GALI A-45 Service Manual Download Page 3

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CONTENT :

1.- INTRODUCIION

2.- AIR STARTER SERIE A

2.1.- CE – CONFORMITY OF STARTERS GALI

2.1.- CE – CONFORMITY OF STARTERS GALI
2.2.- DESCRIPTION OF ELEMENTS

2.2.- DESCRIPTION OF ELEMENTS
2.3.- IDENTIFICATION PLATE

2.3.- IDENTIFICATION PLATE

2.4.- STARTER DATA

2.4.1.- TECHNICAL DATA

2.4.1.- TECHNICAL DATA
2.4.2.- TORQUE/SPEED-POWER DIAGRAM and AIR FLOW DIAGRAM

2.4.2.- TORQUE/SPEED-POWER DIAGRAM and AIR FLOW DIAGRAM
2.4.3.- EXTERNAL DIMENSIONS

2.4.3.- EXTERNAL DIMENSIONS

3.- TRANSPOR

3.- TRANSPORT AND

T AND INFORMATION

INFORMATION FOR ASSEMBLY

FOR ASSEMBLY

3.1.- STATE DELIVERY

3.1.- STATE DELIVERY
3.2.- TRANSPORT

3.2.- TRANSPORT
3.3.- UNPACKING

3.3.- UNPACKING
3.4.- STORAGE

3.4.- STORAGE

4.- ASSEMBLY

4.1.- INSTALATION

4.1.- INSTALATION
4.2 -

4.2 -

FITTING OF CONTROL INSTRUMENTS AND

FITTING OF CONTROL INSTRUMENTS AND SERVOLUBRICATOR

SERVOLUBRICATOR

4.3.- SUPPLY OF COMPRESSED AIR

4.3.- SUPPLY OF COMPRESSED AIR
4.4.- SUPPLY OF ELECTRIC POWER

4.4.- SUPPLY OF ELECTRIC POWER

5.- FIRST START-UP

5.1.- AIR FEEDING CIRCUIT

5.1.- AIR FEEDING CIRCUIT
5.2.- CHECKING ASSEMBLY

5.2.- CHECKING ASSEMBLY
5.3.- PUTTING INTO SERVICE

5.3.- PUTTING INTO SERVICE

5.3.1.- PRIMING OF THE OIL INJECTION SYSTEM

5.3.1.- PRIMING OF THE OIL INJECTION SYSTEM
5.3.2.- LUBRICANTING OILS

5.3.2.- LUBRICANTING OILS

6.- OPERATION

6.1.- START-UP AND ENGAGEMENT

6.1.- START-UP AND ENGAGEMENT
6.2.- START UP

6.2.- START UP
6.3.- SHUTDOWN

6.3.- SHUTDOWN
6.4.- DESENGAGEMENT

6.4.- DESENGAGEMENT
6.5.- RESTART

6.5.- RESTART

7.- SAFETY INDICATORS

8.- MAINTENANCE

8.1.- GENERAL PRECAUTIONS

8.1.- GENERAL PRECAUTIONS
8.2.- MAINTENANCE PROGRAM

8.2.- MAINTENANCE PROGRAM

8.2.1.- MONTHLY REVISION

8.2.1.- MONTHLY REVISION
8.2.2.- ANNUAL REVISION

8.2.2.- ANNUAL REVISION

9.- CORRECTION OF POSSIBLE FAULTS

10.- EXTERNAL

10.- EXTERNAL DIMENSION

DIMENSIONS

11.- ACCESSORIES FOR THE INSTALLATION

12.- SPARE PARTS

12.1.- PARTS OF STARTER A45

12.1.- PARTS OF STARTER A45
12.2.- PARTS OF KIT

12.2.- PARTS OF KIT
12.3.- OTHER ELEMENTS

12.3.- OTHER ELEMENTS

13.- DISTRIBUTION AND SERVICES

Summary of Contents for A-45

Page 1: ... 1 1 SERVICE MANUAL SERVICE MANUAL A AIR IR STA STARTER A RTER A 45 45 ...

Page 2: ...ation ou main gratuir des pieces défectueuses excluant toute autre prestation ou main d oeuvre sur de matériel autre que l d oeuvre sur de matériel autre que le démarreur e démarreur Conditions Conditions 1 Avoir retourné dûment completée la carte jointe 1 Avoir retourné dûment completée la carte jointe 2 Ne pas avoir fait un usage 2 Ne pas avoir fait un usage entretien ou emmagainage inadaptés en...

Page 3: ... OF ELECTRIC POWER 5 FIRST START UP 5 FIRST START UP 5 1 AIR FEEDING CIRCUIT 5 1 AIR FEEDING CIRCUIT 5 2 CHECKING ASSEMBLY 5 2 CHECKING ASSEMBLY 5 3 PUTTING INTO SERVICE 5 3 PUTTING INTO SERVICE 5 3 1 PRIMING OF THE OIL INJECTION SYSTEM 5 3 1 PRIMING OF THE OIL INJECTION SYSTEM 5 3 2 LUBRICANTING OILS 5 3 2 LUBRICANTING OILS 6 OPERATION 6 OPERATION 6 1 START UP AND ENGAGEMENT 6 1 START UP AND ENGA...

Page 4: ...IF THECORRECTIVE ACTIONS DON T TAKE MAY OCCUR INJURY OR DAMAGE DAMAGE IN THE INDICATIONS CORRESPONDING TO IN THE INDICATIONS CORRESPONDING TO SAFETY SAFETY THE SYMBOL MEANINGS ESTABLISHED BY THE THE SYMBOL MEANINGS ESTABLISHED BY THE REGULATIONS IN FORCE HAVE BEEN REGULATIONS IN FORCE HAVE BEEN RESPECTED RESPECTED STARTER ASSEMBLY OF THE ENGINE MUST BE DONE BY QUALIFIED PERSONNEL IN THIS REGARD ST...

Page 5: ...nes for their start up start up These starters are based on the principle of These starters are based on the principle of two geared rotors which are two geared rotors which are turned through the action of air turned through the action of air pressure This movement is subjected to the appropriate reduction to obtain a determined torque on the output pressure This movement is subjected to the appr...

Page 6: ...ing inside inside which th which the rotatio e rotation takes n takes place place Reducer Reducer and o and output utput shaft tran shaft transmission smission necessary necessary to deli to deliver the ver the appropriate appropriate torque torque and and speed speed to the to the output pinion and produce the meshing and unmeshing movements thereof output pinion and produce the meshing and unmes...

Page 7: ...owing data marked on the body arters have the following data marked on the body GALI GALI 30 BAR MAX G A45 30 BAR MAX G A45 X X X X turning turning direction direction R R right right CW CW or or L L left left CCW CCW NUMBER OF BASE NUMBER OF BASE ROTATION ROTATION indicated indicated by by an an arrow arrow according according to to turning turning direction direction In the identification plate ...

Page 8: ... 8 8 2 4 2 2 4 2 TORQUE SPEED POWER DIAGRAM and AIR FLOW DIAGRAM TORQUE SPEED POWER DIAGRAM and AIR FLOW DIAGRAM 2 4 3 EXTERNAL DIMENSIONS 2 4 3 EXTERNAL DIMENSIONS ...

Page 9: ...he inlet nozzle and air outlets the inlet nozzle and air outlets for for accessories These plugs are to prevent dirt from accessories These plugs are to prevent dirt from inside the starter before final assembly inside the starter before final assembly 3 4 STORAGE 3 4 STORAGE To prevent damage the starters have to be To prevent damage the starters have to be stored in a place stored in a place clo...

Page 10: ... means of a front flange front flange To secure the starter to To secure the starter to the flange are used quality screws 8 8 the flange are used quality screws 8 8 and tightened with a torque determined see and tightened with a torque determined see picture below picture below If the coupling has to If the coupling has to be made unavoidab be made unavoidably by cylindrical ly by cylindrical cra...

Page 11: ... adequate play between drive pinion and crown wheel and that it is constant constant over the length of the over the length of the tooth edge Check if the front tooth edge Check if the front distance of the gearing is that distance of the gearing is that indicated Also respect the indicated Also respect the screw tightening torques of the screw tightening torques of the following diagram following...

Page 12: ...and engine control equipment the push button valve V V can be can be replace by a solenoid valve replace by a solenoid valve Fit the Fit the servolubricato servolubricator r S S vertically in vertically in a well visible and practicable place to a well visible and practicable place to allow for easy priming control and allow for easy priming control and refilling refilling 4 3 SUPPLY OF COMPRESSED...

Page 13: ... of recommended The feeding conduit should have as short a run as possible and a minimum of changes of direction changes of direction To guarantee safety in starter maintenance it is necessary to incorporate a lockable and To guarantee safety in starter maintenance it is necessary to incorporate a lockable and airtight shut airtight shutoff valve which assures the isolation against pressure in the...

Page 14: ... charged and that the flow valve is opened valve is opened 5 3 PUTTING INTO SERVICE 5 3 PUTTING INTO SERVICE AL ALWAYS RESPECT THE SAFETY INSTRUCTIONS WAYS RESPECT THE SAFETY INSTRUCTIONS OF THIS MANUAL OF THIS MANUAL Before conne Before connecting cting the starter to an installation that is the starter to an installation that is in service the air should always in service the air should always b...

Page 15: ...lows Adjust the injection volume to its maximum Actuate 2 3 times Adjust the injection volume to its maximum Actuate 2 3 times the push button and then adjust again the oil the push button and then adjust again the oil injection to the volume as per detailed below injection to the volume as per detailed below D Du ur ra at ti io on n p pr re es ss s A A4 45 5 2 3 2 3 2 2 6 6 4 4 6 6 10 10 6 6 Ne N...

Page 16: ...FOR BACKWARD MOTION OF THE DRIVE PINION At the moment when the motor comes into At the moment when the motor comes into operation on its own the greater torque generated by the operation on its own the greater torque generated by the latter latter causes disengagement and an internal mechanism produces shutdown of the starter causes disengagement and an internal mechanism produces shutdown of the ...

Page 17: ... installa the starter to an installation that is tion that is in service you should always in service you should always discharge the air pressure in the same If there is a pressure gauge at the inlet to the discharge the air pressure in the same If there is a pressure gauge at the inlet to the starter use it check f starter use it check for absence of pressure or absence of pressure To a To avoid...

Page 18: ...entive maintena The preventive maintenance of the GALI nce of the GALI starters greatly depends on the use that the starters greatly depends on the use that the corresponding user makes corresponding user makes thereof both for the frequency of start ups and for the type of motor Indeed a starter that never works thereof both for the frequency of start ups and for the type of motor Indeed a starte...

Page 19: ...torque as per point 4 1 Set torque as per point 4 1 9 9 Verify Verify state state of of wiring wiring Visual Visual Replace Replace wiring wiring and and protect protect it it appropriately appropriately 10 10 Verify Verify electrically electrically controlled controlled valve valve securing securing Visual Visual Retighten Retighten screws screws 11 11 Open Open general general shutoff shutoff va...

Page 20: ... 20 20 ...

Page 21: ...s In t In the even he event o t of d f defec efect t 1 1 Close the general shutoff valve with Close the general shutoff valve with padlock and empty the pipe padlock and empty the pipe 2 2 Loosen Loosen the the four four nuts nuts 01 01 and and washer washer 02 02 Allen Allen key key 3 3 Remove Remove head head Manual Manual 4 4 Withdraw Withdraw main main rotor rotor 04 04 and and secondary secon...

Page 22: ...lined shaft shaft 19 19 sticking sticking Disassembl Disassemble e and and clean clean check check spring 22 and reassemble spring 22 and reassemble 4 4 Pinion revolves but does Pinion revolves but does not advance not advance Pneumatic Pneumatic motor motor inoperative inoperative Disassemble Disassemble inspect inspect rotors rotors for for foreign matters between teeth and for foreign matters b...

Page 23: ...mble clean clean oil oil and and resemble replace if resemble replace if needed needed Main Main valve valve 26 26 blocked blocked Disassemble Disassemble clean clean oil oil and and reassemble reassemble Piston Piston 7 7 and and valve valve 8 8 defective defective Disassemble Disassemble clean clean oil oil and and reassemble Replace if needed reassemble Replace if needed Valve Valve 13 13 does ...

Page 24: ... 24 24 10 EXTERNAL DIMENSION 10 EXTERNAL DIMENSION 10 1 KIT REF 10 1 KIT REF SEGUN KIT SEGUN KIT ...

Page 25: ... types of electro valves and pushers Specific GALI references exist if it is wished to have the starter with electro valve have the starter with electro valve incorporated In this case only the incorporated In this case only the electric connection thereof is necessary electric connection thereof is necessary and the main air pipe and the main air pipe 11 2 DRIVE PINIONS 11 2 DRIVE PINIONS Besides...

Page 26: ...o not forget to insert not forget to insert the O ring 05 which is the O ring 05 which is provided between the nozzle and the starter Assure the correct provided between the nozzle and the starter Assure the correct assembly of the same and avoid it assembly of the same and avoid it being badly positioned being badly positioned which would damage the same and mean loss of which would damage the sa...

Page 27: ... starts at maximum injection maximum injection volume allowing the lube pip volume allowing the lube pipe to fill up Thereafter the e to fill up Thereafter the injection volume has to be adjusted again to the desired injection volume has to be adjusted again to the desired volume volume The necessary oil quantity depends upon the starting frequency and duration and on the condition of the feed The...

Page 28: ...07 HAULING HAULING CROWN CROWN RIGHT RIGHT 1 1 5145507 5145507 HAULING HAULING CROWN CROWN LEFT LEFT 1 1 8 8 0821111 0821111 BEARING BEARING ROLLER ROLLER 23 23 9 9 5145009 5145009 SPECIAL SPECIAL JOINT JOINT 1 1 SET SET OF OF SEALS SEALS 10 10 5145010 5145010 BEARING BEARING DISC DISC 1 1 11 11 5145011 5145011 SPLINED SPLINED SHAFT SHAFT RIGHT RIGHT 1 1 5145511 5145511 SPLINED SPLINED SHAFT SHAFT...

Page 29: ...2 2 REPAIR REPAIR KIT KIT 32 32 5290705 5290705 ASSEMBLY ASSEMBLY PUSHER PUSHER 1 1 36 36 0070520 0070520 ALLEN ALLEN SCREW SCREW 2 2 37 37 1250506 1250506 WASHER WASHER 2 2 38 38 5145038 5145038 SECUNDARY SECUNDARY ROTOR ROTOR 1 1 REPAIR REPAIR KIT KIT 40 40 5145040 5145040 MAIN MAIN ROTOR ROTOR 1 1 REPAIR REPAIR KIT KIT 42 42 0423002 0423002 BEARING BEARING DISC DISC 2 2 REPAIR REPAIR KIT KIT 43...

Page 30: ...84 5145084 LONG FLEXIBLE PIPE LONG FLEXIBLE PIPE 1 1 85 85 5147147 5147147 MEMBRANE MEMBRANE 1 1 86 86 6205005 6205005 PLUG PLUG 1 1 87 87 5145087 5145087 ELBOW ELBOW 1 1 88 88 5306180 5306180 SILENCER SILENCER A45 A45 1 1 91 91 0151425 0151425 WASHER WASHER 4 4 92 92 0101411 0101411 NUT NUT 4 4 93 93 1411315 1411315 GUARD GUARD RING RING 8 8 SET SET OF OF SEALS SEALS 94 94 5145094 5145094 SCREW S...

Page 31: ... O RING 1 1 SET SET OF OF SEALS SEALS 68 68 5145068 5145068 INLET INLET NOZZLE NOZZLE 1 1 75 75 0071245 0071245 ALLEN ALLEN SCREW SCREW 4 4 76 76 1251201 1251201 WASHER WASHER 4 4 84 84 5145084 5145084 LONG LONG FLEXIBLE FLEXIBLE PIPE PIPE 1 1 93 93 1411315 1411315 GUARD GUARD RING RING 8 8 SET SET OF OF SEALS SEALS 94 94 5145094 5145094 SCREW SCREW 4 4 102 102 0304435 0304435 O RING O RING 1 1 SE...

Page 32: ... 32 32 12 2 KIT PARTS 12 2 KIT PARTS 12 2 1 12 2 1 KIT PA KIT PARTS RE RTS REF F SEGUN KIT SEGUN KIT POS POS REF REF DESIGNATION DESIGNATION QUANT QUANT OBS OBS 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 ...

Page 33: ...DIATE INTERMEDIATE BODY BODY 1 1 3 3 5202078 5202078 COVER COVER BODY BODY 1 1 4 4 5202079 5202079 PLUNGER PLUNGER WITH WITH GUIDE GUIDE 1 1 5 5 5202080 5202080 PLUNGER PLUNGER 1 1 6 6 5202081 5202081 SPRING SPRING 1 1 7 7 0301302 0301302 O RING O RING 1 1 SET SET OF OF SEALS SEALS 8 8 0070425 0070425 ALLEN ALLEN SCREW SCREW 4 4 9 9 0070430 0070430 ALLEN ALLEN SCREW SCREW 4 4 10 10 5202112 5202112...

Page 34: ...04044 5804044 FILTER FILTER 1 1 3 3 0151002 0151002 WASHER WASHER 4 4 4 4 0011030 0011030 HEXAGONAL HEXAGONAL SCREW SCREW 4 4 5 5 5804051 5804051 COVER COVER FASTENING FASTENING 1 1 6 6 5804033 5804033 DRAINING DRAINING SCREW SCREW 1 1 7 7 0307803 0307803 O RING O RING 1 1 8 8 0305704 0305704 O RING O RING 2 2 SET SET OF OF SEALS SEALS 10 10 5145069 5145069 STUD STUD 4 4 ...

Page 35: ...ION SCREW SCREW 1 1 9 9 5205509 5205509 ASPIRATION ASPIRATION SCREW SCREW 1 1 10 10 5205510 5205510 SPRING SPRING 1 1 11 11 0510820 0510820 RACORD RACORD 1 1 12 12 5205512 5205512 BASE BASE 1 1 13 13 5205513 5205513 TOP TOP COVER COVER 1 1 14 14 5205514 5205514 VALVE VALVE 1 1 19 19 0301704 0301704 O RING O RING 2 2 20 20 0261201 0261201 ELASTIC ELASTIC RING RING 1 1 21 21 0311804 0311804 GASKET G...

Page 36: ...TANK TANK 1 1 36 36 0306602 0306602 O RING O RING 2 2 37 37 0070625 0070625 ALLEN ALLEN SCREW SCREW 2 2 38 38 0302215 0302215 O RING O RING 1 1 39 39 0161015 0161015 WASHER WASHER 2 2 40 40 5701053 5701053 VALVE VALVE 1 1 41 0550445 41 0550445 DOUBLE CONE PIPE NYLON DOUBLE CONE PIPE NYLON 2 2 42 42 0520414 0520414 RACORD RACORD 2 2 SET OF SEALS SERVOLUBRICATOR SL6 SET OF SEALS SERVOLUBRICATOR SL6 ...

Page 37: ... 37 37 REPAIR KIT Ref REPAIR KIT Ref 5290780 includ 5290780 includes set of es set of seals seals ...

Page 38: ... 38 38 SET OF SEALS Ref SET OF SEALS Ref 5290401 5290401 ...

Page 39: ...ES LESBRUYERES F I R E M F I R E M 13011MARSEILLE 13011MARSEILLE 116BouledelaPomme 116BouledelaPomme Tel491952513 Tel491952513 Fax491352909 Fax491352909 ETS LEPETIT ETS LEPETIT 76600LEHAVRE 76600LEHAVRE 80 84 R AviateurGuerin 80 84 R AviateurGuerin Tel 232749840 Tel 232749840 Fax232749849 Fax232749849 S A D SOCIETE S A D SOCIETE D APPLICATIONSDIESEL D APPLICATIONSDIESEL 57000THIONVILLE 57000THIONV...

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GALI A-45, Service Manual

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