T50P -service manual - RJ Mann & Associates, Inc
Contents
1. BEARING 37 PLANET SHAFT 34 RETAINING RING 33 Figure 6 Carrier Shaft Disassembly Page 5 TDI TURBOTWIN rrom TECH DEVELOPMENT 3 4 TURBINE HOUSING 3 4 1 Stage 2 Rotor Removal Remove four screws 4 ECP assembly 5 exhaust support 9 and exhaust guard 10 Units with an exhaust screen no ECP will utilize 8 screws Hold the stage 2 rotor 13 and remove the turbine screw 11 and washer 12 NOTE Secure the sun gear 29 in a soft jaw vise when removing turbine screw Install rotor puller tool P N 52 20076 and remove the stage 2 rotor as shown in figure 7 SQUARE KEY 14 PULLER TOOL 52 20076 gt ROTOR 2 13 Figure 7 Turbine Rotor Removal Remove the square key 14 from turbine shaft 29 3 4 2 Turbine Housing Disassembly Place the turbine on a firm surface with the sun gear end facing up Remove three screws 28 and bearing retainer plate 27 from turbine housing 26 Units with S N 0610 0994 and after will utilize four screws With the exhaust end facing up press turbine shaft 29 through turbine housing 26 as shown in figure 8 Remove labyrinth 24 from turbine shaft Page 6 Remove the aft bearing 152. 4 6 Bendix Drive Removal 5 7 Turbine Rotor Removal 6 8 Turbine Shaft Removal 6 9 Nozzle 2 Removal 6 10 Gear Teeth Wear Allowance 9 11 Turbine Bearing Shaft Removal 10 12 50 Illustrated Parts List 15 13 150 IPB S N 0610 0994 amp After 16 Publication T5 703 Rev 2 Issued July 31 2009 Page i TDI TURBOTWIN rrom TECH DEVELOPMENT SECTION 1 0 INTRODUCTION 1 1 GENERAL INFORMATION This manual provides information for servicing disassembly and re assembly of the TDI Turbotwin T50 P air starter If there are questions not answered by this manual please contact your local TDI distributor or dealer for assistance Illustrations and exploded views are provided to aid in disassembly and re assembly The TDI Turbotwin T50 P engine air starter is specially designed for starting today s automated low emission engines The Turbotwin uses aerodynamic speed control allowing for cranking torque throughout the start cycle The Turbotwin T50 P air starter is suited to operate within a wide range of inlet pressures and ambient temperatures This starter is designed for operation on compressed air and natural gas The robust turbine motor design in the Turbotwin T50 P air starter has no rubbing parts and therefore is tolerant of hard and liquid contamination in the supply to the starter As
3. TDI TURBOTWIN rrom TECH DEVELOPMENT Figure 12 T50 P Illustrated Parts List Publication T5 703 Rev 2 Page 15 Issued July 31 2009 TDI TURBOTWIN rrom TECH DEVELOPMENT T50 P TURBINE ASSEMBLY effective serial 0610 0994 Overhaul Kit ITEM DESCRIPTION PART NUMBER QTY T50P 28533 001 24 Bearing Spacer 9 93114 1 y 24A Seal 2 26719 1 y 26 Turbine Hsg Stage 1 8 Noz RH 2 28354 08R 1 26 Turbine Hsg Stage 1 8 Noz LH 2 28354 08L 1 26 Turbine Hsg Stage 1 10 Noz RH 2 28354 10R 1 26 Turbine Hsg Stage 1 10 Noz LH 2 28354 10L 1 26 Turbine Hsg Stage 1 14 Noz RH 2 28354 14R 1 26 Turbine Hsg Stage 1 14 Noz LH 2 28354 14L 1 27 earing Retainer 2 27406 1 28 Screw 71F 25020 012 4 N Figure 13 Model T50 Series Turbine Assembly Configured for Air amp Natural Gas Effective serial 0610 0994 Page 16 Publication T5 703 Rev 2 Issued July 31 2009
4. Turn the turbine nozzle over exhaust end up and install the labyrinth 18 onto the shaft For units with 0610 0994 and after press lip seal P N 2 26179 onto spacer P N 9 93114 and press lip seal with lips facing MATERIALS SOURCE Petroleum Jelly Commercially Available Parker O Ring Lube Commercially Available up into aft end of nozzle 1 Press the square key 14 into the keyway of turbine shaft 29 until seated Aeroshell 6 Grease Commercially Available Loctite RC290 Commercially Available TDI P N_9 94121 001 Table 6 Materials for Assembly 5 2 TURBINE HOUSING 5 2 1 TURBINE BEARING INSTALLATION Press the turbine bearing 15 onto the turbine shaft 29 until seated Press the turbine bearing shaft assembly 15 29 into the turbine housing 26 Use press tool P N 2 26943 if required per figure 11 Do not press on the end of the shaft because the load could damage the bearing balls Install the bearing retainer 27 into the turbine housing 26 and secure with three screws 28 Torque to 75 in Ibs Units with S N 0610 0994 and after will utilize four screws Install o ring 25 onto turbine housing 20 Page 10 Install stage 1 rotor 23 by sliding over turbine shaft 29 while simultaneously aligning the key with the keyway in the rotor 5 2 3 STAGE 2 NOZLE INSTALLATION Install turbine housing 26 into nozzle 2 containment housing 21 NOTE The air inlet port on nozzle 2 must be alig
5. wavy washers 16 and labyrinth 17 from nozzle 2 Install three screws 42 removed from the gearbox housing into the jack holes on the turbine housing 26 as shown in figure 9 Turn the screws in sequence until the turbine housing 26 is completely removed from the nozzle 2 21 Remove the stage 1 rotor 23 and square key 14 Press turbine shaft 29 through forward bearing 15 to remove bearing from shaft PRESSING TOOL ROTOR STG 1 23 inl J 3 H 34 iim NS TURBINE SHAFT 29 NOZZLE STAGE 1 26 NOZZLE 2 CONTAINMENT RING 21 Figure 8 Turbine Shaft Removal NOZZLE STAGE 1 26 1 4 20 UNC SCREW NX 1 gt 1 3 EZ IH MA 2 Pell TU Le IP 2 7 zd NOZZLE 2 CONTAINMENT RING 21 Figure 9 Nozzle 2 Removal Publication T5 703 Rev 2 Issued July 31 2009 SECTION 4 0 CLEANING and INSPECTION 4 1 CLEANING Degrease all metal parts except bearings using a commercially approved solvent Refer to Table 2 NOTE Never wash bendix assembly or bearings in cleaning solvents It is recommended bearings be replaced with new parts TDI TURBOTW
6. 2 28354 14L 1 27 Bearing Retainer 2 28446 1 28 Screw 71F 25020 012 3 Y 29 Turbine Shaft 11 2 1 2 28339 1 30 O Ring 9 90001 047 2 Y Publication T5 703 Rev 2 Issued July 31 2009 Page 13 TDI TURBOTWIN rrom TECH DEVELOPMENT Overhaul Kit ITEM DESCRIPTION PART NUMBER QTY T50P 28533 001 31 Ring Gear 2 28430 1 32 Carrier Shaft Assembly 2 28358 1 33 Retaining Ring 9 92001 001 3 34 Planet Shaft 2P 20182 3 35 Planet Gear Spacer 9 93004 6 Y 36 Planet Gear 11 2 1 2 28316 3 37 Planet Bearing 9 91004 001 3 Y 38 Bushing 9 91405 1 Y 39 Screw 14F 19024 012 4 Y 40 Dowel Pin 9 91502 007 0 10 1 41 Gearbox Housing 2 28352 1 42 Screw 14F 25020 044 4 Y 43 O Ring 9 90001 035 1 Y 44 Bearing Housing 2 24114 1 45 O Ring 9 90002 331 1 Y 46 Lip Seal 2 23810 1 Y 47 Thrust Washers 9 93085 2 Y 48 Retaining Ring 9 92001 025 1 Y 49 O Ring 9 90002 336 1 Y 50 Pre engage Piston 2 24644 001 1 51 O Ring 9 90002 234 1 Y 52 Split Rings 2 23419 2 Y 53 Drive 6 8P 11T RH 2 22954 1 53 Drive 6 8P 11T LH 2 22956 1 53 Drive 3 5MOD 14T RH 2 26816 1 53 Drive 3 5MOD 14T LH 2 25933 1 53 Drive 6 8P 12T RH 2 26143 001 1 54 Return Spring 9 90422 1 55 O Ring 9 90001 041 1 Y 56 Drive Housing 6 8P 2 24127 007 1 57 Screw 14F 25020 012 12 Y 58 Nose Bearing 6 8P 9 91408 1 Y Page 14 Publication T5 703 Rev 2 Issued July 31 2009
7. CW RH CCW LH when talking to your distributor 510 9910 112 X PART NUMBER T510 60048 01R 4 HOUSING PROOF PRESSURE IS 600 PSIG MAX OPERATING INLET PRESS 120 PSIG WARNING Nor OPERATE UNLOADED WITHOUT EXHAST GUARD OR WITHOUT EXHAUST FITTING NOTE You should always have the starters Part Number Serial Number Operating Pressure and Direction of Rotation information before calling your TDI distributor or dealer Figure 1 TDI TURBOTWIN Nameplate 10 60048 01R 0 00 MODEL T50 PRODUCT ORIENTATION OF INLET CONTROL PORTS NUMBER OF NOZZLES 00 0 DEGREES STD 07 210 DEGREES 08 8 NOZZLES 01 30 DEGREES 08 240 DEGREES 10 10 NOZZLES 02 60 DEGREES 09 270 DEGREES 14 14 NOZZLES 03 90 DEGREES 10 300 DEGREES 04 120 DEGREES 11 330 DEGREES 05 150 DEGREES 06 180 DEGREES DRAWING NUMBER FOR 50 MODEL TYPE 60048 T50P PRE ENGAGED OUTBOARD NOSE 11 2 1 RATIO SAE 3 MOUNT 60051 T50Y PRE ENGAGED OVERHUNG PINION 11 2 1 RATIO SAE 3 MOUNT 60052 T50Y PRE ENGAGED OVERHUNG PINION 11 2 1 RATIO SAE 1 MOUNT EXHAUST OPTIONS 0 EXHAUST SCREEN PINION CODES 1 NOT AVAILABLE 01 6 8 DP 11 ON 12T BLANK 2 00 PD 20 PA z 02 8 10 DP 12T ON 13T BLANK 1 625 PD 20 PA 03 8 10P 10T ON 11T BLANK 1 375 PD 20 PA 4 EXHAUST CLOSURE PLATE ECP 04 3 MOD 9T ON 9 567T BLANK 1 063 PD 14 5 PA 5
8. surface of shaft Raised metal on the keyway Wear must not exceed limits per Table 4 Parallelism of end surfaces Ends must be parallel within 0 0005 Turbine Housing Cracks and breakage Cracks and breakage are not acceptable Minor surface damage is permitted if function is not impaired broken gear teeth Needle Bearings Freedom of needle rollers Replace bearings Ball bearings Freedom of rotation without Replace bearings excessive play between races Containment Corrosion erosion cracks Cracks and breakage are not acceptable Ring Nozzle and broken nozzle edges Minor surface damage is permitted if function is not impaired Turbine Rotors Corrosion erosion cracks Minor tip rub is permitted if function is not and broken edges impaired Bore and key way wear Wear is not permitted Table 3 Parts Inspection Check Requirements Page 8 Publication T5 703 Rev 2 Issued July 31 2009 PART DESCRIPTION LIMIT Inches Ring gear Turbine Housing Internal measurement between two 072 diameter 4 6655 max pins Sun Gear Turbine Shaft Bearing diameter External measurement over two 072 diameter pins 11 2 1 5566 min Planet Gear External measurement over two 085 diameter pins 11 2 1 2 2217 min Table 4 Parts Wear Limits ITEM NUMBER TORQUE In Ibs Nm 4 Screw 190 21 11 Screw 220 25 18 Screw 75 8 28 Screw 113 13 39 Screw 81 9 42 Screw
9. with snap ring 48 using snap ring pliers 5 3 3 DRIVE INSTALLATION Apply a small amount of Aeroshell 6 grease to split rings 52 and install split rings onto drive assembly 53 Install o ring 55 onto drive housing 56 Install the drive assembly 53 onto carrier shaft and place return spring 54 over drive assembly 5 3 4 NOSE BEARING INSTALLATION Place the drive housing onto arbor press with the nose of drive facing down Press needle bearing 58 into drive housing 56 using arbor press The bearing ID stamping must be against pressing tool Do not press bearing tight against the Page 11 drive housing shoulder In addition be sure stamped end is beneath shoulder of bearing bore 5 4 FINAL ASSEMBLY Apply o ring grease to o ring 30 and install onto gearbox housing Apply liberal amounts of grease 100 grams to planet gears 36 turbine shaft sun gear 29 and ring gear 31 Temporarily install one screw 42 into ring gear 31 to prevent it from rotating while applying grease Page 12 TDI TURBOTWIN rrom TECH DEVELOPMENT Align gearbox assembly with turbine assembly and fasten together with four screws 42 Install drive housing 56 onto gearbox housing 41 and secure with twelve screws 57 Torque to 150 in Ib Install exhaust closure plate assembly using four screws 4 Torque to 150 in Ib Publication T5 703 Rev 2 Issued July 31 2009 SECTION 6 0 PARTS LIST TDI TUR
10. with all TDI air starter products there are no rubbing parts so there is no lubrication required This eliminates failures due to lubricator problems the expense of installing and maintaining the system and the messy and hazardous oil film around the starter exhaust The starter is factory grease packed for the life of the starter so it requires no maintenance Please review the rest of this manual before attempting to service the TDI Turbotwin T50 P air starter 1 2 WARNINGS CAUTIONS amp NOTES Throughout this manual certain types of information will be highlighted for your attention WARNING used where injury to personnel or damage to equipment is possible CAUTION used where there is the possibility of damage to equipment Publication T5 703 Rev 2 Issued July 31 2009 NOTE use to point out special interest information 1 3 DESCRIPTION OF OPERATION The Turbotwin T50 P air starter is powered by a two stage axial flow turbine coupled to a simple planetary gear reduction set The T50 P air starter incorporates a pre engaged drive coupled to the starter gearbox drive train to provide a means of disengaging the pinion from the engine s ring gear The high horsepower of the turbine air motor combined with the planetary gear speed reducer results in a very efficient and compact unit The Turbotwin T50 P air starters can be used over a wide range of drive pressures from 40 psig 2 7 BAR to 120 psig 8 BAR and a
11. 190 21 57 Screw 190 21 Refer to section 6 for part number identification Table 5 Torque Values Publication T5 703 Rev 2 Issued July 31 2009 TDI TURBOTWIN rrom TECH DEVELOPMENT MAXIMUM PERMISSIBLE WEAR ON EACH SIDE OF TOOTH DIMENSION B IS APPROXIMATELY TEN PERCENT OF DIMENSION A uc DIM B DIM A CENTER OF TOOTH NEW TOOTH WORN TOOTH TYPICAL TYPICAL Figure 10 Gear Teeth Wear Allowances Page 9 SECTION 5 0 ASSEMBLY 5 1 GENERAL INFORMATION The tools listed in Table 1 are suggested for use by technicians servicing the Turbotwin T50 P air starter The best results can be expected when these tools are used Replace all screws o rings lip seals and bearings These parts are included in the overhaul kit shown in the Parts List Section 6 0 Always press the inner race of a ball bearing when installing a bearing onto a shaft Always press the outer race of a ball bearing when installing into a housing DO NOT LOAD BEARING BALLS Lubricate all o rings with petroleum jelly or Parker O ring Lube before assembly Refer to Table 5 for a list of materials to be used during assembly TDI TURBOTWIN rrom TECH DEVELOPMENT ARBOR PRESS PRESSING TOOL 2 26943 A VUA tlg p Figure 11 Turbine Bearing Shaft Installation 5 2 2 ROTOR 1 INSTALLATION
12. BOTWIN rrom TECH DEVELOPMENT The components illustrated and or described in this section are for the Turbotwin T50 P air starter When rebuilding T50 P air starter it is recommended to purchase and completely install the appropriate service kit s T50 P ILLUSTRATED PARTS LIST Overhaul Kit ITEM DESCRIPTION PART NUMBER QTY T50P 28533 001 1 Nut Hex 9 92155 06 1 Y 2 Washer Flat 9 93018 011 2 3 Plate Baffle 2 20192 1 4 Screw 14F 25020 014 8 Y 5 Housing Exhaust Cover 2 28369 1 6 Bushing 9 91436 1 7 Spring Compression 9 90408 016 1 8 Post 2 27223 1 9 Exhaust Support 2 271475 1 10 Exhaust Guard 2 28380 1 11 Screw Rotor Attachment 14F 25028 012 1 12 Rotor Washer 9 93047 1 13 Stage 2 Rotor 2 28410 1 14 Square Key 1 8 9 90220 050 2 Y 15 Turbine Bearing 9 91224 2 Y 16 Bearing Pre Load Spring 9 90439 2 Y 17 Spacer Labyrinth 2 28445 1 Y 18 Screw 71F 31218 020 4 19 Inlet Flange 2 28360 1 20 O Ring 9 90001 031 1 Y 21 Containment Nozzle 2 RH 2 28359 00R 1 21 Containment Nozzle 2 LH 2 28359 00L 1 22 Hollow Hex Plug 9 93501 002 1 23 Stage 1 Rotor 2 27225 1 24 Spacer Labyrinth 2 28444 1 Y 25 O Ring 9 90001 047 1 Y 26 Turbine Hsg Stage 1 10 Noz RH 2 28354 10R 1 26 Turbine Hsg Stage 1 10 Noz LH 2 28354 10L 1 26 Turbine Hsg Stage 1 14 Noz RH 2 28354 14R 1 26 Turbine Hsg Stage 1 14 Noz LH
13. IN rrom TECH DEVELOPMENT Clean aluminum parts using the solutions per Table 2 soak for 5 minutes Remove parts rinse in hot water and dry thoroughly Clean corroded steel approved stripper parts with a commercially Clean corroded aluminum parts by cleaning as stated above and then immerse the parts in chromic nitric phosphoric acid pickle solution per Table 2 Rinse in hot water and dry thoroughly MATERIAL or COMPOUND MANUFACTURER Degreasing Solvent Trichloroethylene O T 634 Commercially Available Commercially Available Aluminum Cleaning Solution Steel Cleaner Rust amp Corrosion Chromic Nitric Phosphoric Acid Pickle Solution Diversey Corp 212 W Monroe Chicago IL 60606 Dissolve 5 oz of Diversey 808 per gallon of water at 155 165 F Oakite Products Corp 50 Valley Heights NJ 07992 Rd Berkeley Mix 3 5 Ib of Oakite rust Stripper per gallon of water use at 160 180 F Mix 8lb of chromic acid 1 9 gal of phosphoric acid 1 5 gal of nitric acid with enough water to make a total of 10 gal of solution WARNING Follow all instructions provided with the MSDS sheets on the materials and compounds listed above Table 2 Cleaning Materials and Compounds 4 2 INSPECTION Use Table 3 as a guide to check for acceptable condition of the parts listed Check all threaded parts for galled crossed stripped or broken threads Check all parts for cracks corrosion distortion s
14. NOT AVAILABLE 05 3 MOD 11T ON 11 7 BLANK 1 209 PD 14 5 PA 6 NOT AVAILABLE 06 3 5 MOD 11T ON 11 64T BLANK 1 516 PD 14 5 PA 7 NOT AVAILABLE 07 3 5 MOD 13T ON 13 7T BLANK 1 791 PD 14 5 PA 8 NOT AVAILABLE 08 8 10P 13T ON 14T BLANK 1 750 PD 20 PA 09 3 5 MOD 15T ON 15 66T BLANK 1 772 PD 14 5 PA ROTATION 10 USE CODE 03 THIS IS A LH VERSION RE RH 412 3 5 MOD 17T ON 17 67T BLANK 2 343 PD 14 5 PA L LH CCW 12 USE CODE 02 THIS IS A LH VERSION 13 3 5 MOD 14T ON 14 7T BLANK 1 929 PD 14 5 14 8 100 12T ON 12T BLANK 1 500 PD 20 PA 15 4 25 MOD 11T ON 11T BLANK 1 840 PD 20 PA 16 6 8DP 12T ON 12 7T BLANK 2 126 PD 20 PA 17 USE CODE 01 THIS IS A LH VERSION 18 USE CODE 07 THIS IS A LH VERSION 19 8 10 DP 12T ON 13T BLANK 1 625 PD 20 PA 20 3 5 MOD 14T ON 14 7T BLANK 2 026 PD 20 PA 21 4 MOD 15T ON 15 65T BLANK 2 465 PD 0 325 CORRECTION FACTOR 14 5 PA 22 3 5 MOD 14T ON 14 68T BLANK 2 023 PD 0 34 CORRECTION FACTOR 14 5 PA 23 3 5 MOD 14T 2 023 PD 0 34 CORRECTION FACTOR 20 PA Figure 2 T50 Series Nameplate Identification Page 2 ew Publication T5 703 Rev 2 Issued July 31 2009 SECTION 2 0 DESCRIPTION OF BASIC GROUPS 2 1 GENERAL The TDI Turbotwin T50 P air starter is a lightweight compact unit driven by a two stage turbine air motor The starter is composed of three basic assembly groups Turbin
15. SS b pm po Publication T5 703 Rev 2 SES Dated July 31 2009 a TECH DEVELOPMENT SERVICE MANUAL T50 P TURBOTWIN Engine Air Starter w C TURBOTWIN y NE 4 2 gt 7 gt G f 7 fp 1 at ree att AN 99 447 amp ine Engine Controls amp Panels Compressor Parta 860 North 9th Avenue Brighton CO 80603 Ph 303 659 5139 Fax 303 659 5309 www rjmann com TDI TURBOTWIN FROM TECH DEVELOPMENT TABLE OF CONTENTS Section Subject Page 1 0 1 2 0 Description of Basic Groups 3 3 0 5 4 0 Cleaning and Inspection 7 5 0 10 6 0 Parts List rrr 13 LIST OF TABLES Table No Title Page 1 T50 Series Service Tool Kits 5 2 Cleaning Materials amp Compounds 7 3 Parts Inspection Check 8 4 Parts Wear 9 5 Torque 9 6 Materials for Assembly 10 LIST OF ILLUSTRATIONS Figure Title Page 1 TDI Turbotwin Nameplate 2 2 T50 Series Part Number Coding 2 3 Turbine Housing Assembly 3 4 Gearbox Housing Assembly 4 5 Drive
16. aring 58 which is installed in the nose of the drive housing Split rings 52 and a return spring 54 aid in the disengagement of the pinion from the engine s ring gear Figure 5 Drive Assembly Page 4 Publication T5 703 Rev 2 Issued July 31 2009 SECTION 3 0 DISASSEMBLY 3 1 GENERAL Always mark adjacent parts on the starter Nozzle 2 Containment Ring 21 Turbine Housing 26 Gearbox Housing 41 and Drive Housing 56 so these parts can be located in the same relative position when the starter is reassembled Do not disassemble the starter any further than necessary to replace a worn or damaged part Always have a complete overhaul kit on hand before starting any overall of a Turbotwin T50 Pair starter Never use old screws seals and o rings The tools listed in Table 1 are suggested for use by technicians servicing the Turbotwin T50 P air starter The best results can be expected when these tools are used TOOL DESCRIPTION TDI PN Spanner Wrench 2 27272 Stage 2 Rotor Puller Tool 52 20076 Tool Turbine Bearing 45 25294 Tool Bearing Seal 2 26943 Tool Seal Positioning 45 25316 Table 1 T50 Series Service Tools P N T50 28570 3 2 DRIVE HOUSING 3 2 1 Removal of Drive Housing Mark position of drive pinion opening relative to gearbox housing for reference during re assembly Remove the 12 screws 57 and pull drive housing 56 from gearbox housing 41 If drive housing is too tight tap i
17. coring or general damage Publication T5 703 Rev 2 Issued July 31 2009 Check all bearing bores for wear Check gear teeth and turbine housing ring gear for wear In general visually check for spalling fretting surface flaking chipping splitting and corrosion If wear is apparent check the gear teeth dimensions in accordance with Table 4 Nicks and dents that cannot be felt with a 020 inch radius scribe are acceptable Page 7 TDI TURBOTWIN rrom TECH DEVELOPMENT Check For Requirements Description Defective Parts Must Be Replaced Drive Worn loose or missing parts Defective unit to be replaced Use figure 10 as a guideline for acceptable pinion wear Cracks and breakage Cracks are not acceptable Planet Gear Cracked chipped worn or Wear must not exceed limits per table 4 galled teeth There shall be no evidence of excessive wear Carrier Shaft Cracks scoring or raised Deformation of metal smearing in planet metal in planet shaft holes pin holes amp keyways not acceptable and keyways Integrity of Scoring on bearing diameter not to knurl keyed connection exceed 005 depth Wear must not exceed limits per Table 4 Planet Pins Wear grooves or flat spots Wear grooves in flat spots not permitted Woarsooves ornato wear must not exceed mis per Tabie Gearbox Housing Sungear Turbine Cracks scoring wear Shaft grooves chipped or broken gear teeth galling or scoring on bearing
18. e Housing Assembly Gearbox Housing Assembly and Bendix Drive Assembly TDI TURBOTWIN rrom TECH DEVELOPMENT 2 2 TURBINE HOUSING ASSEMBLY The Turbine housing assembly refer to figure 3 consists of a stage one 23 and a stage two 13 turbine rotor mounted on sungear shaft 29 The front bearing 15 is secured by a retainer plate 27 and the aft bearing is pre load by a spring washer 16 The ring gear 31 is installed between the turbine assembly 26 and the gearbox housing 41 and secured by four screws 42 Figure 3 Turbine Housing Assembly Publication T5 703 Rev 2 Issued July 31 2009 Page 3 2 3 GEARBOX HOUSING ASSEMBLY The gearbox housing assembly refer to figure 4 consists of a planet gear carrier and output shaft 32 three planet gears 36 needle bearings 37 spacers 35 and planet shafts 34 TDI TURBOTWIN rrom TECH DEVELOPMENT The carrier shaft 32 is mounted on a single bearing 38 in the gearbox housing 41 The retainer ring 48 secures the carrier shaft in the gearbox housing The bearing housing 44 and pre engaged piston 50 are installed in the gearbox housing 31 Figure 4 Gearbox Housing Assembly 2 4 DRIVE ASSEMBLY The drive assembly refer to figure 5 consists of a pre engagement drive 53 and drive housing 56 Twelve screws 57 secure the drive housing to the gearbox housing The front end of the carrier shaft 32 is mounted in a needle be
19. ned with the casting indentation on the turbine housing 5 2 4 ROTOR 2 INSTALLATION Turn the turbine nozzle over exhaust end up and install the labyrinth 17 onto the shaft Install pre load springs 16 into bearing bore of nozzle 2 containment housing 21 Publication T5 703 Rev 2 Issued July 31 2009 Apply a light coating of oil to the bearing bore in the Nozzle Containment Assembly and press the turbine bearing 15 over the turbine shaft and into the bearing bore using press tool P N 2 26943 Insert key 14 into turbine shaft keyway and install stage 2 rotor 13 onto shaft while simultaneously aligning the key with the keyway in the rotor Secure stage 2 rotor with rotor washer 12 and rotor screw 11 Torque to 220 in lb Turn turbine housing over and install o ring 30 into the o ring groove on the turbine housing 26 Install plug 22 into Nozzle Containment Assembly Install the ring gear 31 onto turbine housing with the dowel pin hole facing up Install dowel pin 40 into dowel pin hole in ring rear 31 5 3 GEAR BOX ASSEMBLY 5 3 1 PLANETARY GEAR CARRIER ASSEMBLY Press needle bearings 37 into planet gears 36 using arbor press The bearing ID stamping must be against pressing tool bearing should be centered between gear faces Place thrust washer 35 on each side of planet gear 36 and install into carrier shaft 32 slot Install planet shaft 34 into the carrier and secu
20. re suitable for operation on compressed air and natural gas The T50 P weighs approximately 34 pounds 15 KG and is capable of delivering over 45 HP 33 6 kW of cranking power at the maximum pressure of 120 psig 8 BAR 1 4 INSTALLATION AND SERVICE It is important to properly install and operate the TDI T50 P air starter to receive the full benefits of the turbine drive advantages lt must be installed in accordance with the instructions provided by Tech Development TDI Failure to properly install the starter or failure to operate it according to instructions provided by TDI may result in damage to the starter or engine or cause personal injury DO NOT OPERATE THIS STARTER UNLESS IT IS PROPERLY ATTACHED TO AN ENGINE Repair technicians or service organizations without turbine starter experience should not attempt to repair this starter until they receive factory approved training from TDI or its representatives Proper operation and repair of your TDI Turbotwin will assure continuous reliability and superior performance for many years Page 1 TDI TURBOTWIN rrom TECH DEVELOPMENT 1 5 NAMEPLATE INFORMATION N TURBOTWIN The nameplate located on the turbine housing provides PNUEMATIC STARTER important information regarding the construction of your E 4 50 air starter refer to Figure 1 part number coding explanation refer to Figure 2 can help you MODEL NO SERIAL NO
21. re with snap ring 33 Be sure the anti rotation pin is inserted into the slot on the carrier shaft 5 3 2 CARRIER SHAFT INSTALLATION Install o ring 43 into forward side of gearbox housing 41 If removed press gearbox bushing 38 into bearing housing 44 Press the lip seal 46 into the forward side of the bearing housing 44 until seated using press tool P N 2 26943 Publication T5 703 Rev 2 Issued July 31 2009 TDI TURBOTWIN rrom TECH DEVELOPMENT Install o ring 43 into the groove on the bearing housing 44 NOTE Apply a small amount of Aeroshell grease to the outer wall of the bearing hub and the inside wall of the gearbox housing to allow for easier housing installation Install the bearing housing assembly 38 44 46 in the forward side of the gearbox housing 41 and secure with four screws 39 Torque to 81 In Lbs Install two o rings 49 51 into the grooves on the pre engaged piston 50 NOTE Apply a small amount of Aeroshell 6 grease to the inner and inner walls of the pre engaged piston to allow for easier installation Press pre engaged piston into the forward side of the gearbox housing and remove any excess grease from gearbox housing Install lip seal tool PN 45 25316 into forward side of gearbox housing 41 placing tapered end of tool into lip seal 46 Install gearbox housing onto carrier shaft and place two thrust washers 47 on carrier shaft 32 Secure
22. t with a mallet to loosen 3 2 2 Removal of Drive Remove return spring 54 and pull drive 53 from carrier shaft assembly 32 Remove split rings 52 from drive assembly 3 2 3 Drive Bearing Removal Press needle bearing 58 from drive housing 56 using press tool Publication T5 703 Rev 2 Issued July 31 2009 TDI TURBOTWIN TECH DEVELOPMENT 3 3 GEARBOX HOUSING 3 3 1 Removal of Gearbox Housing Remove the four screws 42 and separate the gearbox assembly from the turbine assembly If the gearbox is too tight tap it with a mallet to loosen 3 3 2 Gearbox Disassembly Remove snap ring 48 and two thrust washers 47 from carrier shaft 32 Apply pressure to the carrier shaft to remove it from the gearbox housing Remove four screws 39 and press the bearing housing pre engaged piston assembly 44 50 from the gearbox housing Hand press bearing housing 44 out of pre engaged piston 50 3 3 3 Carrier Shaft Planet Gear Disassembly Remove snap ring 33 from planet shaft 34 and push shaft through holes in assembly Refer to figure 6 Slide the planet gear 36 out from the carrier shaft and remove the two spacers 35 Press the needle bearing 37 from the planet gear 36 to remove it CARRIER SHAFT ASSEMBLY 32 PLANET GEAR 77 SPACER 35 PLANET GEAR 36 IN LANET
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