GALI A-45 Service Manual

Air starter

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SERVICE MANUAL

A AIR

STARTER A

STA

RTER

A-45

-45

-1-

- 1-

Table of Contents

Summary of Contents for GALI A-45

Page 1 SERVICE MANUAL SERVICE MANUAL A AIR STARTER A RTER A-45 - 1- -1- ...
Page 2 4.- Haber seguido las instrucciones de instalación del Manual de Servicio. del Manual de Servicio. GALI rehúsa toda responsabilidad por daños y perjuicios GALI rehúsa toda responsabilidad por daños y perjuicios que puedan producirse durante la instalación y funcionamiento que puedan producirse durante la instalación y funcionamiento de sus productos.
Page 3: Table Of Contents
CONTENT : 1.- INTRODUCIION 1.- INTRODUCIION 2.- AIR STARTER SERIE A 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...
Page 4 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS IN THE COURSE OF THE TEXT, VARIOUS INDICATIONS APPEAR. FOR THEIR CORRECT IN THE COURSE OF THE TEXT, VARIOUS INDICATIONS APPEAR. FOR THEIR CORRECT INTERPRETATION THE FOLLOWING MEANINGS OF THE SYMBOLS SHOULD BE KEPT INTERPRETATION THE FOLLOWING MEANINGS OF THE SYMBOLS SHOULD BE KEPT IN MIND: IN MIND: MANDATORY REQUIREMENT: ANY INSTALLATION OF THE STARTER THAT DOES...
Page 5: Air Starter Serie A
1.- INTRODUCTION 1.- INTRODUCTION These instructions are for installing GALI starters in These instructions are for installing GALI starters in the correspondent motor safely. If you read and the correspondent motor safely. If you read and respected respected the following information, the team will have a proper operation and have a long service the following information, the team will have a proper operation and have a long service life.
Page 6: Description Of Elements
2.2. - DESCRIPTION OF THE ELEMENTS 2.2. - DESCRIPTION OF THE ELEMENTS The starter is made up The starter is made up of the following major blocks: of the following major blocks: Main Main valve: valve: it serves it serves for o for opening...
Page 7: Identification Plate
2.3.- IDENTIFICATION PLATE In the plate is In the plate is included the GALI reference assembly, the serial number and the year of included the GALI reference assembly, the serial number and the year of manufacture. The plate manufacture. The plate is situated in a is situated in a visible place and accessible.
Page 8: Torque/Speed-Power Diagram And Air Flow Diagram
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 - 8- -8- ...
Page 9: State Delivery
3.- TRANSPORT AND INFORMATION FOR ASSEMBLY 3.1.- ESTATE DELIVERY 3.1.- ESTATE DELIVERY Before delivery, GALI starters Before delivery, GALI starters have been examined and tested under various have been examined and tested under various operating condition operating conditions. The s. The results...
Page 10: Assembly
4.- ASSEMBLY 4.- ASSEMBLY 4.1.- INSTALATION 4.1.- INSTALATION Not allowed to modify the starter Not allowed to modify the starter when the security and performance can be adversely when the security and performance can be adversely affected.
Page 11 Independ Independently of the assembly positions of t ently of the assembly positions of the starter as a he starter as a whole with respect to the whole with respect to the motor, both the intake motor, both the intake nozzle and the exhaust silencer are directional, to facilitate their adaptation to the motor.
Page 12: Supply Of Compressed Air
GALI starting limiter. GALI starting limiter. In installation comprising automatic starting and engine control equipment, the push-button valve In installation comprising automatic starting and engine control equipment, the push-button valve can be...
Page 13: Supply Of Electric Power
GALI air and a GALI air filter be connected immediately before the starter. The filter be connected immediately before the starter. The installation should foresee a horizontal stretch for installation of the filter.
Page 14: First Start-Up
5.- FIRST START UP 5.- FIRST START UP 5.1. - AIR FEEDING CIRCUIT 5.1. - AIR FEEDING CIRCUIT The tube should be cleaned with pressurised air before being coupled to the starter, t The tube should be cleaned with pressurised air before being coupled to the starter, taking aking particular care to prevent loose particles reaching the interior, due to particular care to prevent loose particles reaching the interior, due to welding the pipes or for...
Page 15: Priming Of The Oil Injection System
Do not operate the starter at pressures higher than those in Do not operate the starter at pressures higher than those in dicated in the dicated in the chara characteristics cteristics of t of t he equipme he equipment.
Page 16: Operation
6. - OPERATION 6. - OPERATION 6.1. - START-UP AND MESHING 6.1. - START-UP AND MESHING The starter has two successive operations: The starter has two successive operations: First actio First action: in n: in which th which the pin e pinion carrie ion carries out...
Page 17: Safety Indicators
7. – SAFETY INDICATIONS 7. – SAFETY INDICATIONS Al Alw w ays ays pay pay th th e max e maxim imum um att att ent entio io n t n to p o p os os si si bl ble air e air leak leaks.
Page 18: Maintenance
Then lubricate all parts with the new oil and re-assemble the starter. oil and re-assemble the starter. To achieve maximum duration and reliability in the operation of the GALI starter, To achieve maximum duration and reliability in the operation of the GALI starter, the maintenan maintenance program should be ce program should be carried out which carried out which is detailed next.
Page 19: Monthly Revision
8.2.1. - MONTHLY REVISION 8.2.1. - MONTHLY REVISION GENERAL REVISION OF INSTALLATION GENERAL REVISION OF INSTALLATION Ac Ac ti ti on on to to car carry ry ou out t Too ls ls In t In t he even he even t o t o f d...
Page 20 - 20- -20- ...
Page 21 -GENERAL REVISION: REVISION OF ROTORS -GENERAL REVISION: REVISION OF ROTORS AND LUBRICATION AND LUBRICATION Be sure to have at Be sure to have at hand a repair kit ref. hand a repair kit ref. 5290780 5290780 GENERAL REVISION: REVISION OF ROTORS AND LUBRICATION GENERAL REVISION: REVISION OF ROTORS AND LUBRICATION Ac...
Page 22: Correction Of Possible Faults
9. – CORRECTION OF POSSIBLE FAULTS 9. – CORRECTION OF POSSIBLE FAULTS FAIL FAILURE POSIBLE POSIBLE CAUSE CAUSE CORRECTION CORRECTION On pressing push- On pressing push- Empty Empty air air receiver receiver (s) (s) ...
Page 23 After starting the engine, After starting the engine, Incorrect Incorrect bore bore of of main main pipe pipe work. work. Check Check entire entire pipe pipe work work for for correct correct ...
Page 24: External 10.- External Dimension
10. – EXTERNAL DIMENSION 10. – EXTERNAL DIMENSION (SEGUN KIT) (SEGUN KIT) 10.1.- KIT REF. 10.1.- KIT REF. - 24- -24- ...
Page 25: Accessories For The Installation
GALI can serve different types of electro valves and pushers. Specific GALI references exist if it is wished to 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 have the starter with electro valve incorporated.
Page 26 11.3. – INTAKE NOZZLE 11.3. – INTAKE NOZZLE The starters are delivered fitted with a The starters are delivered fitted with a standard connection nozzle (01) to which the air intake standard connection nozzle (01) to which the air intake tube (02) can be tube (02) can be welded which connects it with the tank welded which connects it with the tank (or with the...
Page 27 As well as As well as a great number of standardized flanges, GALI can deliver specific front a great number of standardized flanges, GALI can deliver specific front securing flanges for any securing flanges for any application of its starters.
Page 28: Spare Parts
12.- SPARE PARTS 12.- SPARE PARTS 12.1.- PARTS OF STARTER A45 R-L 12.1.- PARTS OF STARTER A45 R-L POS. POS. REF. REF. Nº Nº DESIGNATION DESIGNATION QUANT. QUANT. OBSERV. OBSERV. 5145001 5145001 FRONTAL FRONTAL COVER COVER 5145002 5145002 BEARING...
Page 29 POS. POS. REF. REF. Nº Nº DESIGNATION DESIGNATION QUANT. QUANT. OBSERV. OBSERV. 5145019* 5145019* MOTOR MOTOR BODY BODY RIGHT RIGHT 5145519** 5145519** MOTOR MOTOR BODY BODY LEFT LEFT 26 26 5145026 5145026 STUD STUD 27 27 5145027 5145027 RING...
Page 30 POS. POS. REF. REF. Nº Nº DESIGNATION DESIGNATION QUANT. QUANT. OBSERV. OBSERV. 49 49 5145049 5145049 STUD STUD M8 51 51 0150816 0150816 WASHER WASHER 53 53 0100865 0100865 NUT M8 64 64 0121012.30 0121012.30 77 77 0151002 0151002 WASHER...
Page 31 POS. POS. REF. REF. Nº Nº DESIGNATION DESIGNATION QUANT. QUANT. OBSERV. OBSERV. 55 55 0306004 0306004 O-RING O-RING SET OF OF SEALS SEALS 56 56 5145056 5145056 MAIN MAIN VALVE VALVE 57 57 5145057 5145057 SPECIAL SPECIAL NUT 58 58 5145058...
Page 32 12.2 KIT PARTS 12.2 KIT PARTS (SEGUN KIT) (SEGUN KIT) 12.2.1 12.2.1 KIT PA PARTS RE REF. POS. POS. REF. REF. DESIGNATION DESIGNATION QUANT. QUANT. OBS. OBS. - 32- -32- ...
Page 33: Other Elements
12.3.- OTHER ELEMENTS 12.3.- OTHER ELEMENTS -SERVO-INTERLOCK: Ref. -SERVO-INTERLOCK: Ref. 5202075 5202075 POS. POS. REF. REF. DESIGNATION DESIGNATION QUANT. QUANT. OBS. OBS. 5202076 5202076 CILINDER CILINDER BODY BODY 5202077 5202077 INTERMEDIATE INTERMEDIATE BODY BODY 5202078 5202078 COVER COVER BODY BODY...
Page 34 -FILTER: Ref. -FILTER: Ref. 580404 5804045 POS. POS. REF. REF. Nº Nº DESIGNATION DESIGNATION QUANT. QUANT. OBSERV. OBSERV. 5804041 5804041 FILTER FILTER BODY BODY 5804044 5804044 FILTER FILTER 0151002 0151002 WASHER WASHER 0011030 0011030 HEXAGONAL HEXAGONAL SCREW SCREW 5804051 5804051...
Page 35 -SERVOLUBRICATOR SL6: Ref. -SERVOLUBRICATOR SL6: Ref. 520550 5205500 POS. POS. REF. REF. Nº Nº DESIGNATION DESIGNATION QUANT. QUANT. OBSERV. OBSERV. 5205501 5205501 CENTRAL CENTRAL BODY BODY 5205502 5205502 REGULATOR REGULATOR BODY BODY 5205503 5205503 SMALL SMALL WINDOW WINDOW 5205504 5205504...
Page 36 31 31 0070430 0070430 ALLEN ALLEN SCREW SCREW 32 32 0070415 0070415 ALLEN ALLEN SCREW SCREW 33 33 5205002 5205002 FILTER FILTER 34 34 5205001 5205001 TANK TANK CAP 35 35 5205007 5205007 TANK TANK 36 36 0306602 0306602 O-RING...
Page 37 -REPAIR KIT: Ref. -REPAIR KIT: Ref. 5290780 (includ 5290780 (includes set of es set of seals) seals) - 37- -37- ...
Page 38 -SET OF SEALS: Ref. -SET OF SEALS: Ref. 5290401 5290401 - 38- -38- ...
Page 39 CHINA: GALI FRANCE, S.A. GALI FRANCE, S.A. GALI DEUTSCHLAND GmbH GALI DEUTSCHLAND GmbH GALI ITALIA, s.r.l. GALI ITALIA, s.r.l. GALI (CHINA) TRADING COMPANY GALI (CHINA) TRADING COMPANY 66200 ELNE 66200 ELNE 55411 BINGEN 55411 BINGEN 22070 SENNA COMASCO (CO)