Be sure to have at hand a repair kit ref.

5290109

GENERAL REVISION: REVISION OF ROTORS AND LUBRICATION

Action to carry out Tools In the event of defect
Close the general shutoff valve with
1
padlock and empty the pipe.
2 Loosen the four nuts 01 Flat star key 11
3 Remove head and 4 washers 02 Manual
4 Withdraw main rotor 03 and secondary 04 Manual
Examine state of rotors (wear, cracks, Visual Replace with new rotors
5
etc.)
Dismantle reten 05-06-07-08 according key 09 Replace with new
instructions (see next page) ref.GALI5907188 Key Facon FACOM U-49P5 y U-49P6
6
(includes in
repair kit)
Grease bearings Grease
7 KLUBERPLEX
BEM 34-132
8 Loosen the four screws 10 Allen key 6
Grease crown teeth Krafft KL
9
COMPLEX
Grease bearings Grease
10 KLUBERPLEX
BEM 34-132
Replace the head with the four nuts 01 Flat star key 11
11
and washers 02
Replace the crown wheel and front cover Allen key 06
12
with the four screws and their washers
13 Open general shutoff valve

For lubrication always use the grease and oil indicated below:

O-rings: TELLUS 32 oil.

Bearings and rollers: KLUBERPLEX BEM 34-132 grease.

Ref. GALI 5290553 (includes in repair kit)

Main rotor and crown teeth: KRAFFT KL COMPLEX grease

Ref. GALI 5290552 (includes in repair kit)

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-Disassemby and assembly retainer, in motor body and valve body A-27 R:

- Disassemby and assembly retainer, in motor body and valve body A-27 L:

Mbc -22
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
 Filter 30 obstructed  Remove and clean filter 30
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
circuit closed position guides or change parts.
 Electro valve or filter choked.  Remove and clean the same
 Filter 30 obstructed  Remove and clean filter 30
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.

Mbc -23
 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
7

After starting of diesel  Filter 31 obstructed  Remove and clean filter 31

engine, the driving
pinion of starter
11 disengages from the
flywheel and it continues
rotating for a period of
time

Mbc -24
10. – EXTERNAL DIMENSIONS

10.1.- KIT REF. 5127000.G01 (R-CW)

Mbc -25
10.2.- KIT REF. 5127500.G01 (L- CCW)

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11. – ACCESORIES 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 (see point 4.1)

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.

Mbc -27
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).

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.

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.

Mbc -28
12.- SPARE PARTS

12.1. – PARTS STARTER A27 R-L

POS. REF. Nº DESIGNATION QUANT. OBSERV.

1 5290606 SUB-ASSEMBLY FRONT COVER A27 1 See detail below
4 0071030 ALLEN SCREW 4
7 5125009 SPECIAL JOINT 1 SET OF SEALS
9 0820707 BEARING ROLLER 25
10 5125010 BEARING DISC 1
15 5290101* HAULING CROWN RIGHT 1
5290102** HAULING CROWN LEFT 1
16 5125013* SPRING RIGHT 1
5125513** SPRING LEFT 1
17 5125011* SPLINED SHAFT RIGHT 1
5125511** SPLINED SHAFT LEFT 1

- Detail SUB-ASSEMBLY FRONT COVER A27

POS. REF. Nº DESIGNATION QUANT. OBSERV.

3 0924520 NEEDLE BEARING 1
6 5127120 FRONT COVER 1
8 5125002 BEARING OUTER RING 1
11 0275902 TENSION WASHER 1
79 5127122 CUT RING 1 SET OF SEALS
80 5127121 CUT RING 1 SET OF SEALS

Mbc -29
POS. REF. Nº DESIGNATION QUANT. OBSERV.
18 5290703 SUB-ASSEMBLY PUSHER A27 1
19 0301615 O-RING 1 SET OF SEALS
21 1170585 ALLEN SCREW 2
23 5127124* MOTOR BODY RIGHT 1
5127624** MOTOR BODY LEFT 1
24 5127128 MAIN ROTOR 1 REPAIR KIT
41 5125026 STUD 4
42 5125091 FLAT WASHER 4
43 5125092 WASHER 4
44 5127136 SECUNDARY ROTOR 1 REPAIR KIT
73 5125096 PLETINE 1
74 0301102 O-RING 1 SET OF SEALS
81 5127139* FRONT LOCKER R. LEFT 1
5127639** FRONT LOCKER R. RIGHT 1
82 0303715 O-RING 1 SET OF SEALS
83 0922023 NEEDLE BEARING 1 REPAIR KIT
84 0303715 O-RING 1 SET OF SEALS
85 5127127* RETAINER 1 REPAIR KIT
5127137** RETAINER 1 REPAIR KIT
90 0302815 O-RING 1 SET OF SEALS
91 0921518 NEEDLE BEARING 1 REPAIR KIT
92 0302815 O-RING 1 SET OF SEALS
93 5127141* RETAINER 1 REPAIR KIT
5127140** RETAINER 1 REPAIR KIT
94 0220620 PIN 2

Mbc -30
POS. REF. Nº DESIGNATION QUANT. OBSERV.
25 5127134* VALVE BODY RIGHT 1
5127634** VALVE BODY LEFT 1
26 5290525 SILENCER 1
27 5127180 ELBOW 1
28 0120810 NUT 1
30 0121011 NUT 2
32 5124252 STUD 2
34 5202300 SERVO-LOCKER 1 See detail next page
39 5125084 PIPE 1
40 5290103 SILENCER 1
45 5290104 CHECK VALVE 1
46 0200208 SLEEVE 1
47 5115085 MEMBRANE 1 SET OF SEALS
48 5127086 PLUG 1
71 5127158 PIPE FOR STOP SIGNAL 1
72 0200616 ELASTIC SPINE 1
75 0300615 O-RING 1 SET OF SEALS
76 0300415 O-RING 1 SET OF SEALS
86 5127137* FRONT LOCKER 1 REPAIR KIT
5127127** FRONT LOCKER 1 REPAIR KIT
87 0303715 O-RING 1 SET OF SEALS
88 0922023 NEEDLE BEARING 1 REPAIR KIT
89 0303715 O-RING 1 SET OF SEALS
95 5127140* RETAINER 1 REPAIR KIT
5127141** RETAINER 1 REPAIR KIT
96 0302815 O-RING 1 SET OF SEALS
97 0921518 NEEDLE BEARING 1 REPAIR KIT
98 0302815 O-RING 1 SET OF SEALS
103 5400141 RACOR 1
104 5400140 SUPPORT FILTER 1
105 1631212 FILTER 1
106 0440618 RACOR G1/8”-Ø6 1
107 0639708 PLUG G 1/8” 1

Mbc -31
-Detail SERVO-LOCKER: Ref. 5202300

POS. REF. Nº DESIGNATION QUANT. OBSERV.

01 0070470 ALLEN SCREW 4
02 1250405 SPECIAL WASHER 8
03 5202301 CILINDER 1
04 5290735 PILOT 1
05 5202176 LOCKER BODY 1
07 5202175 VALVE 1
08 5202183 SPRING 1
09 5202177 SUPPORT 1
11 5202187 PISTON 1
12 0311627 SEALER 1 SET OF SEALS
13 5202185 SPRING 1
14 5202186 ARRESTER RING 1
15 5202179 BODY VALVE 1
16 0300802 O-RING 1 SET OF SEALS
17 5290723 VALVE 1 SET OF SEALS
18 5202184 SPRING 1
19 0070530 ALLEN SCREW 2
20 1250506 SPECIAL WASHER 2
23 0301702 O-RING 1 SET OF SEALS
24 5202182 CONECTOR BODY 1
26 0070425 ALLEN SCREW 4

SET OF SEALS 5290845

Mbc -32
POS. REF. Nº DESIGNATION QUANT. OBSERV.
50 5290651 SUB-ASSEMBLY DISTRIBUITOR A27 1 See detail below
60 5125065 SPRING 1
61 5125069 STUD 4
64 0051310 STUD 1
67 5125068 INLET NOZZLE 1
68 0306625 O-RING 1 SET OF SEALS
69 1251001 SPECIAL WASHER 4
70 0071030 ALLEN SCREW 4

-Detail SUB-ASSEMBLY DISTRIBUITOR A27: Ref. 5290651

POS. REF. Nº DESIGNATION QUANT. OBSERV.

1 5125058 LIP SEAL 1 SET OF SEALS
2 5127170 MAIN VALVE 1
3 0304125 O-RING 1 SET OF SEALS
4 5125105 DISTRIBUTOR 1
5 5127171 BUSHING 1
6 0300615 O-RING 1 SET OF SEALS
7 0302703 O-RING 1 SET OF SEALS
8 5127172 JOINT SHELL 1
9 0160516.30 SPECIAL WASHER 1
10 0120606.30 NUT 1

* For starter A27R

** For starter A27 L
REPAIR KIT (include set of seals) 5290109

SET OF SEALS 5290108

Mbc -33
12.2. – BILL OF PARTS KIT

12.2.1 PARTS KIT REF. 5127000.G01 (R – CW)

POS. REF. Nº DESIGNATION QUANT. OBSERV.

1 0121218 ESPECIAL NUT 1
2 0151225 WASHER 1
3 9480002407 CONNECTOR 1
4 191544 SOLENOID VALVE 1
5 772002407 FILTER 1 SET OF SEALS
6 5106076 PIPE 1
7 0120810 TWOLOCK NUT 4
8 5125071 FLANGE 1
9 0303835 O-RING 1 SET OF SEALS
10 5127000 AIR STARTER A27-R 1

Mbc -34
 12.2.2 PARTS KIT REF. 5127500.G01 (L-CCW)

POS. REF. Nº DESIGNATION QUANT. OBSERV.

1 0121218 ESPECIAL NUT 1
2 0151225 WASHER 1
3 9480002407 CONNECTOR 1
4 191544 SOLENOID VALVE 1
5 772002407 FILTER 1 SET OF SEALS
6 5106076 PIPE 1
7 0120810 TWOLOCK NUT 4
8 5125071 FLANGE 1
9 0303835 O-RING 1 SET OF SEALS
10 5127500 AIR STARTER A27-L 1

Mbc -35
12.3.- OTHER ELEMENTS: (SALES REFERENCE)

-SOLENOID VALVE: Ref. 191544

Mbc -36
-REPAIR KIT: Ref. 5290109

Mbc -37
-SET OF SEALS: Ref. 5290108

Mbc -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 INTERNACIONAL, S.A.
66200 ELNE 55411 BINGEN 22070 SENNA COMASCO (CO) SHANGHAI OFFICE
Rue B. Thimonnier – Z.I. Am Ockenheimer Graben 32 Via Canturina Vecchia, 19 Room 808, Century Space Building
Tel. 468 22 20 05 Tel. 0049-6721-10026/10027 Tel. 31 461 224 – 461 230 Urumoi Bei Road, 199
Fax 468 22 47 44 Fax 0049-6721-13144 Fax 31 461 245 SHANGHAI – Post code 200040
Tel. 86-21-62489643
Fax 86-21-62489745

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

Mbc -39