándola si su diámetro interiorno es el adecuado.

• Insufficient air pressure. • Increase pressure in receiver.

8

Lack of starter power..

• Badly worn rotors. • Replace.• Incorrect bore of main pipework.

• Check entire pipe work forcorrect bore and replace if incorrect.

• Idling of main valve 26. • Disassemble, clean, oil andresemble.

9

After starting theengine, pinion tries to-reengage and hits thering gear which resultsin damage to both. • Valve 29 or pilot 28 blocked. • Disassemble, clean, oil and

resemble. replace if needed.• Main valve 26 blocked • Disassemble, clean, oil and

reassemble.•

Piston 7 and valve 8 defective.•

Disassemble, clean, oil andreassemble. Replace if needed.• Valve 13 does not close

properly• Disassemble, check for correctclosing of the ball and the plug,

press the valve against its seat.• Splined shaft 19 blocked. • Disassemble, clean., check

spring 7

10

Starter motor will notstop. .

28 29

7 8

19 22 11 13 17 26

9


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9. - ACCESSORIES FOR INSTALLATION

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

GALI can furnish the following accessories to facilitate its assembly when the client prefers to carry out his owninstallation:

9.1. – DRIVE PINIONS

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

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

X

X X

X

X

X

X X

REFERENCIA

ROTACION

The usual fastening of the drive pinion is implemented by means of a two-part lock nut, with the tighteningtorques indicated:

Different fastening methods can be supplied to order.

REFERENCE


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Installation of the starter on the motor should assure the assembly of the same sothat the pinion is suffic iently protected to avoid risk of entrapments between the latterand the crown wheel of the motor, or rubbing against the same. This protectionshould be designed such that it catches possible fragments in the event of breakageof the pinion or crown teeth.

9.3. – INTAKE NOZZLE

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

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

6 0

35O

05

04

0302

01

The nozzle has to be fixed to the starter with the four self-locking nuts (04) which are supplied untightened. Donot forget to insert the O-ring (05) which is provided between the nozzle and the starter. Assure the correctassembly of the same and avoid it being badly positioned, which would damage the same and mean loss of air.

If, during the assembly, this gasket is damaged it will be necessary to replace it with a new identical one.

9.2. - FRONT SECURING FLANGE

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


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12.- DISTRIBUTION AND SERVICE

GALI GROUPESPAÑA:

GALI INTERNACIONAL, S.A.08181 SENTMENAT

Ctra. Molins de Rei a Vic, Km.32.7 Apartado 11

Tel. 93 715 31 11Fax 93 726 43 85 / 715 07 51

FRANCE: GALI FRANCE, S.A.

66200 ELNERue B. Thimonnier – Z.I.

Tel. 468 22 20 05Fax 468 22 47 44

DEUTSCHLAND (D): GALI DEUTSCHLAND GmbH

55411 BINGEN Am Ockenheimer Graben 32Tel. 0049-6721-10026/10027

Fax 0049-6721-13144

ITALIA: GALI ITALIA, s.r.l.

22070 SENNA COMASCO (CO)Via Canturina Vecchia, 19Tel. 31 461 224 – 461 230

Fax 31 461 245

OTHER COMPANIES

ESPAÑATANAJET, S.L.08039 BARCELONAMuelle Levante, 5Tel. 93 221 19 48

Fax 93 221 30 78

COMERCIAL DIESEL, S.L.20110 PASAJE SAN PEDROGUIPÚZCOA

Arrandegi, 2Tel. 943 40 11 12

Fax 943 39 13 72

ARDORA, S.A.36208 VIGOTomás A. Alonso, 150-152Tel. 986 21 32 38Fax 986 21 45 77

Teles 83206

DISTRIMAR, S.L.35009 LAS PALMAS GRAN CANARIAUrbanización Nueva IsletaBloque 6 bajosTel. 928 46 61 55

Fax 928 46 72 07FRANCE:GASCOGNE ENERGELEC32000 AUCH4 Rue Amiral BugardTel. 562 05 41 31Fax 562 05 38 78

LES BRUYERESF.I.R.E.M.13011 MARSEILLE116 Boule de la PommeTel 491 95 25 13Fax 491 35 29 09

ETS. LEPETIT76600 LE HAVRE80-84, R. Aviateur GuerinTel. 232 74 98 40Fax 232 74 98 49

S.A.D. – SOCIETE D’APPLICATIONSDIESEL57000 THIONVILLE50, Rue de da DigueTel. 382 88 62 62Fax 382 88 58 36

AES BUEAS44300 NANTES38, Rue l’Ouche BuronTel. 251 89 62 62Fax 240 49 99 67

DEUTSCHLAND (D)

CARL BAGUHN GmbH20537 HAMBURGWendenstrasse 252Tel. 0049-40-251 55-119Fax 0049-40-251 55-150

NEDERLAND:

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

NORGE:

SEA-TEK A/S1820 SPYDEBERGVillaveien 1 UTel. 69 83 80 80Fax 69 83 83 66

SVERIGE:

ATLAS MARIN & INDUSTRI41502 GOTEBORGMarielholmsgatan 40Tel. 31 84 45 50Fax 31 25 65 09

PORTUGAL: JAMECOR PRODUCTOS QUÍMICOS4200 PORTOD. Eduardo Santos Silva, 261Tel. 2 540 07 65Fax 2 540 20 78

KOREA: SAMSAWON, INC.110-607 SEOUL

CHONGO-KUTel. 2 395 34 00Fax 2 396 03 40

SINGAPORE: ADEX ZONEX PTE. LTD.628623 SINGAPORE

1 LOK YANG WAY NO.19B,JURONTel. 261 56 11Fax 266 53 32

NEW ZEALAND: VM DIESELS (NZ) LIMITED118-120 NELSON STREET

PETONETel. 4 568 88 43Fax 4 568 56 43

Gali Air Starter Service Manuel A27!10!08-06

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Transcript of Gali Air Starter Service Manuel A27!10!08-06