T100 Series Service Manual - RJ Mann & Associates, Inc
Contents
1. PaneGearCamerShat za 36 wee esos 38 Lee Roller Bearing g 991040 v NEN Planet Shaft 3 2P 20182 Woodruff Key 2 9 90211 019 Bearing 2 9 91351 Page 22 Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT Wave Spring Washer 9 90402 025 Bearing Space seg I ER Gearbox Housing 2 22226 14F 25020 028 ee Drive Housing 2 22301 cu diced o Retaining Ring Included wih tem 50 0r57 included wih item zez Needle Bearing 9 91393 Adapter Plate 2 22794 ii Inertia Drive Assembly L H Gearbox Housing em tock wut 622005 6 nemzeos 4 o c Needle Bearing 995 fv Tv m cartrsnan 6502 Le p oomememae 65 Bearing 9 91356 Publication T1 701 Rev 1 Page 23 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT 6 1 IN Snap Ring 9 92001 006 Lock Nut 9 92105 008 Inertia Drive Assembly R H 2 22147 68 Inertia Drive Assembly L H 2 22148 Drive Housing 2 20826 9 m memes Leen 1 Ce mre sl o poo 11 5 5 sme2. 2 26943 LIP SEAL 9 ST E GE EE EE Ss SS Y C 4 d SY i A dE All gt ay Figure 21 Pressing Aft Bearing onto Shaft Install the seal spacer 8 with the small end facing the aft bearing 10 Press the lip seal 9 into the stage 2 nozzle using press tool P N 2 26943 with lip seal facing up Install the stage 2 woodruff key 7 into the shaft 33 5 2 4 Stage 2 Rotor Installation Install the stage 2 rotor 6 onto the shaft Use press tool P N 2 26943 if required Visually inspect that the key was not pushed out during assembly Note that the direction of rotation was oriented properly This turbine can be installed backwards Install the rotor washer 5 and secure with screws 4 Tighten screw to 100 in lb Install the exhaust screen 3 and back plate 2 Secure with six screws 1 Tighten the screws to 80 in Ib Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT 5 2 5 Air Inlet Installation Place 23 the O ring 24 into the groove on the air inlet Install the 2 NPT air inlet flange 23 and secure with six screws 22 Tighten the six screws to 170 in lb Mark the number of stage 1 nozzles usual
3. e 1 LLLI 1 oW 3 Model Overhaul Kit for S N s before 9611 191 Overhaul Kit for S N s after 9611 192 B T10B 27618 T10B 27634 D T10D 27619 T10D 27635 F T10F 27617 T10F 27633 P T10P 27620 T10P 27636 Page 24 Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT Figure 29 Illustrated Parts Breakdown T112B T121B Publication T1 701 Rev 1 Page 25 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT mms Semi Deg LR b sse Figure 30 Illustrated Parts Breakdown T109P 1115P Page 26 Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT Figure 31 Illustrated Parts Breakdown T112D T121D Standard Mesh Publication T1 701 Rev 1 Page 27 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT Figure 32 Illustrated Parts Breakdown T112D T121D Long Mesh Page 28 Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT Figure 33 Illustrated Parts Breakdown T106F T112F Publication T1 701 Rev 1 Page 29 Issued April 15 2006 SECTION 7 0 ACCESSORIES TDI TURBOTWIN FROM TECH DEVELOPMENT SIZE PART NUMBER SIZE PART NUMBER RELAY VALV ES GAUGES 1 2 STAINLESS STEEL AMOT 52 9
4. 58 HOLDING TOOL 52 20202 FIX TO BENCH Figure 25 Tightening Retainer Nut 5 4 DRIVE HOUSING T112B T121B T112D T121D T109P T115P 5 4 1 Bendix Drive Installation Install two woodruff keys 40 properly installed per Figure 26 Ensure keys are Position bendix assembly 57 on shaft with retainer set screw 53 removed Install spring 52 between bendix cavity and end of output shaft Slide bendix over shaft until set screw hole aligns with set screw hole in shaft Install set screw and tighten firmly Slip retainer 51 ring into set screw slot 5 4 2 Bendix Drive Housing Installation If disassembled press needle bearing 62 P 80 into drive housing 61 until flush with bottom surface Mount drive housing over bendix drive and align holes for desired bendix opening orientation with starter inlet connection Torque bolts and nuts to 90 120 in lbs Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT 5 5 DRIVE GEARBOX HOUSING T106F T112F 5 5 1 Planetary Gear Carrier Reassembly If disassembled press needle bearing 38 into planet gears 37 The planet gears are not identified by part number therefore dimensionally check if correct gears are being used Use table 4 for over the wire measurements With a thrust washer 36 on each side of gear slide gear into carrier shaft slots 63 and align with pin holes Lightly slide plant shafts 39
5. 39 using snap ring pliers and push shaft through holes in assembly Slide the planet gear 37 out from the carrier shaft and remove the two nylon spacer 36 Unless the needle roller bearings 38 are damaged do not remove f removal is necessary simply press bearing out SPANNER WRENCH 52 20134 RETAINER NUT 48 LOCKWASHER 47 GEARBOX HOUSING 58 HOLDING TOOL 52 20202 FIX TO BENCH Figure 11 Gearbox Retainer Nut Removal 3 5 GEARBOX HOUSING T1T12B T121B T112D T121D T109P T115P The drive housing removal procedure should be performed before performing this procedure 3 5 1 Removal of Gearbox Housing Remove the six screws 27 and lift the gearbox assembly from the turbine assembly If the gearbox assembly is too tight tap it with a mallet to loosen 3 5 2 Gearbox Disassembly Mount the gearbox on the TDI holding tool P N 52 20202 placing the three holes on the gearbox over the dow pins Refer to Figure 1 1 Page 9 Remove woodruff keys 40 from shaft by tapping them with a chisel and hammer With screwdriver remove tang of lockwasher 47 from slot of retainer nut 48 Place TDI tool P N 52 20134 Spanner Wrench over shaft and into slots of retainer nut Hold gearbox down and remove nut In most cases the gearbox housing 58 D 44 can be removed from the carrier shaft 35 by holding shaft down and pulling directly up on housing If this is not the case press carrier shaft fro
6. 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 Ring Gear Cracks wear chipped or broken gear teeth Cracks and breakage are not acceptable Minor surface damage is permitted if function is not impaired Wear must not exceed limits per Table 4 Seal Assembly Wear grooves or scratched Wear is not permitted surfaces on carbon ring Seal Spacer Wear Grooves No wear permitted Needle Bearings Freedom of needle rollers Replace bearings of rotation without excessive between races Ball bearings Corrosion erosion cracks Cracks and hn ME are not er Ring Nozzle and broken nozzle edges Minor surface damage is permitted i function is not impaired Corrosion erosion cracks and broken edges Turbine Rotors Tip wear bore and key way Minor tip rub is permitted if function is not impaired Wear is not permitted Table 3 Parts Inspection Check Requirements Publication T1 701 Rev 1 Issued April 15 2006 Page 13 TDI TURBOTWIN FROM TECH DEVELOPMENT PART DESCRIPTION LIMIT Inches Ring gear Turbine Housing Internal measurement between two 084 diameter 5 0890 max pins Sun Gear Turbine Shaft Bearing diameter 0 6690 min External measurement over two 096 diameter pins 0 952 min 0 808 min 0
7. TDI TURBOTWIN FROM TECH DEVELOPMENT 3 4 DRIVE GEARBOX HOUSING T106F T112F 3 4 1 Removal of Drive Housing Mark position of bendix pinion opening relative to turbine housing 26 for reference during reassembly Per Figure 10 remove the six screws 27 Pull drive housing 69 from turbine housing If drive housing is too tight tap it with a mallet to loosen SCREWS 31 BEARING 65 SNAP RING 66 DRIVE HOUSING INERTIA DRIVE 68 RETAINER PLATE 64 CARRIER SHAFT ASSEMBLY 63 NEEDLE BEARING 70 Figure 10 Bendix Drive Removal T106F T112F 3 4 2 Removal of Bendix Drive Remove four screws 31 Pull carrier shaft assembly 63 from drive housing 69 The bendix 68 will remain in the drive housing With snap ring tool remove snap ring 66 and bendix drive 68 from drive housing If it is necessary to remove needle bearing 70 from drive housing simply press bearing out Mount the carrier shaft assembly on the TDI holding tool P N 52 20202 placing the three holes on the gearbox over the dow pins Refer to Figure 1 Place TDI tool P N 52 21345 Spanner Wrench over shaft and into slots of retainer nut 67 Hold down carrier shaft and remove nut Publication T1 701 Rev 1 Issued April 15 2006 Remove bearing 65 from shaft by pressing shaft while supporting inner race of bearing Remove bearing retainer plate 64 3 4 3 Planet Gear Disassembly Remove snap ring 34 from planet shaft
8. 12 3 Parts Inspection Check Req 13 4 Parts Wear Limits 14 5 Materials for Assembly 15 LIST OF ILLUSTRATIONS Figure Title Page 1 TDI Turbotwin Nameplate 2 2 T30 Series Part Number Coding 3 3 Turbine Housing Assembly 4 4 Gearbox Housing Assembly B P 5 5 Gearbox Housing Assembly F 5 6 Gearbox Housing Assembly D Std 6 7 Gearbox Housing Assembly D Lg 6 8 Bendix Drive Assembly 7 9 Bendix Drive Removal 8 10 Bendix Drive Removal F 9 11 Gearbox Retainer Nut Removal 9 12 Pressing Out Carrier Shaft 10 13 Turbine Rotor Removal 10 14 Turbine Shaft Removal 11 15 Nozzle 2 Removal 11 16 Gear Teeth Wear Allowance 14 17 Pressing Front Turbine Bearing 15 18 Pressing Spacer onto Bearing 15 19 Installation of Turbine Shaft 16 20 Installing the Aft Seal into Nozzle 1 16 21 Pressing Aft Bearing onto Shaft 17 22 Planet Gear Carrier Shaft Assembly 17 Publication T1 701 Rev 1 Issued April 15 2006 Page i TDI TURBOTWIN FROM TECH DEVELOPMENT SECTION 1 0 INTRODUCTION 1 1 GENERAL INFORMATION This manual provides information for servicing disassembly and reassembly of the TDI Turbotwin T100 series a
9. 42 43 into bearing bore of the gearbox housing 58 Lift up on housing and slide shaft down If shaft will not slide into bearing bore press housing per Figure 24 until bearing is seated 41 Place gearbox assembly on TDI Tool P N 2 20202 per Figure 25 Install lockwasher 47 and then retainer nut 48 Torque to 600 800 in Ib Tang lockwasher into retainer nut slot Place O ring 14 onto outer diameter of gearbox assembly Thoroughly grease planet gears ring gear and sun gear using the grease specified in Table 5 and pack the center of the gears with grease 5 3 3 Gearbox to Turbine Housing Assembly Rotate carrier shaft 35 slightly and at the same time align gearbox into the front of turbine housing 26 Install six screws and torque 90 120 in Ibs Page 18 TDI TURBOTWIN FROM TECH DEVELOPMENT TOOL 52 20143 CARRIER SHAFT 35 BEARING 41 Figure 23 Pressing Rear Bearing onto Carrier Shaft EE TOOL 52 20143 N GEARBOX SPACER HOUSING 58 43 N BEARING WAVY ll Sy 41 SPRING Bs 16 1 Figure 24 Installing Carrier Shaft into Gearbox Housing Publication T1 701 Rev 1 Issued April 15 2006 SPANNER RETAINER EEN HUT 48 22 LOCKWASHER 47 GEARBOX HOUSING
10. 670 min Planet Gear External measurement over two 0864 diameter pins 2 3067 min 2 3699 min 2 4359 min Carrier Shaft Bearing Diameter 1 1800 min Planet Pin Bore Ge 6750 max Bearing Diameter oom 4 873 min Thickness 055 min Table 4 Parts Wear Limits MAXIMUM PERMISSIBLE WEAR ON EACH SIDE OF TOOTH DIMENSION B IS APPROXIMATELY TEN PERCENT OF DIMENSION A ar DIM B DIM A CENTER OF TOOTH NEW TOOTH WORN TOOTH TYPICAL TYPICAL Figure 16 Gear Teeth Wear Allowances Page 14 Publication T1 701 Rev 1 Issued April 15 2006 SECTION 5 0 ASSEMBLY 5 1 GENERAL The tools listed in Table 1 are suggested for use by technicians servicing the T100 Series starters The best results can be expected when the proper tools are used however use of other tools is acceptable CAUTION Replace all screws O rings lip seals and bearings when the T100 Series starter is reassembled These parts are included in the overhaul kits shown in Section 6 0 NOTE Always press the inner race of a ball bearing when installing a bearing on a shaft Always press the outer race of a ball bearing when installing into a housing Refer to Section 6 0 for a list of kits and components which are available to aid in rebuilding T100 Series starters 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 use during assemb
11. Housing 75 Hold the stage 2 rotor 6 and remove the turbine screw 4 and washer 5 Install the rotor puller tool P N 52 20076 and remove the stage 2 rotor per Figure 13 Remove the woodruff key 7 using a hammer and chisel STAGE 2 ROTOR PULLER TOOL 52 20076 TURBINE ROTOR 6 SCREW Figure 13 Turbine Rotor Removal Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT 3 6 Turbine Shaft Removal Using the shaft removal tool P N 2 26945 per figure 14 press on the turbine shaft 33 while supporting the turbine housing Press the shaft assembly 33 through the aft bearing 10 and continue pressing until the shaft assembly is completely out of the housing 26 Remove the woodruff key 16 seal spacer 8 bearing spacer 30 and bearing 10 from the shaft The bearing can be removed from the shaft by pressing the shaft through the bearing Note that if T100 is the original design SN 9501 239 10961 1 191 the bearing will be pressed inside a spacer ARBOR PRESS TURBINE SHAFT 33 Figure 14 Turbine Shaft Removal Publication T1 701 Rev 1 Issued April 15 2006 Separate the stage 2 nozzle assembly 13 from the turbine assembly 26 by firmly holding the turbine assembly while tapping nozzle 2 with a mallet If nozzle 2 is too tight it can be removed by installing two threaded screws into nozzle 2 and using them
12. as jacks to separate nozzle 2 from the turbine assembly Refer to Figure 15 Rotate the stage 1 rotor if necessary to allow the jacks to travel through the large holes in the rotor The jacks will damage the stage 1 rotor if pressure is applied to them while removing nozzle 2 The stage 1 rotor 15 may now be removed Remove the four screws 18 and nozzle 1 19 from the turbine assembly It may be necessary to tap the screws with a hammer and chisel to loosen On the stage 2 nozzle 13 remove the seal spacer 8 from the forward side of the nozzle Place the stage 2 nozzle on the exhaust end Press through the lip seal onto the bearing until it including the 27 lip seal and seal spacer disengages from the nozzle Turn the nozzle over and press on the lip seal to remove 3 8 16 UNC 3 8 16 UNC NUTS THREADED ROD NOZZLE 2 ASSEMBLY 13 Page 11 TDI TURBOTWIN FROM TECH DEVELOPMENT 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 t is recommended that the bearings be replaced with new parts 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
13. into aligned holes making sure snap ring groove on end of pins goes in first NOTE Make sure anti rotation pins on shafts are properly located in the retaining slots of the carrier shafts 63 5 5 2 Planetary Carrier Bearing Installation Install bearing retainer plate 64 over carrier shaft 63 Press bearing 65 onto shaft making sure pressing force is on inner race of bearing only Place carrier shaft assembly onto TDI Tool P N 52 20202 see Figure 27 Thread retainer nut 67 onto shaft 63 Hold carrier assembly down and torque nut to 600 800 Ib in with spanner wrench TDI Tool P N 52 21345 WOODRUFF KEY 40 SHAFT 33 WRONG KEY SEAT 8 N RIGHT LL Figure 26 Woodruff Key Installation Page 19 TDI TURBOTWIN FROM TECH DEVELOPMENT SPANNER WRENCH TOOL 52 21345 LOCK NUT 67 HOLDING TOOL 52 20202 FIX TO BENCH INERTIA DRIVE 68 RETAINER PLATE 64 CARRIER SHAFT ASSEMBLY 63 NEEDLE BEARING 70 Figure 27 Tightening Retainer Nut T106F T112F 5 5 3 Bendix Drive Installation Install bendix drive 68 into drive housing 69 aligning bendix shaft into front needle bearing 70 With snap ring tool install snap ring 66 into drive housing 69 Align carrier shaft assembly 63 into bendix drive and push assembly until seated against snap ring 66 per Figure 28 Install six screws 27 and torque 90 to 120 Ib in Page 20 F
14. 1 TURRBOTWIN T112B T121B STARTER 0 EXHAUST GUARD SCREEN STD 60002 TURBOTWIN T106F T112F STARTER 1 3 NPT STRAIGHT EXHAUST 60003 TURBOTWIN T112D T121D STD STARTER 2 4 NPT STRAIGHT EXHAUST 60004 TURBOTWIN T112D T121D LONG STARTER 3 EXHAUST CLOSURE PLATE 60013 TURBOTWIN T109P T115P STARTER 6 LONG MUFFLER SPECIAL FEATURES STARTER FRAME 0 7 51 GEAR RATIO STD 8 SAE 3 MOUNTING FLANGE INERTIA DRIVE 275 300 FT LB 1 9 1 GEAR RATIO SPECIAL F SAE 3 MOUNTING FLANGE INERTIA DRIVE 150 165 FT LB 2 11 4 1 GEAR RATIO NOT RELEASED D D TYPE MOUNTING FLANGE INERTIA DRIVE 275 300 FT LB P SAE 3 MOUNTING FLANGE W SHORTENED DRIVE HOUSING INERTIA DRIVE 275 300 FT LB ROTATION R RIGHT HAND CW L LEFT HAND CCW TDI Part Rotation Teeth Pressu Code Number Blank Pitch Angle 1 1188228 RH 2 119083 LH 3 222147 RH 4 222148 LH ES RH 6 LH LH 2 22795 2 22796 Figure 2 Part Number Coding Publication T1 701 Rev 1 Page 3 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT SECTION 2 0 DESCRIPTION OF BASIC GROUPS 2 1 GENERAL The TDI Turbotwin T100 Series air starters are lightweight compact units driven by a dual stage turbine type air motor The starter is composed of three basic assembly groups Turbine Housing Assembly Gearbox Housing Assembly and Bendix Drive Assembly 2 2 TURBINE HOUSING ASSEMBLY The Turbine housing assembly refe
15. 21B weighs approximately 55 pounds 25 KG and each is capable of delivering over 80 HP 60 kW of cranking power at their maximum pressure of either 150 psig 10 BAR or 90 psig 6 BAR respectively The Turbotwin T112D amp T121D weighs approximately 70 pounds 32 KG and each is capable of delivering over 80 HP 60 kW of cranking power at their maximum pressure of either 150 psig 10 BAR or 90 psig 6 BAR respectively The Turbotwin T109P amp T115P weighs approximately 59 pounds 27 KG and is capable of delivering over 60 HP 41 kW of cranking power at their maximum pressure of either 150 psig 10 BAR or 90 psig 6 BAR respectively 1 4 INSTALLATION AND SERVICE It is important to properly install and operate the TDI Turbotwin T100 series starters to receive the full benefits of the turbine drive advantages It must be installed in accordance with the instructions provided by Tech Development Inc TDI Page 1 TDI TURBOTWIN FROM TECH DEVELOPMENT WARNING Failure to properly install the starter or failure to operate it according to instructions provided byTDI may result in damage to the starter or engine or cause personal injury DO NOT OPERATE THIS STARTER UNLESS IT ENGINE IS PROPERLY ATTACHED TO AN 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 Pr
16. 3505 REAR CENTER MOUNT 52 21982 2 STAINLESS STEEL AMOT 52 93505 100 U CLAMP REAR CENTER MOUNT 52 21982 100 1v 316 SST MANUALLY 52 93508 300 BOTTOM MOUNT 52 21982 200 OPERATED 2 316 SST MANUALLY 52 93508 400 OPERATED 1 NPT BUNA N RLVA 25683 001 1 EXHAUST 1v NPT BUNA RLVA 25683 001 1 01 3 ELBOW KIT 1100 27015 1 NPT VITON RLVA 25683 001 2 ECP KIT 1100 27068 11 2 NPT VITON RLVA 25683 001 2 01 MUFFLER KIT 21 NOZ T100 27074 12VDC 1 BUNA N RLVA 25683 012 1 MUFFLER KIT 6 12 NOZ T100 27075 12VDC 1 2 BUNA N RLVA 25683 012 1 01 3 NPT ADAPTER KIT T100 27651 FEMALE 12VDC 114 VITON RLVA 25683 012 2 4 NPT ADAPTER KIT T100 27652 FEMALE 12VDC 112 VITON RLVA 25683 012 2 01 4 STRAIGHT PIPE KIT T100 27791 24VDC 114 BUNA N RLVA 25683 024 1 3 ELBOW KIT T100 27900 24VDC 172 BUNA N RLVA 25683 024 1 01 EXHAUST ELBOW W 3 PIPE WELD FLANGE T100 28182 001 24VDC 114 VITON RLVA 25683 024 2 EXHAUST ELBOW W OUT WELD FLANGE T100 281 82 002 24VDC 1772 VITON RLVA 25683 024 2 01 110VDC 11 VITON RLVA 25683 110 2 01 CONTROL amp SOLENOID VALVES 120VAC 112 VITON RLVA 25683 120 2 01 1 8 NPT STR CONROL VALVE 52 93504 1 4 24 VDC CONDUIT 52 21981 PRESSURE REGULATORS 1 4 12 VDC GROMMET 52 21981 002 2 GAS 300 52 93552 1 4 120 VAC CONDUIT
17. 52 93506 100 2 GAS 125 52 93553 1 4 120 VAC GROMMET 52 93506 200 112 AIR MAX 1200 SCFM 52 20724 100 1 4 24 VDC CONDUIT 52 93506 300 2 AIR MAX 1600 SCFM 52 20724 200 1 4 24 VDC GROMMET 52 93506 400 1 4 72 VDC 52 93506 500 Y STRAINERS 1v CARBON STEEL BODY 40 MESH SST SCREEN 52 93549 100 2 CARBON STEEL BODY 40 MESH SST SCREEN 52 93549 200 1 2 CAST IRON BODY 40 MESH SST SCREEN 52 93550 100 2 CAST IRON BODY 40 MESH SST SCREEN 52 93550 200 Page 30 Publication T1 701 Rev 1 Issued April 15 2006
18. SS pmm PEE Publication T1 701 Rev 1 a m Dated April 15 2006 TECH DEVELOPMENT SERVICE MANUAL 1100 Series T112B T1215 T112D T121D T106F T112F T109P T115P TURBOTWIN ENGINE AIR STARTERS ww S A d ii K S V a TunoTim TES E Ki 2 DWH e 9 8 Engine Coutrols d Panels Compresser Parte North 9th Avenue Brighton CO 80603 h 303 659 5139 Fax 303 659 5309 du rimann com TDI TURBOTWIN FROM TECH DEVELOPMENT TABLE OF CONTENTS LIST OF ILLUSTRATIONS Section Subject Page Figure Title Page 1 0 JotodHODIE 1 23 Pressing Bearing onto 5 8 18 2 0 Description of Basic Groups 4 24 Installing Shaft into Gearbox Hsg 18 3 0 Disssselnbly i oerte ana 8 25 Tightening Retainer Nut 19 4 0 Cleaning and Inspecton 12 26 Woodruff Key Installation 19 DU ASSET er E 15 27 Tightening Retainer Nut T106F 20 6 0 Parts Uet eee 21 28 Drive Hsg Installation T106F 20 7 0 ACCESSOT ES err ies 30 29 Illustrated Parts Breakdown B 25 30 Illustrated Parts Breakdown P 26 LIST OF TABLES 31 Illustrated Parts Breakdown D 27 32 Illustrated Parts Breakdown D 28 Table No Title Page 33 Illustrated Parts Breakdown F 29 1 T100 Series Service Tool Kits 8 2 Cleaning Materials amp Compounds
19. er to figure 8 consists of housing an inertial engagement drive or bendix 57 and drive housing 61 The bendix is mounted to the output shaft with two keys and a retaining set screw 53 Figure 8 Bendix Drive Assembly T112B T121B T112D T121D T109P T115P Publication T1 701 Rev 1 Page 7 Issued April 15 2006 SECTION 3 0 DISASSEMBLY 3 1 GENERAL Always mark adjacent parts on the starter housing Nozzle 2 Containment Ring 13 Turbine Housing 26 Gearbox Housing 58 and Bendix Drive Housing 61 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 set of seals and o rings on hand before starting any overall of a Turbotwin T100 series starter Never use old seals or o rings The tools listed in Table 1 are suggested for use by technicians servicing the Turbotwin T100 series starters The best results can be expected when these tools are used however the use of other tools are acceptable Table 1 T100 Series Service Tools 3 2 DRIVE HOUSING T112B T121B T109P T115P 3 2 1 Removal of Drive Housing Mark position of bendix pinion opening relative to gearbox housing for reference during reassembly Remove the six bolts 60 and lock nuts 59 Pull drive housing 61 from gearbox housing 58 f drive housing is too tight tap it with a malle
20. essed air or natural gas Please review the rest of this manual before attempting to provide service to the TDI Turbotwin T100 series starters 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 likely Publication T1 701 Rev 1 Issued April 15 2006 CAUTION used where there is the possibility of damage to equipment NOTE use to point out special interest information 1 3 DESCRIPTION OF OPERATION The Turbotwin T100 series starters are powered by a pair of axial flow turbines coupled to a simple planetary gear reduction set The T100 series starters incorporate an inertia bendix 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 T100 series starters can be used over a wide range of drive pressures from 30 psig 2 BAR to 150 psig 10 BAR and are suitable for operation on either air or natural gas The Turbotwin T106F amp T112F weighs approximately 47 pounds 21 KG and each is capable of delivering over 44 HP 33 kW of cranking power at their maximum pressure of either 150 psig 10 BAR or 90 psig 6 BAR respectively The Turbotwin T112B amp T1
21. he bearing Page 15 Install bearing retainer plate 32 and secure with four screws 18 Torque screws to 30 in lbs Or eHvEL 33 Honeine Se r LOBBIVE j v 3730043 fo zu des VBBOB bBE22 Figure 19 Installation of Turbine Shaft Place turbine housing front surface sungear end on flat surface Install long bearing space 30 over shaft Install the seal spacer 8 onto the shaft Note the small end of the spacer faces the long bearing spacer Install the O ring 21 into the aft face of the turbine housing 26 5 2 2 Nozzle 1 Installation Press the aft seal 17 into nozzle 1 19 using press tool P N 2 26943 per Figure 20 with the lips facing up NOZZLE 1 19 Figure 20 Installing the aft seal into Nozzle 1 Page 16 TDI TURBOTWIN FROM TECH DEVELOPMENT Install nozzle 1 onto the turbine housing 26 Orient the nozzles facing the air inlet 23 Install four screws 18 to secure the nozzle Do not tighten the screws at this time 5 2 3 Rotor 1 Installation Install the woodruff key large key 16 for stage 1 rotor into the shaft 33 Install the stage 1 rotor 15 while supporting sun gear end of shaft onto the turbine shaft by aligning the slo
22. igure 28 Gearbox Drive Housing Installation T106F T112F Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT SECTION 6 0 PARTS LIST The components illustrated and or described in this section are for the Turbotwin T100 series air starters When rebuilding a T100 series starter it is recommended to purchase and completely install the appropriate service kit s 19F 25028 012 Washer 2 14 7 Wave Spring Washer 9 90439 13i Nozzle 2 Containment Ring 2 27333 00R R H 13ii Nozzle 2 Containment Ring 2 27333 00L L H ig ii Meet Lnane 22762 19 Nozzle 1 L H 12 Noz 2 26718 12L s 1 11 1 1 1101 11 e SC 3 90001 027 ATS aie KR Publication T1 701 Rev 1 Page 21 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT Key Number Description Part Number B D F P 19v Nozzle 1 R H 6 Noz 2 26718 06R Nozzle 1 L H 6 Noz 2 26718 06L e seme _ O ring 9 90001 034 Es Screw 6 or 12 for 14F 31218 016 T112D T121D std Inlet Flange 9 90001 037 Set Screw See Note 1 52F 50013 016 EMEN Turbine Housing See Note 2 27045 1 200968 v v Pipe Plug 9 93501 004 Ring Gear See Note 1 1 18780 Bearing Spacer 98 0 mooo a 1 1 ss 22 sa eem
23. ir starters 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 reassembly The TDI Turbotwin T100 series of engine starters are specially designed for starting today s automated low emission engines The Turbotwin uses aerodynamic speed control eliminating the need for a mechanical automatic trip valve ATV to control starter motor speed The Turbotwin T100 series air starters are suited to operate within a wide range of inlet pressures and ambient temperatures These starters are designed for operation with either compressed air or natural gas The robust turbine motor design in the Turbotwin T100 series starters has no rubbing parts and is therefore tolerant of hard and liquid contamination in the supply gas with almost no adverse affects The motor is well adapted to running on sour natural gas As 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 NOTE Throughout this manual the term air is used to donate the starter drive medium Unless otherwise stated ai means compr
24. ly SOURCE Commercially Available Commercially Available Commercially Available TDI P N 9 94121 001 Table 5 Materials for Assembly CAUTION The screws that secure the Containment Ring Stage 2 Nozzle must have a drop of Loctite RC290 applied to the threads before being used 5 2 TURBINE HOUSING 5 2 1 Turbine Shaft Installation Press the bearing 10 onto the shaft 33 until seated Support the shaft and press on the inner race only with press tool P N 2 269483 per Figure 17 Note that if Figure 17 Pressing Front Turbine Bearing Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT 2 26943 SPACER 30 EN SPACER 31 Wy a A ENNS 10 ANN S Gd ieee er N NN SHAFT 33 N N BEFORE AFTER S N 96 192 S N 96 192 Figure 18 Pressing Spacer onto Bearing TOOL 2 26943 BEARING 10 SPACER 31 T100 is the original design SN 9501 239 to 9611 191 press the spacer 31 onto the outer race of the bearing 10 per Figure 18 by supporting the bearing outer race and then press the bearing spacer 10 31 onto the shaft Press the bearing shaft assembly keyway end first into bearing housing of the turbine housing Use press tool P N 2 26943 if required per Figure 19 Do not press on the end of the shaft because the load could damage the balls of t
25. ly 6 12 or 21 onto the O D of the unit for identification of the unit prior to name plate installation 5 3 GEARBOX HOUSING T112B T121B T112D T121D T109P T115P 5 3 1 Planetary Gear Carrier Reassembly If disassembled press needle bearing 38 into planet gears 37 The planet gears are not identified by part number therefore dimensionally check if correct gears are being used Use table 4 for over the wire measurements With a thrust washer 36 on each side of gear slide gear into carrier shaft slots 35 and align with pin holes Lightly slide plant shafts into aligned holes making sure snap ring groove on end of pins goes in first per Figure 22 ANTI ROTATION PIN GEAR 37 SNAP RING 34 Figure 22 Planet Gear Carrier Shaft Assembly NOTE Page 17 Make sure that anti rotation pins on shafts are properly located in retaining slots of carrier shaft 35 Install snap ring 34 with a snap ring tool 5 3 2 Gearbox Reassembly Press the bearing 41 into the forward side of the gearbox housing 58 D 44 Pressing force should be on the outer race only Install retainer plate 46 and secure with six screws 18 Press rear bearing 41 onto carrier shaft 35 using TDI Tool P N 52 20143 per Figure 23 Pressing force should be on the inner race of bearing Install spring washer 42 and bearing spacer 43 onto shaft and locate against bearing Position carrier shaft assembly 35 41
26. m housing per Figure 12 SHAFT 35 GEARBOX HOUSING 58 SUPPORT HOUSING LOCATION Figure 12 Pressing Out Carrier Shaft The aft bearing 41 spring washer 42 and bearing spacer 43 will come out with the shaft Remove aft bearing 41 from shaft by pressing shaft while supporting bearing If the aft bearing 41 is retained in the gearbox housing when the carrier shaft is removed apply pressure through housing to the bearing to remove it It will be necessary to elevate the housing with a brace to remove the bearing completely Remove the six screws 18 and retainer plate 46 The front bearing may then be removed by lightly tapping 3 5 3 Planet Gear Disassembly Remove snap ring 34 from planet shaft 39 and push shaft through holes in assembly Page 10 TDI TURBOTWIN FROM TECH DEVELOPMENT Slide the planet gear 37 out from the carrier shaft and remove the two nylon spacer 36 Unless the needle roller bearings 38 are damaged do not remove If removal is necessary simply press bearing out 3 6 TURBINE HOUSING 3 6 1 Stage 2 Rotor Removal Remove the six screws 27 that connect the gearbox assembly to the turbine housing and separate the two assemblies Remove the four screws 18 and the clamping plate 32 Turn the turbine to the exhaust end up and remove the six screws 1 screen support ring 2 and the screen 3 For the T109P remove six screws 74 and Exhaust Cover
27. oper operation and repair of your TDI Turbotwin will assure continuous reliability and superior performance for many years 1 5 NAMEPLATE INFORMATION The nameplate located on the turbine housing provides important information regarding the construction of your T100 series starters refer to Figure 1 The part number coding explanation refer to Figure 2 can help you when talking to your distributor Page 2 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 TDI TURBOSTART ENGINE AIR STARTERS FROM TECH DEVELOPMENT INC BARBER COLEMAN a Siebe Company 6800 POE AVE DAYTON OH 45414 MODEL NO SERIAL NO PART NUMBER T112 60001 B1R CCW LH AIR or NAT GAS USAGE MAX PRESS 150 PSIG MAESURED AT INLET WHILE OPERATING PROOF PRESSURE OF HOUSING IS 600 PSIG ARNING Do NOT OPERATE UNLOADED OR WITHOUT TURBINE GUARD OR EXHAUST FITTING U S PATENT 4509896 Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT STANDARD T100 STARTERS PUSTOM FEATURES T1 12 60001 B 1 Rl 0 12 TURBOTWIN PRORUCT LINE INLET ORIENTATION 0 0 STANDARD 1 60 2 120 NUMBER OF NOZZLES 3 180 06 6 NOZZLES 4 240 12 12 NOZZLES 5 300 21 21 NOZZLES 6 0 W 2 BSP PIPE THREAD DESIGNATES DRAWING NUMBER EXHAUST OPTIONS 6000
28. r 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 Publication T1 701 Rev 1 Issued April 15 2006 Part Check For Description pu Worn loose or missing parts Bendix TDI TURBOTWIN FROM TECH DEVELOPMENT Requirements Defective Parts Must Be Replaced Defective unit to be replaced Use figure 5 as a guideline for acceptable pinion wear Cracks and breakage Cracks are not acceptable Planet Gear Cracked chipped or galled teeth Wear must not exceed limits per Table 4 Carrier Shaft Cracks scoring or raised metal in planet shaft holes and keyways Integrity of knurl connection Wear must not exceed limits per table 4 There shall be no evidence of excessive wear Deformation of metal smearing in planet pin holes amp keyways not acceptable Scoring on bearing diameter not to 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 Wear must not exceed limits per Table 4 Wear created grooves Wear must not exceed limits per Table 4 Cracks and Breakage Cracks and breakage not acceptable Sungear Turbine Shaft Cracks scoring wear created grooves chipped or broken gear teeth galling or scoring on bearing surface of shaft
29. r to figure 3 consists of a stage one 15 and a stage two 6 turbine wheel mounted on sungear shaft 33 The front bearing 10 is secured by a retainer plate 32 The aft bearing is preloaded by wavy spring 12 The ring gear 29 is heat shrunk into the front of the turbine housing 26 and secured by a setscrew 25 Figure 3 Turbine Housing Assembly Page 4 Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT The carrier shaft is mounted on two ball bearings 41 2 3 GEARBOX HOUSING ASSEMBLY in the gearbox housing 58 The retainer nut 48 secures the carrier shaft in the gearbox housing The front bearing 41 is secured by a retainer plate 46 The back bearing is preloaded by use of a spring washer 42 The gearbox housing assembly refer to figures 4 consist of a planet gear carrier and output shaft 35 three planet gears 37 needle bearings 38 spacers 86 and bearing pins 39 Figure 5 Gearbox Bendix Assembly T106F T112F Publication T1 701 Rev 1 Page 5 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT Figure 7 Gearbox Assembly 1112D T121D LONG MESH Page 6 Publication T1 701 Rev 1 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT 2 4 BENDIX DRIVE ASSEMBLY The other end of the drive unit is mounted into a needle bearing 54 which is installed in the nose of the drive The Bendix drive assembly ref
30. 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 Acetone Aluminum Cleaning Solution Steel Cleaner Rust amp Corrosion Chromic Nitric Phosphoric Acid Pickle Solution Commercially Available Commercially Available 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 Mix 3 5 Ib of Oakite rust Stripper per gallon of water Rd Berkeley 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 scoring or general damage Page 12 Check all bearing bores for wear and scoring Bearing bores shall be free of scoring lines not to exceed 0 005 width and 0 005 depth Check gear teeth and turbine housing ring gear for wear In general visually check fo
31. t in the rotor with the woodruff key and hand press the rotor until firmly seated Use press tool P N 2 26943 if required Visually inspect that the key was not pushed out during assembly Note that the direction of rotation was oriented properly This turbine rotor can be installed backwards Temporarily install Nozzle 2 on the turbine housing Tighten the four screws that secure nozzle 1 18 to 30 in lb The four screws can be accessed via the holes in nozzle 2 and the first stage turbine rotor Remove Nozzle 2 when the four screws are tight 5 2 3 Nozzle 2 Installation Press the lip seal 9 into the forward side of nozzle 2 with seal lip facing up Use press tool P N 2 26943 Install the O ring 11 into the bearing bore of nozzle 2 13 DO NOT LUBRICATE THIS O RING Install O ring 14 onto the outer diameter of nozzle 2 Install nozzle 2 13 onto the turbine housing 26 The three flats of nozzle 2 are always oriented opposite the turbine housing air inlet SN 9505 213 to 9611 191 Install the seal spacer 8 onto the shaft with the small end facing the aft bearing 10 Install the wavy spring washer 12 into the bearing bore of the stage 2 nozzle Support the sun gear end of the shaft Press the aft bearing 10 onto the shaft by pressing onto the inner and outer race simultaneously Use press tool per Figure 21 Press until bearing is seated Publication T1 701 Rev 1 Issued April 15 2006 NOZZLE 2 13
32. t to loosen 3 2 2 Removal of Bendix Drive In loaded spring area of drive 57 remove retaining ring 51 from set screw 53 slot Remove set screw using a flat head screwdriver Figure 9 and pull the bendix assembly from the starter carrier shaft Remove spring 52 This spring fits loosely between the bendix assembly and carrier Page 8 TDI TURBOTWIN FROM TECH DEVELOPMENT shaft Remove the needle bearing 62 if necessary by simply tapping out the welch plug from the front of the drive housing and press bearing out 3 3 DRIVE HOUSING T112D T121D 3 3 1 Removal of Drive Housing Remove the six screws 22 Mark position of bendix pinion opening relative to gearbox housing for reference during reassembly Pull drive housing 49 from gearbox housing 44 If drive housing is too tight tap it with a mallet to loosen 3 3 2 Removal of Bendix Drive In loaded spring area of drive 57 remove retaining ring b1 from set screw 53 slot Remove set screw using a flat head screwdriver Figure 9 and pull the bendix assembly from the starter carrier shaft Remove spring 52 This spring fits loosely between the bendix assembly and carrier shaft Remove the needle bearing 62 if necessary by simply tapping out the welch plug from the front of the drive housing and press bearing out SNAP RING 51 8 5 a 5 b o Figure 9 Bendix Drive Removal Publication T1 701 Rev 1 Issued April 15 2006
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