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TECH DEVELOPMENT INC.
Publication T1-721, Revision 2
Dated: May 14, 2001

INSTALLATION AND OPERATING

) ·� ..MANUAL

:
__ )

MODEL: T100-V
TURBO TWIN Engine Air Starters

AN 98-440 From Tech Development Inc

6800 Poe Ave. -Dayton OH 45414
Tel: (937) 898-9600 •Fax: (·937) 898-8431
Website: tdiairstarters.com

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 ) TDI TURBOTW/fvl'M
FROM TECH DEVELOPMENT, Inc

TABLE OF CONTENTS

SECTION SUBJECT PAGE

1.0 General Information 1

2.0 Orientation of the Starter 2
3.0 Installing the Starter 2
4.0 Starter Operation 4
5.0 T100-V Warranty 6
6.0 Troubleshooting Guide 7

I
LIST OF ILLUSTRATIONS
' )
FIGURE TITLE PAGE
1 Direction of Rotation 2
2 T100-V with Exhaust Guard 8
3 T100-V with Exhaust Elbow 9
4 T100-V Installation Drawing 10
5 T100-V Multiple Starter Drawing 11
Performance Curves 12

__ )

Publication T1- 721, Rev. 2

Issued May 14, 2001
Page: i

�
- ... ,
i
 TDI TURBOTW/WM
FROM TECH DEVELOPMENT, Inc

1.0 GENERAL INFORMATION 1.1 DESCRIPTION

This manual provides instructions for the installation and The T100-V features three basic subassemblies: a
operation of the TOI T100-V TURBOTWIN Air Starters. If unique two stage turbine motor section, an offset/spur
there are questions not answered in this manual, please gear assembly and a pre-engage drive assembly.
contact your TOI TURBOTWtN distributor or dealer for
assistance. The two stage motor section features greater stal' torque
than a single stage turbine plus aerodynamic speed
The T100-V starters are turbine driven starters with a control. This aerodynamic speed control helps protect
pre-engaged starter drive. The T100-V starters have the T100-V starter from damage caused by starter motor
applications ranging from 1800 CID (30 Liters) on diesel over speed. In addition, a specially designed motor
engines and up to 18000 CID (300 Liters) on gas housing module and low-mass rotors provide fail-safe
engines. The T100-V models are suited to operate within operation.
a wide range of inlet pressures and ambient
temperatures. The engine size and parasitic loading will The T100-Vemploys 9.25:1 ratio spur gearbox. This low
determine the exact minimum pressure that will assure gear ratio allows the turbine motor to spin at low speeds
reliable cranking. for long bearing life. At a typical 3000 rpm pinion speed,
,· the turbine is rotating at a low 27750 rpm .
../
The T100-V starters are designed �for
operation with
compressed air or natural gas: materials used are A reliable pre-engaged drive delivers the torque to the
compatible with "sour" natural gas and marine pinion. The pinion is translated out to engage the
environments. Small amounts of foreign matter or liquid engine's ring gear via the starter's engagement piston.
in the air supply will not adversely affect T100-V starters.
As with all TOI starters, no lubrication is required in the Compressed air or natural gas is used to power the
air supply. T100-Vthrough the inlet port. The air or gas is expanded
through the first nozzle or stators. The high velocity gas
Please review the rest of this manual before installing impinges on the first stage rotor to yield torque to the
the T100-Vair starter. gearbox through momentum exchange. The gas is
further directed through the second stage stators which
WARNINGS, CAUTIONS, ANO NOTES impart additional torque to the second stage rotor.

Certain types of information are highlighted in this 1.2 PRODUCT IDENTIFICATION

manual for your attention:
The starter nameplate which is attached to the turbine
WARNING - used where mJury to personnel or housing contains the following information: modei
damage to the equipment is possible. number, serial number, part number, direction of rotation
and the maximum rated operating pressure.
CAUTION - used where there is the possibility of
) damage to the equipment. The directions of rotation are either right hand or left
hand rotation as shown in Figure 1. Right Hand rotation
NOTE - used to point out special interest is defined as clockwise rotation as viewed from the
information. pinion end of the starter, and left Hand rotation is
counter clockwise rotation viewed from the pinion end of
NOTE the starter.
Throughout this manual, the term "air" is used to
designate the starter drive medium. Unless otherwise
stated, "air" means either compressed air or natural gas.

Publication T1-721, Rev. 2 Page 1

Issued May 14, 2001
TDI TURBOTWIN™ )
FROM TECH DEVELOPMENT, Inc

2.0 ORIENTATION OF THE STARTER

AT/
RIGHT HAND LEF"T HAND
ROT �ATION If the factory orientation of the starter turbine housing
assembly does not fit your engine installation, this
component can be re-oriented.

Determine the required orientation of the turbine housing

assembly and gearbox housing assembly. The turbine
housing assembly can be rotated to six different
positions relative to the gearbox housing assembly. The
drive assembly can be rotated to twenty four positions
relative to the inlet port.

Orientation of the starter should be accomplished prior to

installing the starter on the engine.

CAUTION
All screw threads are treated at the factory with a
fastener retention compound. Every screw and tapped . _ j
Figure 1. Direction of Rotation viewed from Pinion End. hole must be clean and have a drop of Loctite 242
applied to the threads before being installed.
The maximum operating pressure identified on the
nameplate is measured at the check port on the starter
inlet with the starter in operation. 3.0 INSTALLING THE STARTER

CAUTION A turbine air starter does not require lubrication in the

Exceeding the maximum pressure shown on the supply air. Therefore, if a vane type starter motor is
nameplate may result in drive failure, damage to the being replaced, TOI recommends that all lubrication
starter, or damage to the engine. devices and lines be removed to minimize flow
restrictions.
The housing proof pressure is 600 psig and is also
shown on the nameplate. This means that the turbine WARNING
housing will not burst when subjected to a static If a fuel (pulse) lubricator has previously been installed in l
pressure of 600 psig. the system. disconnect and plug the line to eliminate
spraying diesel fuel on the engine.
1.3 PHYSICAL CHARACTERISTICS
The starter should be installed with the inlet valve in a
Figure 2 shows the standard configuration for the T100- position between horizontal and straight down. Any
V with exhaust screen. This model weighs condensation will be restricted to the air lines and not in
approximately 54 lbs. and is 16.8 inches in length. The the starter. . )
turbine housing diameter is 6.8 inches. which is common
to all T100 TURBOTWIN air starters. WARNING
Do not operate this starter unless it is properly ·
1.4 PERFORMANCE connected to an engine.

The performance curve for the T100-V illustrates the 3.1 SUPPLY LINE INSTALLATION
pinion torque versus pinion speed (rpm) at a constant
drive air pressure, and horsepower versus pinion WARNING
speed at a constant drive air pressure. The pinion Be sure to either breed the pressurized air reservoir ·
speed is shown on the horizontal axis while the pinion and/or safety the system such as closing all valves prior :
torque is shown on the left edge of the vertical axis. Air to installing any starter supply line. ·
consumption rates are given for the various drive
pressures. The drive gas used for the performance
curve is air.

Page 2 Publication T1-721, Rev. 2

Issued May 14, 2001
 )
TDI TURBOTW/WM
FROM TECH DEVELOPMENT, Inc

T100-V starters come standard with a 2" NPT female threaded joints should be sealed with Loctite Pipe
pipe thread for the inlet connection port. The supply line Thread Sealant (TOI P/N 9-94085) or equivalent for leak
consists of the line from the air source, a pressure tight joints prior to final assembly. Be sure to tighten all
regulator (when necessary), a manual or relay valve, joints to proper torque after final assembly.
and the connection to the starter inlet. Hard piping may
be used, but a section of flexible tubing should be CAUTION
installed at the starter to prevent leaks due to engine In cold weather climates, care should be taken while
vibration. designing your installation to prevent condensation from
developing in the starter system. In systems with a
Care must be taken to ensure that all inlet supply line regulator valve or relay valve, there is the possibility of
piping is no fess than 1.5" and that all components used freeze-ups.
are capable of passing the required air flow.
A tee connection with a quick disconnect can be added
NOTE to the inlet. This will allow an external air source to be
! Valves with a Cv of 40 or higher are recommended. used to accomplish a "blow start" if the system freezes.
Once the engine has been started, the other system
,· ff the supply line must be longer than 20 feet, the inlet components may be thawed.
/ supply line piping should be increased to 2" in diameter
to ensure proper performance by your TURBOTWIN. CAUTION
On new installations, it is strongly recommended to blow
Because turbine starters such as the T100-V are out the supply line with air to remove possible dirt and
sensitive to flow restrictions, care must be taken to use welding slag prior to final connection to the TURBO TWIN
uniform hose or tubing and fittings for connection of the starter. Be sure to secure the free end of the supply line
supply line. Tees, elbows and fine length must be kept prior to blowing out the line.
to a minimum. TOI recommends that hose or flex
couplings be installed to eliminate possible leakage
caused by strain on the supply line. 3.2 INLET PRESSURE PO RT

Normally, an air strainer is not required. In dirty A 1/4" NPT port is located on the air inlet. This port may
environments, use of a #40 mesh Y-strainer is be used to check the supply pressure at the starter when
recommended. The T100-V is highly tolerant of dirt in the starter is operating. Remove the 1/4" NPT pipe plug
the air line, however, starter life can be increased with and save for later use. Install 1/4" minimum size tubing
the use of an air strainer. to the port. Route the tubing away from the starter to a
safe location away from the engine. Install a pressure
A pressure regulator is required when the air supply gauge on the tubing. This pressure monitoring
pressure is great enough to exceed the starter operating line/gauge may be permanently installed. Use Loctite
pressure (at the inlet port) and/or the maximum torque. Pipe Thread Sealant or equivalent. Alternately, a
pressure transducer may be installed at the pressure
._) A manual ball valve may be used to admit drive air/gas
to the starter. The manual valve should be located in a
check port and electrical lines routed to a digital display
at the operator's station.
safe position away from the engine.
This pressure port is invaluable in diagnosing air starter
A preferred valve is pilot-operated, which can be and/or installation problems.
pneumatically or electrically actuated. The valve should
be located close to or even on the starter inlet for best 3.3 EXHAUST PIPING
performance. Pneumatic or electrical control lines may
be routed virtually anywhere for the customer's preferred The turbine exhaust may be plumbed away from the
operating station. This type of valve actuates from a fully starter area. All starters using natural gas must be piped
closed to a fully open position very rapidly. TOI offers a according to industry codes and local regulations.
variety of relay valves such as P/N RLVA-25683-001-2-
01, which is a 1-1 /2" port, pneumatically actuated valve. The performance of a turbine starter will be decreased
because of back pressure when smaller than
The supply line should be dry-fitted for proper recommended exhaust piping is installed. If back
alignmenUlocation prior to final assembly. All pipe- pressure hampers starter performance, compensation

Publication T1-721, Rev. 2 Page 3

Issued May 14, 2001
 TDI TURBOTWIN™ )
FROM TECH DEVELOPMENT, Inc

can be made by increasing the supply pressure. Consult primary turbine shaft seal. Remove this 3/B"NPT plug
your TOI distributor for advice. and install a line to carry gas away from the starter area.

Exhaust piping should be routed downward to help WARNING

prevent any accumulation of condensation in the starter Do not connect the turbine housing vent line to the
motor. turbine exhaust line. Exhaust gas can pressurize the
turbine housing.
If the overhung section of the starter is not otherwise
supported, TOI recommends that the exhaust piping be 3.6 PIPING SYSTEM
supported with a suitable bracket(s).
Only type approved metallic hose assemblies are
3.4 SOFT START VALVE & FILTER FITTING approved in permanently pressurized compressed air
lines of starters. Non-metallic hose assemblies are
The "soft start" fitting (PIN: 2·28243), by providing a allowed only in case the piping system will be emptied
slower opening of the starter relay valve, eliminates after the starting procedure.
excessive starter pinion gear loading. The soft start
fitting is identified by the mark "EL-SOFT ST ART" found Pipe unions must be type approved by GL. Downstream
on its body. This fitting MUST be installed. at the starter of the pressure regulator a pressure relief valve is to be
relay valve as shown in figure 4. It is screwed into the provided. )
applied pressure ("IN" or "APP") port on the starter relay
valve. There are currently no approved substitutions for
this fitting. 4.0 STARTER OPERATION

The filter fitting (P/N: 2-28270) provides contamination Prior to operation, check that all connections are tight
protection to the starter's pre-engagement mechanism and free from leaks. Check the 1/4" NPT pipe plug or a
and the soft start fitting installed downstream. The filter pressure gauge/transducer that may be connected to the
fitting is to be installed on the "IN" port of the starter as pressure port on the starter inlet.
shown in figure 4. It appears similar to the soft start
fitting, however, there are no identifying marks on the WARNING
filter fitting. Do not operate the TOI TuRBOTWIN starter with air
pressure greater than the pressure rating on the
For multiple starter applications, a soft start fitting must nameplate. This pressure is measured at the starter
be installed on EACH relay valve and a filter fitting must inlet while the starter is running.
be installed on EACH starter as shown in figure 5.
The maximum operating pressure limit is the inlet
CAUTION pressure measured at the starter's inlet pressure check
For maximum pinion life and full warranty coverage, port. In order to check the starter, a 1/4"NPT pipe tap
the soft start valve (P/N: 2-28243) MUST be installed connection is provided in the inlet housing to attach a
in the applied pressure port (APP) of the relay valve. pressure gauge/transducer). The maximum pressure
assumes an open exhaust (the standard turbine exhaust
3.5 NATURAL GAS INSTALLATION guard). The standard exhaust guard causes no back )
pressure.
The installation of the starter using natural gas is similar
The static non-flowing supply pressure will always be
to the air installation except all fittings. piping, valves and
higher than the operating (dynamic) pressure. The
regulators must be compatible withnatural gas.
maximum pressure limit (proof pressure) that the T100-V
starter housings may be subjected to is 600 PSIG (42
Proper control of natural gas is a major consideration
BAR). System pressure that exceeds the maximum
when used in the starter system. All starters using
operating limit must use a pressure reducing device to
natural gas must pipe the exhaust according to industry
ensure that the operating pressure limit to the T100-V
codes and local regulations.
starter is maintained.
There is a natural gas vent port in the turbine housing
System static pressure that exceeds the 600 PSIG (42
that is plugged for compressed air use. This vent is used
BAR) limit must. in addition to pressure reducer devices.
to remove any natural gas that could leak past the

Page4 Publication T1-721, Rev. 2

Issued May 14, 2001
 TDI TURBOTW/WM
FROM TECH DEVELOPMENT, Inc

incorporate a pressure relief valve set below 600 PSIG operating unloaded (i.e. the engine is running) will
(42 BAR) in the supply air line. maximize starter life. If a start is aborted, a restart may
be attempted after the engine and the starter has come
NOTE to rest.
For maximum life of the starter pinion and for the
protection of the engine ring gear, limit the operating CAUTION
pressure to that necessary to start the engine at its most I Do not engage the starter while the engine is running.
difficult starting conditions.
The drive air pressure is the primary starter control
All appropriate local pressure codes and pressure parameter. It is important. especially on new
limitations on other system components must be installations, to measure this pressure during several
adhered to and supersede the guidelines given in this engine starts. The secondary parameter is the starter
manual. pinion speed. This speed is usually measured by
knowledge of the engine starting speed and the starter
Consult your TOI distributor if you have exhaust cranking ratio. The cranking ratio is the number of ring
plumbing that creates back pressure and reduces starter gear teeth divided by the number of pinion teeth. The
performance. You may be able to increase the supply starter pinion speed is then found by multiplying the
_I pressure to restore the lost power. engine speed by the cranking ratio. The pinion speed is
usually 2000-3500 rpm at typical engine starting speed.
Follow the engine manufacturer's instructions for starting
the engine. 4.2 AUTOMATED START PANEL

4.1 BASIC OPERATION The starter drive pressure measured at the starter inlet
will need to be set. As noted above, for maximum life of
The basic operation of the starter follows: the starter pinion and for the protection of the engine ring
gear, limit the operating pressure to that necessary to
Pressurized air or natural gas is admitted to the starter's start the engine at its most difficult starting conditions.
engagement piston chamber via the "in" control port by
opening the manual or solenoid valve. The air then The speed control parameter will then need to be set.
translates the starter's piston forward allowing the pinion Engine starting speed along with the cranking ratio
to engage the engine's ring gear. number can be used to determine starter pinion speed.
The pinion speed is usually 2000-3500 rpm for a typical
The forward movement of the piston causes the starter's engine starting speed. Once the start sequence has
"out" control port to open. Air is then transmitted to the begun, the air is admitted to the starter. The starter
automatic pilot port (APP) on the relay valve causing the begins to accelerate the engine. Once the firing speed of
relay valve to open. the engine is reached. the automated start panel may
deliver fuel to the engine. The engine will begin to
Pressurized air or natural gas is admitted to the starter's accelerate under its own power. The starter should be
turbine assembly by the opening of the relay valve. The dropped out of the sequence at a rpm higher than the
air expands through the turbine which produces shaft firing speed, but less than the engine idle speed.
rotation and torque. The starter motor torque causes the
engine to accelerate. The fuel and ignition systems now The automated start panel should monitor engine speed
fire the engine. Closing the relay valve stops the starter. to determine air on and air off. Do not simply use time
as a control parameter. Avoiding excessive operation of
The operator may decrease starter life by the continual the starter after the engine is firing will maximize the
operation of the starter after the engine has started. starter life.
Upon a successful engine start. turn the air off to the
starter immediately. Minimizing the time the starter is

Publication T1-721, Rev. 2 Page 5

Issued May 14, 2001
TDI TURBOTWIN™ j
FROM TECH DEVELOPMENT, Inc

5.0 WARRANTY

TOI TURBO TWIN ENGINE ST ARTER WARRANTY

Tech Development Inc. (TOI) warrants to the original user of the TOI TURBO TWIN™ Model T100-V Series air starters to;
be free from defects in material and workmanship for a period of one year from the date of installation. The warranty;
period shall not extend beyond two years from the date the unit was manufactured. (i.e.: a unit with a manufactured date:
of July 1999 (SN: 9907-101) will not be covered under warranty after July 2001 ). The conditions of this warranty are: a)
TOI is notified within this period by return of such product to TOI or its authorized distributor/dealer, transportation prepaid
by user; b) the starter has been installed according to TOl's specifications: c) the starter has not been misused, abused,
or improperly maintained by user; d) the defect is not the result of normal wear and tear; e) the starter has been repaired.
with parts manufactured or authorized by TOI; and f) TOI installation and repair procedures as outlined in the appropriate
manual were properly followed.

Tech Development Inc. will repair, or at its option, replace the unit during the warranty period at no charge to the
customer, provided it is returned to TOI with the proper return procedure.

Tech Development Inc. makes no other �arranty, and implied warranties including any warranty or merchantability or
fitness for a particular purpose are hereby dlsclaimed. . .j

This warranty constitutes the entire obligation of Tech Development Inc. relating to the sale and use of such product. and
TOl's maximum liability is limited to the purchase price of such product at the date of purchase. In no event shall TOI be
liable for incidental, indirect, consequential, or special damages of any nature arising from the sale or use of such engine
starter roduct.

Page 6 Publication T 1-721. Rev. 2

Issued May 14. 2001
 j TDI TURBOTW/WM
FROM TECH DEVELOPMENT, Inc

6.0 OPERATOR'S TROUBLESHOOTING GUIDE

TROUBLE PROBABLE CAUSE SOLUTION
1. Air always flow through A. Relay valve improperly A. Check typical installation
exhaust installed. diagram and correct.
B. Relay valve not sealing B. Check for damaged sealing
properly. ring, replace relay valve or
damaged parts.
C. Solenoid is not sealing, C. Check solenoid potential at the
pressure remains in APP port of lead to ground should be 0. If not,
relay valve. fix ignition switch problem.
2. Starter engages but does not A. Bad relay valve A. Replace relay valve.
run,
3. Starter does not run, small air A. Nozzle blockage. A. Remove blockage or obstruction
flow from turbine exhaust or from nozzles.
drive housing.
4. Starter does not run. Normal A. Excessive bends in the A. Shorten length or straighten
)
air flow from exhaust. �- suoolvline. suooly air line.
5. Pinion does not engage A. Air pressure is too low A. Increase air pressure to 40 -
150 psig.
B. Control lines to starter ports B. Check installation diagram and
reversed. correct.
C. Solenoid valve not operating C. Check wiring and solenoid
or plugged. operation. Correct wiring, remove
blockage, or replace solenoid
valve as needed.
0. Damaged pinion teeth. 0. Replace pinion or starter drive
as necessarv.
6. Starter runs but engine cranks A. Air pressure too low A. Increase air pressure to 40 -
slowly or not at all. 150 psig.
B. Excessive back pressure. B. Check Exhaust Closure Plate.
C. Nozzle blocked or damaged. C. RemovA blockage or replace
damaged parts.
7. Starter continues to operate A. Solenoid valve is not sealing A. See 1 C above
after start button is released. correctly.
B. Relay valve is not sealing B. See 1 B above
correctly.
---·· ··
._J 8. Air tank pressure decays after
extended shut down.
A. Air connections are not tight. A. Tighten loose fittings. Repair or
replace damaged fittings.
8. Damaged air lines: crushed, B. Replace damaged lines.
frayed, and kinked.
C. Relay valve is not sealing C. See 1 B above
correctly.
0. Solenoid valve is stuck open. 0. A. See 1C above

Publication T 1- 721, Rev. 2 Page 7

Issued May 14, 2001
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_..
0
0
<
�
�
0
?� AIR/GAS SUPPLY
"------,,-t

)>
:;· SEE PIPE SIZE CHART
to
w
::l. RECOMMENDED PIPE/HOSE SIZING••
� FOR MULTIPLE T100V STARTER INSTALLATIONS
3" NUMBER
(/) INLET & SUPPLY EXHAUSJ"
w OF
STARTERS PIPING• PIPING
� 3• MANIFOLD TO 1-112• 3• EXHAUST PIPE{S) OR
5· 2
INLET PIPING INTO 4• MANIFOLD
::::, TOI PIN T100-28012

p
0 4" MANIFOLD TO 2• 3• EXHAUST PIPE{S) (39 PIPE BUTT-WELD) .___,

I I � -t
ii,
3 I INLET PIPING INTO s• MANIFOLD

�-
:E
s' 4 I 4" MANIFOLD TO
INLET PIPING
'Z' 3"-4" EXHAUST PIPE{S)
INTO 6"-8" MANIFOLD � 'Cl .. � II I
�c
IO
CONSULT CONSULT
� 5 I FACTORY FACTORY
c
;:;
-a· ·see notes on air/gas Pressunt Regulator requirements/selection.
ro
�'"�11t lh
��
11� i
(/) ""These are minimum pipe sizes for multiple lnstaUatlons of
w
::l.
low-pressure (T121V) models. EXHAUSTSCREEN"
(I) TOI PIN 2-28175 •
�
� OJ
11��
"'C FILTER FITTING
Q)
TOI PIN 2-28270
IO
(I) ON EACH STARTER

��
:i�
g �
TDI TURBOTW/WM \
/
FROM TECH DEVELOPMENT, Inc

TORQUE
Model:T112-V Performance Curve �
Nm lb.ft. 12 Nozzles, Compressed Air, 9.25: 1 Ratio Hp Kw
476 350 70 52 2
Inlet Pressure SCFM Nm31h '
150 psig 1472 2502
408 300 120 psig 1199 2038 I 60 44.8
90 psig 929 1579 I

250 60 psig 657 1117 !

340 50 37.2

272 200 40 29.8

204 150 30 224

136 100 20 14.9

68 50 10 75 )

0 0 ..f:�--1--�--L-...L-L---J.-J_��___J��.:;i;���U.o 0

0 1,000 2,000 3,000 4,000 5,000

Pinion Speed (rpm)

Model: T121-V Performance Curve POWER

TORQUE
Nm lb.ft
21 Nozzles, Compressed Air, 9.25: 1 Ratio Hp Kw

544 400 80 59.6

Inlet Pressure SCFM Nm3/h
90 psig 1606 2730
476 350 60 psig 1158 1969 70 52.2
40 psig 848 1442
408 300 60 44.8

340 250 50 37.2

/

272 200 40 29.8

204 150 30 22 4

136 10_0 20 14.9

68 50 10 75

0 0 0 0

0 1,000 2,000 3,000 4,000 5,000

Pinion Speed (rpm)

Page 12 Publication T1-721, Rev. 2

Issued May 14, 2001
 )

�� 11 )I
TECH DEVELOPMENT INC.
Publication T1-723

SERVICE MANUAL
.)

�-_·_)
MODEL: T100-V
TURBOTWIN Engine Air Starters

Preliminary From Tech Development Inc

6800 Poe Ave. -Dayton OH 45414
Tel: (937) 898--9600 •Fax: (937) 898-8431
 ) TDI TURBOTW/Nt"M
FROM TECH DEVELOPMENT, INC.

CAUTION - used where there is the possibility

SECTION 1.0 INTRODUCTION
of damage to equipment.
NOTE - use to point out special interest
1.1 GENERAL INFORMATION information.
This manual provides information for servicing,
1.3 DESCRIPTION OF OPERATION
disassembly, and reassembly of the TOI Turbotwin
T100-V air starters. If there are questions not
The Turbotwin T100-V starters are powered by a pair of
answered by this manual, please contact your local TOI
axial flow turbines coupled to a simple planetary gear
distributor or dealer for assistance. Illustrations and
reduction set. The T100-V starters incorporate an
exploded views are provided to aid in disassembly and
reassembly. inertia bendix drive coupled to the starter gearbox drive
train to provide a means of disengaging the pinion from
The TOI Turbotwin T100-V the engine's ring gear.
engine starters are
specially designed for starting today's automated, low-
The high horsepower of the turbine air motor combined
emission engines. The Turbotwin uses aerodynamic
with the spur gear speed reducer results in a very
speed control, eliminating the need for a mechanical
efficient and compact unit. The Turbotwin T100-V
automatic trip valve (A TV) to control starter motor
· �- starters can be used over a wide range of drive
. .J speed.
pressures from 40 psig (2.6 BAR) to 150 psig (10 BAR)
and are suitable for operation on air or natural gas.
The Turbotwin T100-V air starters are suited to operate
within a wide range of inlet pressures and ambient
temperatures. These starters are designed for 1.4 INSTALLATION AND SERVICE
operation with either compressed air or natural gas.
It is important to properly install and operate the TOI
The robust turbine motor design in the Turbotwin T100- Turbotwin T100-V starters to receive the full benefits of
V starters has no rubbing parts, and is therefore the turbine drive advantages. It must be installed in
tolerant of hard and liquid contamination in the supply accordance with the instructions provided by Tech
gas with almost no adverse affects. The motor is well Development, Inc. (TOI).
adapted to running on "sour" natural gas.
WARNING
As with all TOI air starter products, there are no rubbing Failure to properly install the starter or failure to operate
parts so there is no lubrication required. This it according to instructions provided byTOI may result in
eliminates failures due to lubricator problems. the damage to the starter or engine, or cause personal
expense of installing and maintaining the system, and injury. DO NOT OPERATE THIS STARTER UNLESS
the messy and hazardous oil film around the starter IT IS PROPERLY ATTACHED TOAN ENGINE.
exhaust. The starter is factory grease packed for the
life of the starter so it requires no maintenance. Repair technicians or service organizations without
turbine starter experience should not attempt to repair
) ·NOTE this starter until they receive factory approved training
Throughout this manual, the term "air" is used to donate from TOI, or its representatives. Proper operation and
the starter drive medium. Unless otherwise stated, "air" repair of your TOI Turbotwin will assure continuous
means compressed air or natural gas. reliability and superior performance for many years.

Please review the rest of this manual before attempting 1.5 NAMEPLATE INFORMATION
to provide service to the TOI Turbotwin T100-V starters.
The nameplate located on the turbine housing provides
1.2 WARNINGS, CAUTIONS, & NOTES important information regarding the construction of your
T100-V starters. Refer to Figure 1.
Throughout this manual, certain types of information will
be highlighted for your attention: NOTE
You should always have the starter's Part Number.
WARNING - used where injury to personnel or damage Serial Number. Operating Pressure. and Direction of
to equipment is possible. Rotation information before calling your TOI distributor
or dealer.

Publication T1-723 Page 1

 TDI TURBOTW/WM )
FROM TECH DEVELOPMENT INC.

IIJI
motor. The starter is composed of three basic
TURBOTWINTM assembly groups: Turbine Housing Assembly; Gearbox
PNUEMATIC STARTER Housing Assembly; and Drive Assembly.
TECH DEVELOPMENT
INC.
2.2 TURBINE HOUSING ASSEMBLY
f
6800 POE AVE .. OAYTON OH
MODEL NO. SERIAL NO. Wx(RT
tr112v I �911-2101 The Turbine housing assembly, refer to figure 3,
PART NUMBER consists of a stage one (13) and a stage two (5) turbine
!AIR OR NAT. GAS USAGE
T112-60031-01R-1-03
HOUSll'iG PROOF PRESSURE IS 600
... I
PSIG
wheel mounted on sungear shaft (30) . The front
bearing (8) is secured by a retainer plate (29). The aft
bearing (8) is preloaded by a wavy spring (10).
MAX OPERATING INLET PRESS. !150 PSIG !
WARNING oo NOT OPERATE UNLOADED. w1THOUT EXHAST The ring gear (27) is installed between the turbine
"----�G_u__ A R.. ,. ._
o o""'=w
R . ,.T=
. ,1 o__
H u.,.._
T _H.x .,. A. . . ,us,. ,. T_F_r_n
1 _,,GN ___. assembly (23) and the gearbox housing and secured by
e

Figure 1. TD/ Turbotwin Nameplate four screws (25).

2.0 DESCRIPTION OF BASIC GROUPS

2.1 GENERAL ' )

The TOI Turbotwin T100-V air starters are lightweight,

compact units driven by a dual stage turbine type air

- _)

Figure 3. Turbine Housing Assembly

Page 2 Publication T1-723

 I TURBOTW/NrM
TD TECHI IDEVELOPMENT, INC.
FROM
.
23 H --------- . ounted on two ba II bearings (38) m
The carrier shaft
h�ugs:I� msher
(48)� The aft be:r� in ard
is preloade_d
--------- the gearbox �
is
OUSING ASS EM BL y use of spn (39J- T� owhich isbearing
( ;)
lhe(:j ring housing • secur: �
GEARBOX housing earners)
ass7m bly f r tothree
h�ftre(32). figures
Pa 4, �stalled into
, gearbox e I anet by four scre.wst to the gea'.bo=h tand sing. The sp
��
The
consist of a
gear� (3� ),(
bearing pins n::,.
plan;let gear ,
bearings (35 spacers (33), nd
gear (45). is ins a lled on the earner
the beann g locknut (47 ) .
secured by

_}

Publication T1-723 Page 3

 TDI TURBOTW/HfM
FROM TECH DEVELOPMENT INC.

2.4 DRIVE ASSEMBLY The roller bearing (69) is installed into spur gear (65)
and secured by retaining ring (70). The forward bearing
The drive assembly, refer to figure 5, consists of a (66) is pressed into the drive housing. The lip seal (75)
piston (53), helical shaft spline (56), dental clutch (58) is pressed into the forward side of drive housing (72).
and drive pinion shaft (61). The clutch assembly (56
thru 64) is installed into the spur gear (65). The spur The pinion collar (76) is installed on pinion shaft (61)
gear (65) is supported by the aft bearing (66), which is behind pinion (77), which is secured by washer (78) and
secured by the retaining ring (67). screw (79).

rive Assembly

Page 4 Publication T1-723

 ) TDI TURBOTWIN™
FROM TECH DEVELOPMENT, INC.

SECTION 3.0 DISASSEMBLY

3.2.2 Pre-engaged Drive Disassembly
3.1 GENERAL
Secure pinion (77) in a soft tooth vise while supporting
aft end of the T100-V air starter. Rotate pinion screw
Always mark adjacent parts on the starter housing;
(79) counterclockwise to remove using a 3/4" socket
Nozzle 2/ Containment Ring (11 ). Turbine Housing (23),
and wrench.
Gearbox Housing (48), and Drive Housing (72) so these
parts can be located in the same relative position when
NOTE
the starter is reassembled.
Use only a soft tooth vise to secure the pinion to avoid
Do not disassemble the starter any further than damaging pinion.
necessary to replace a worn or damaged part
This screw is torqued to 60 lb ft during assembly
Always have a complete set of seals and o-rings on therefore a large wrench may be required when
hand before starting any overall of a Turbotwin T100-V removing screw.
starter. Never use old seals or o-rings.
Remove washer (78), pinion (77) and spacer (76) from
The tools listed in Table 1 are �uggested for use by pinion shaft (61 ). If pinion is too tight, place a
)
technicians servicing the T100-V Turbotwin starters. screwdriver underneath pinion and lift up on pinion to
The best results can be expected when these tools are remove from shaft.
used, however the use of other tools are acceptable.
Contact TOI for a list of additional tools that maybe Remove helical spline shaft assembly (54-64) from
required when overhauling T100-V air starters. spur gear shaft (65). Remove spring (64) from shaft.

TOOL DESCRIPTION TDI/PN Use press tool and arbor press to remove spur gear
Soanner wrench 52-20134 shaft (65) from drive housing (72) as shown in figure?.
Soanner wrench 52-21345
Use a screwdriver to remove lip seal (75) from forward
Shaft Removal Tool 2-26945
end of drive housing (72).
Staoe 2 Rotor Puller Tool 52-20076
Carrier Shaft Holdina Tool 52-20202 Remove retainer ring (70) and bearing (69) from
Tool, Bearina Pressino 52-20143 forward end of spur gear shaft (65).
Tool, Bearina/Seal 2-26943
Table 1. T100-V Service Tools Remove retainer ring (67) and press bearing (66) from
spur ��ar shaft (65) as shown in figure?.
3.2 DRIVE HOUSING
Remove retainer ring (54) and bearing (55) from helical
3.2.1 Removal of Drive Housing spline shaft (56).
=. __ _)
Mark position of drive assembly (72) relative to gearbox 3.5 GEARBOX HOUSING
housing (48) for reference during reassembly.
3.5.1 Removal of Gearbox Housing
Remove the eight screws (73) and pull drive assembly
from gearbox housing. If drive housing is too tight, tap Remove the screws (25) securing the gearbox (48) to
it with a mallet to loosen. the turbine assembly (23).
Remove o-ring (71) from aft end of drive housing(72). Remove ring gear (27) from turbine (23) or gearbox
assembly (48). The ring gear could remain on either
NOTE assembly when separation occurs.
Before removing the eight screws (73), install a spacer
between pinion (77) and drive housing (72) to allow for 3.5.2 Gearbox Disassembly
easy installation during reassembly.
Place gearbox assembly (48) on flat surface with aft
end facing up.
Publication T1-723 Page 5
 TDI TURBOTW/NTM )
FROM TECH DEVELOPMENT INC.

Remove four screws (44) and lift carrier shaft assembly Remove the woodruff key (6) from the turbine shaft
(32) from gearbox housing. (30).

Place carrier shaft assembly on carrier shaft holding 3.6 Turbine Shaft Removal
tool (52-20202) and use a screwdriver to remove tang
of lock washer (46) from slot of retainer nut (47). Place the turbine housing on a flat surface with the sun
gear end facing up.

Place TDI tool PIN 52-20134 (Spanner Wrench) over Remove four screws ( 16) and bearing retainer plate
shaft and into slots of retainer nut (47). Hold carrier (29) from turbine housing.
shaft assembly down and turn spanner wrench counter
clockwise to remove retainer nut, lock washer (46), spur Using the shaft removal tool P/N 2-26945. press on the
gear (45), and woodruff key (37) from carrier shaft (32) aft end of the turbine shaft (30) while supporting the
as shown in figure ? . turbine housing (23). See figure '?.

Use an arbor press to remove carrier shaft (32) from Press the turbine shaft (30) through the aft bearing (8)
bearing housing (43). The bearing housing must be until the shaft is completely out of the housing (23) as
elevated and supported to remove carrier shaft per shown in figure?.
figure? ·.
Remove the woodruff key (14), seal spacer (7). bearing .J
NOTE spacer (28), and bearing (8) from turbine shaft (30).
Do not support the bearing housing on the four lips as The bearing can be removed from the shaft by pressing
they could break while pressing on carrier shaft. the shaft through the bearing while supporting bearing.

Remove spring washer (39), spring retaining plates Separate the stage 2 nozzle assembly (11) from the
(40), and bearing spacer (42) from carrier shaft. turbine assembly (23) by firmly holding the turbine
assembly, while tapping nozzle 2 with a mallet. If
Remove aft bearing (38) from shaft by pressing shaft nozzle 2 is too tight, it can be removed by installing two
while supporting bearing. threaded screws into nozzle 2 and using them as jacks
to separate nozzle 2 from the turbine assembly.
3.5.3 Planet Gear Disassembly
NOTE
Remove retainer ring (31) from planet shaft (36) and Rotate the stage 1 rotor if necessary to allow the jacks
push planet shaft through assembly. to travel through the large holes in the rotor. The jacks
will damage the stage 1 rotor if pressure is applied to
Slide the planet gear (34) from carrier shaft and the rotor while removing nozzle 2.
remove two spacers (33).
Remove stage 1 rotor (13) and o-ring (12) from nozzle
Use press tool to remove needle bearing (35) from 2.
planet gear (34 ).
Remove the four screws (16) and nozzle 1 (17) from . __)
3.6 TURBINE HOUSING the turbine assembly. It may be necessary to tap the
screws with a hammer and chisel to loosen.
3.6.1 Stage 2 Rotor Removal
Remove o-ring (19) f,.om aft end of turbine housing.
Place the turbine assembly (23) with ring gear (27) on a
Remove the seal spacer (15) from the forward side of
flat surface with ( exhaust) end up and remove the six
nozzle 2 ( 11 ). Place the stage 2 nozzle on the exhaust
screws (1 ), and the screen (2).
end. Press through the forward lip seal onto the
bearing until it. including the aft lip seal and seal spacer
Secure the stage 2 rotor (5) and remove the turbine
disengages from the nozzle. Turn the nozzle over and
screw (3) and washer (4 ).
press on the forwarc tip seal to remove.
Install the rotor puller tool P/N 52-20076 and remove
the stage 2 rotor as shown if figure ? .

Page 6 Publication T1-723

 l
)
TDI TURBOTWIN1'M
FROM TECH DEVELOPMENT, INC.

SECTION 4.0 CLEANING and · Clean aluminum parts using the solutions per Table 2;
soak for 5 minutes. Remove parts, rinse in hot water,
INSPECTION and dry thoroughly.

4.1 CLEANING Clean corroded steel parts with a commercially

approved stripper.
Degrease all metal parts, except bearings, using a
commercially approved solvent. Refer to Table 2. 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

Deqreaslnc Solvent Commercially Available
Acetone Commercially Available
Aluminum Cleaning Solution Diversey Corp., 212 W. Monroe, Chicago, IL 60606
j . �. Dissolve 5 oz of Diversey 808 per gallon of water at
155°- 165°F.
Steel Cleaner - Rust & Corrosion Oakite Products Corp., 50 Valley Rd., Berkeley
Heights. NJ 07992
Mix 3-5 lb. of Oakite rust Stripper per gallon of water:
use at 160°- 1800F.
Chromic-Nitric-Phosphoric Acid Pickle Solution Mix Sib. of chromic acid, 1.9 gal. of phosphoric acid,
1.5 gal. of nitric acid with enough water to make a total
of 10 aal. 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 Check all bearing bores for wear and scoring. Bearing
bores shall be free of scoring lines, not to exceed
Use Table 3 as a guide to check for acceptable 0.005" width and 0.005" depth.
condition of the parts listed.
Check gear teeth and turbine housing ring gear for
Check all threaded parts for galled, crossed stripped, or wear. In general, visually check for spalling, fretting,
broken threads. surface flaking, chipping, splitting, and corrosion. If
_) Check all parts for cracks, corrosion, distortion, scoring,
wear is apparent, check the gear teeth dimensions in
accordance with Table 4. Nicks and dents that cannot
or general damage. be felt with a .020 inch radius scribe are acceptable.

Publication T 1-723 Page 7

 TDI TURBOTWIN™ l
/
FROM TECH DEVELOPMENT INC.

Part Check For Requirements

Description (Defective Parts Must Be Replaced)
Pinion Chipped Teeth, Cracks Defective unit to be replaced. Use figure 5
as a ouideline for acceptable pinion wear.
Drive Housino Cracks and breakage Cracks are not acceptable
Planet Gear Cracked, chipped, or galled Wear must not exceed limits per table 4.
teeth. Wear must not exceed
limits per Table 4. 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 and pin holes & keyways not acceptable.
keyways. Integrity of knurl Scoring on bearing diameter not to
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.
Wear must not exceed limits per Table 4.
Washers Wear created grooves Wear must not exceed limits per Table 4.
Gearbox Housing Cracks and Breakage·,. ·· Cracks and breakage not acceptable.
Sungear I Turbine Cracks. scoring, wear created )
Shaft grooves, chipped or broken
gear- teeth, galling or scoring
on bearing surface of shaft.
Raised metal on the kevwav. Wear must not exceed limits per Table 4.
Spacers 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.

Ring Gear Cracks, wear, chipped, or

broken oear teeth. Wear must not exceed limits per Table 4.
Seal Assembly Wear grooves or scratched Wear is not permitted.
surfaces on carbon rino.
Seal Spacer Wear Grooves No wear permitted.
Needle Bearinos Freedom of needle rollers Reolace bearlnos
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.

Tip wear: bore and key way Wear is not permitted.

wear
Table 3. Parts Inspection Check Requirements

Page 8 Publication 11-723

 ) TDI TURBOTWIN™
FROM TECH DEVELOPMENT, INC.

PART DESCRIPTION LIMIT, Inches

Ring gear I Turbine Housing
Internal measurement
between two .084" diameter 5.0890 max.
pins.
Sun Gear I Turbine Shaft
Bearing diameter 0.6690 min
External measurement over
two .096 diameter pins.
7.5:1 0.952 min
9:1 0.808 min
11.4:1 0.670 min
Planet Gear
External measurement over
two .0864" diameter pins.
7.5:1 2.3067 min
9:1 2.3699 min
} 11.4:1 ... �.4359 min
Carrier Shaft
Bearing Diameter 1.1800 min
Planet Pin Bore 0.8750 max
Planet Pins
Bearing Diameter 0.873 min
Thrust Washer
Thickness .055 min
Table 4. Parts Wear Limits

_ _)

Publication T1-723 Page 9

 TDI TURBOTW/HfM '!
j
FROM TECH DEVELOPMENT INC.

SECTION 5.0 ASSEMBLY Install bearing retainer plate (29) and secure with four
screws (16). Torque screws to 40 in-lbs.
5.1 GENERAL Place turbine housing with sun gear end down on a flat
surface, while using ring gear to support turbine
The tools listed in Table 1 are suggested for use by housing. Install long bearing space (28) and seal
technicians servicing the T100-V starters. The best spacer (7) over shaft.
results can be expected when the proper tools are
used. however, use of other tools is acceptable. Install the 0-ring (19) into the aft face of the turbine
housing (23).
CAUTION
Replace all screws , 0-rings, lip seals, and bearings 5.2.2 Nozzle 1 Installation
when the T100-V starter is reassembled. These parts
are included in the overhaul kit shown in Section 6.0 Press the aft seal (15) into nozzle 1 (19) using press
tool P/N 2-26943 per Figure ? with the lips facing up.
NOTE
Always press the inner race of a ball bearing when Install nozzle 1 onto the turbine housing (23). Orient
installing a bearing on a shaft. Always press the outer the nozzles facing the air inlet (21) and install four
race of a ball bearing when installing into a hOl:ising. screws (16) to secure the nozzle. Do not tighten the j
screws at this time.
Refer to Section 6.0, for a list of kits and components,
which are available to aid in rebuilding T100-V starters. NOTE
The rotation of the turbine assembly is opposite from
Lubricate all 0-rings with petroleum jelly or Parker-0- the pinion rotation, therefore this nozzle must be
Ring Lube before assembly. Refer to Table 5 for a list configured for LH (CCW) if the pinion rotation is RH
of materials to be use during assembly. (CCW), or configured for RH (CW) if pinion rotation is
LH (CCW).
MATERIALS SOURCE
Petroleum Jelly Commercially Available 5.2.3 Rotor 1 Installation
Parker-0-Ring Lube Commercially Available
Loctite RC290 Commercially Available Install the large woodruff key (14) for stage 1 rotor into
Grease, cearbox TOI P/N 9-94121-001 the turbine shaft (30).
Table 5. Materials for Assembly
Install the stage 1 rotor (13), while supporting sun gear
CAUTION end of shaft, onto the turbine shaft by aligning the slot in
the rotor with the woodruff key and hand press the rotor
The screws that secure the Containment Ring/ Stage 2
until firmly seated. Use press tool PIN 2-26943 if
Nozzle must have a drop of Loctite RC290 applied to
required.
the threads before being used.
.....
Visually inspect that the key was not pushed out during )
5.2 TURBINE HOUSING assembly. Note that the direction of rotation was
oriented properly. This turbine rotor can be installed
5.2.1 Turbine Shaft Installation backwards.

Press the bearing (8) onto the shaft (30) until seated. Install spacer (7) onto sun gear (30).
Support the shaft and press on the inner race only with
press tool PIN 2-26943 as shown in figure ? . To center nozzle 1, temporarily install Nozzle 2 (11) on
the turbine housing and tighten the four screws that
Press the bearing/shaft assembly (8, 30). keyway end secure nozzle 1 (17) to 30 in-lb. The four screws can
first. into bearing housing of the turbine housing (23). be accessed via the holes in nozzle 2 and the first stage
Use press tool PIN 2-26943 if required. Do not press on turbine rotor. Remove Nozzle 2 when the four screws
the end of the shaft because the load could damage the are tight.
balls of the bearing.

Page 10 Publication T1-723

 ) TDI TURBOTWIN™
FROM TECH DEVELOPMENT, INC.

5.2.4 Nozzle 2 Installation therefore, dimensionally check if correct gears are

being used. Use table 4 for over the wire
Install the 0-ring (9) into the bearing bore of nozzle 2 measurements.
(11 ). DO NOT LUBRICATE THIS 0-RING.
With a thrust washer (33) on each side of gear, slide
Install 0-ring (12) onto the outer diameter of nozzle 2 gear into carrier shaft slots (32), and align with pin
and install nozzle 2 (11) onto the turbine housing (23). holes.

NOTE Lightly slide plant shafts into aligned holes, making sure
The rotation of the turbine assembly is opposite from retainer ring groove on end of pins goes in first.
the pinion rotation. therefore this nozzle must be
configured for LH (CCW) rotation if the pinion rotation is NOTE
RH (CW), or configured for RH (CW) if pinion rotation is Make sure that anti-rotation pins on shafts are properly
LH (CCW). located in retaining slots of carrier shaft (32).

Install the seal spacer (7) onto the shaft and the wavy Install retainer ring (31) onto planet shaft (36) using a
spring washer (10) into the bearing bore of the stage 2 retainer ring tool. See figure ?
_) nozzle.
5.3.2 Gearbox Reassembly
While supporting the sun gear end of the shaft, press
the aft bearing (8) onto the shaft by pressing onto the Install bearing (38) into the bearing housing (43) and
inner and outer race simultaneously. Use press tool 2- secure with retaining ring (41 ).
26943 per Figure ?. Press until bearing is seated.
Press aft bearing (38) onto carrier shaft (32) using TOI
Install the stage 2 woodruff key (6) into the shaft (30). Tool P/N 52-20143 per Figure ? Pressing force should
be on the inner race of bearing.
5.2.4 Stage 2 Rotor Installation
Install spring washer (39), spring retaining plate (40)
Install the stage 2 rotor (5) onto the shaft. Use press and bearing spacer (42) onto shaft and locate against
tool P/N 2-26943 if required. Visually inspect that the bearing.
key was not pushed out during assembly. Note that the
direction of rotation was oriented properly. This turbine Position bearing housing assembly (38,41,43) over
can be installed backwards. carrier shaft (32) and press until firmly seated.

Install the rotor washer (4) and secure with screws (3). Install woodruff key (37) into slot on carrier shaft (32)
Tighten screw to 100 in-lb. and install spur gear (45) on carrier shaft aligning slot
on gear with woodruff key.
Install the exhaust screen (2) and secure with six
) screws (1 ). Tighten the screws to 80 in-lb. Place bearing housing assembly on carrier shaft
holding tool PIN 2-20202 per Figure ?. Install
5.2.S Air Inlet Installation lockwasher (46) and retainer nut (47). Torque to 90-
100 ft.lb. Tang lock washer into retainer nut slot.
Place the 0-ring (22) into the groove on the air inlet
(21 ). Place 0-ring (12) onto outer diameter of gearbox
housing (48).
Install the 2" NPT air inlet flange (21) and secure with
six screws (20). Tighten the six screws to 170 in-lb. Install carrier shaft assembly into aft side of gearbox
housing (48) and secure with four screws (44). Torque
5.3 GEARBOX HOUSING to 113 in-lbs.

5.3.1 Planetary Gear Carrier Reassembly

Press needle bearing (35) into planet gears (34 ). The

planet gears are not identified by part number.
Publication T1-723 Page 11
 TDI TURBOTW/1/fM
/
\
FROM TECH DEVELOPMENT INC.

Rotate carrier shaft (35) slightly, and at the same time,

5.4 DRIVE HOUSING align gearbox into the front of turbine housing (26).
5.4.1 Drive Reassembly Install six gearbox to turbine assembly screws (25) and
Install bearing (69) into forward end of spur gear shaft
torque 113 in-lbs.
(65) and secure with retaining ring (70).
Install drive assembly (72) onto gearbox assembly (48)
Press bearing (66) onto spur gear shaft (65) and secure and secure with eight screws (73). Torque to 113 in.
with retaining ring (67) as shown in figure?.
lbs.
Press bearing (68) into drive housing (72) until seated
firmly into housing.

Press lip seal (75) into forward end of drive housing

(72) and install 0-ring into 0-ring groove on drive
housing.

Install spur gear assembly (65-67) into gearbox drive

housing (72) until firmly seated. · ,...
)
Install bearing (55) onto aft end of drive shaft assembly
(56-61) and secure with retaining ring (54). Lubricate
drive shaft assembly using TOI grease PIN: 9-94121-
002.

Lubricate inner diameter of spur gear assembly (65)

using TOI grease PIN: 9-94121-002.

Install spacer (62), spring (64 ), and pinion spacer (76)

onto pinion drive shaft assembly (56-61) then install into
aft end of spur gear (65). The gears on helical shaft
(56) must be aligned into the aft end of the spur gear
shaft (65).

Press the helical shaft assembly into the spur gear

shaft (65) until end of shaft protrudes from forward end
of drive housing as shown in figure ?

Maintain pressing force and install pinion onto drive

shaft (61 ). Secure with screw (79). Torque to 60 ft. lb.

Install spacer between pinion (79) and drive housing

-._)
(72) before releasing pressure from helical shaft.

5.5 FINAL ASSEMBLY

Place turbine assembly (23) with aft end on a flat
surface and install ring gear. Ensure notches on ring
gear are aligned with screw positions on turbine
housing.

Thoroughly grease planet gears (34 ). ring gear (27),

sun gear (30), spur gears (45, 65) using TOI grease
PIN: 9-94121-002.

Page 12 Publication T1-723

 TDI TURBOTW/NrM
FROM TECH DEVELOPMENT, INC.

SECTION 6.0 PARTS LIST

The components illustrated and/or described

in this section are for the Turbotwin T100-V
air starters. When rebuilding a T100-V
starter, it is recommended to purchase, and
completely install the appropriate service kit(s).

ILLUSTRATED PARTS LIST FOR MODEL T/00-V SERI/ES .-UR STARTERS

KE\'NO. DESCRIPTION PART NUMBER OVERHAUL KIT

PIN: Tl0\'-28574
I Screw (6) 11 f. 25020-064 x
·._) . ....
2 Exhaust Guard 2-28175
x
3 Screw 19F- 25028-012

4 x
Washer 9-93047

5 Rotor 2 2-26604

6 x
Woodruff Kev 9-9021 1-006
x
7 Bearing Spacer (3) 9-93091-005
x
8 Bearing (:!) 9-91224
x
9 0-rintit (I) 9-90001-027
x
10 Wave Snrina Washer 9-90439

I Ii Nozzle 2/Containment Ring R.H. (See Note) 2-27825-00R

I Iii Nozzle 2/Containment Rim! L.H. (Sec Note) 2-27825-00L

x
IL 0-rint,tm 9-90001-050

13 Rotor I 2-26603

14 Woodruff Kev 9-90211-009

x
15 Lip Seal 2-22376
x
16 Screw (8) 14F-19024-008

Publication T1-723 Page 13

 TDI TURBOTWIN™ )
FROM TECH DEVELOPMENT INC.

KEY NO.
OVERHAUL KIT
DESCRIPTION PART NUMBER
PIN: TIOV-28574
17i Nozzle I, R.H .• 9 Nozzles (Sec Note) 2-26718-09R

t 7ii Nozzle I, L.H .• 9 Nozzles (See Note) 2-26 7 t 8-09L

t 7iii Nozzle I, R.H., 12 Nozzles (See Note) 2-267 t 8-t 2R

t 7iv Nozzle I, L.H., 12 Nozzles (See Note) 2-26718-12L

t7v Nozzle I, R.H .. 15 Nozzles (See Note) 2-26718-15R

17\'i Nozzle I, L.H., 15 Nozzles (Sec Note) 2-26 718-15 L

I 7vii Nozzle I, R.H .. 21 Nozzles.(See Note) 2-26718-21 R

j
t 7viii Nozzle I, L.H., 21 Nozzles (See Note) 2-26718-21 L

18 Pine Plue 9-93556-004

19 Ovrinu 9-90001-034 x

20 Screw (6) 14F-31218-016 x

21 Inlet Flange 1-18967

22 0-rine 9-90001-037 x

23 Turbine Housinu 2-27869

24 Pipe PIUJ:! 9-93501-004

25 Screw (6) 71 F-25020-036 x

26 0-Ring 9-90001-050 x

'17 Ring Gear 2-27870

28 Bearing Spacer 9-93091-00 I )

29 Clamping Plate 2-26750

30 Turbine Shaft 2-27238

31 Retainer Ring (3) 9-92001-00 I

Page 14 Publication T1-723

) TDI TURBOTW/NrM
FROM TECH DEVELOPMENT, INC.

KEY DESCRIPTION
PART NUl\1 BER OVERHAUL KIT
NO.
P/N: TIOV-28574
32 Carrier Shaft (9: I) 2-27798-00 I

33 Spacer. Gear (6) 9-93004

34 Planet Gear (3) 1-18779

35 Needle Roller Bearing (3) 9-91004-00 I x

36 Planet Shaft (3) 2P-20182

37 Woodruff Key 9-90227-025

38 Bearina (2) 9-91003 x

39 Wave Spring Washer 9-90402-025

)
40 Spring Retaining Plate 2-27731

41 Retaining Rin2 9-92001-033

42 Bearing Spacer 9-93007-003

43 Housing. Bearing 2-27226

44 Screw (.4) 14F-25020-012 x

45 Gear. Sour 2-27712

46 Lockwasher, Bearing 9-93061-007

47 Locknut. Bearing 9-92127-007

48 Housing. Gearbox 2-27728

49 Locknut (6) 9-92 134-00 I

50 Fitting. Filter 2-28270

51 Plug. Pipe (2) 9-93556-004

52 0-Ring, Piston 9-90001-327 x

53 Piston 2-27921

54 Retainer Ring 9-92001-041

55 Bearing 9-91254 x

56i Spline. Helical Shaft. R.H. (See Note I) 2-27977-00R

56ii Spline, Helical Shaft, L.H. (See Note I) 2-27977-00L

Publication T1-723 Page 15

 TDI TURBOTWIN™ t
I
FROM TECH DEVELOPMENT INC.

KEY NO. DESCRIPTION

PART NUMBER OVERHAUL KIT
PIN: TIOV-28574
57 Soring. Compression 9-90444

58i Clutch, Helical. R.H. 2-27713

ssu Clutch, Helical, L.H. 2-27716

59 Ring. Retainer 9-92001-03 7

60 Bearing. Needle Roller 9-91409 x

61i Shaft. Drive Pinion R.H. 2-28169-00 I

6lii Shaft, Drive Pinion L.H. 2-28169-002

62 Washer. Thrust •,...

9-93120 x

63 Ring. Retainer 2-28051

64 Spring, Compression 9-90447

65 Gearshaft. Sour 2-27711

66 Bearinu, Ball 9-91431 x

67 Ring, Retaining 9-92001-036

68 Bearing, Ball 9-91434 x

69 Bearing. Needle Roller 9-91435 x
70 Ring. Retainer 9-92001-04:?

71 0-Ring 9-90001-1 58 x
72 Housing. SAE 2-27729

73 Screw 71F-25020-016 x
74 Fining. Vent 9-93662-012

75 Seal. Lip 2-22084 x

76 Spacer. Pinion 2-28178

77i Pinion. R.H. 6t8P. I 2T 2-28167-001

77ii Pinion. l.H. 6.18P. I 2T 2-28167-002

78 Washer. Pinion 9-93 I 24 x

79 Screw 71F-50020-016 x

Note: The rotation of the turbine assembly is opposite from the pinion rotation. therefore this nozzle must be
configured for LH (CCW) rotation if the pinion rotation is RH (CW). or configured for RH (CW) if pinion rotation
is LH (CCW).
Page 16 Publication T1-723
 ) TURBO TW/NrM
TOITECH D EVELOPMENT, INC.
FROM

_)
 11 )I
TECH DEVELOPMENT INC.
Publication T1-724, Rev. C
Dated: March 15, 2002

ILLUSTRATED PARTS
BREAKDOWN
)' .. �.. .

MODEL: TlOO-V
TURBOTWIN Engine Air Starter

IM PORT ANT NOTE

The purpose of this illustrated parts breakdown is to provide part
number identification of the various components of the listed
starters. Only those parts which may be disassembled at the
field or repair shop level are broken out and identified. Certain
parts or components are "factory only" assemblies, and should
not be disassembled below the level shown in this document. Do
not disassemble or reassemble the starter without referring to
the proper TOI TURBOTWIN service manual. The use of
improper procedures. non-authorized replacement parts or
incorrect tools. may result in a faulty operating starter which
could affect its performance or create a hazardous condition.

AN98-439 From Tech Development Inc

6800 Poe Ave .. -Dayton OH 45414
Tel: (937) 898-9600 •Fax: (937) 898-8431
Website: www.tdiairstarters.com
 TDI TURBOTWJN'f'M
rRm1 TECH DEVELOPMENT INC.

TOP ASSEMBLY NUMBER COVERED IN THIS PUBLICATION

MODEL PART NUMBER PRESSURE NO.OF GEAR ROTATION TOI PINION PART
RANGE NOZZLES RATIO NUMBER
T109-V T 1 09-60031-01 R-1-03 60-150 9 9.25:1 RH 2-28167-001
T109-V T109-60031-02L-1-03 60-150 9 9.25:1 LH 2-28167-002
T112-V T112-60031-01R-1-03 60-150 12 9.25:1 RH 2-28167-001
T112-V T 112-60031-02L-1-03 60-150 12 9.25:1 LH 2-28167-002
T115-V T115-60031-01 R-1-03 40-90 15 9.25:1 RH 2-28167-001
T115-V T115-60031-02L-1-03 40-90 15 9.25:1 LH 2-28167-002
T121-V T121-60031-01 R-1-03 40-90 21 9.25:1 RH 2-28167-001
T121-V T 121-60031-02L-1-03 40-90 21 9.25:1 LH 2-28167-002

ILLUSTRATED PARTS LIST FOR MODEL T100-V SERIIES AIR STARTERS

) ...
KEY
DESCRIPTION PART NUMBER OVERHAUL KIT
NO.
P/N: T10V-28574

1 Screw (6) 11 F- 25020-064 x

2 Exhaust Guard 2-28175
3 Screw 19F- 25028-012 x

4 Washer 9-93047 x

5 Rotor 2 (See Note) 2-26604

6 Woodruff Key 9-90211-006 x

7 Bearing Spacer (3) 9-93091-005 x

8 Bearing (2) 9-91224

x
(.......')·
9 0-ring (1) 9-90001-027
x

10 Wave Spring Washer 9-90439 x

11 Screw (4) 11A-37516-008 x

12 Nozzle 2, R.H. (See Note) 2-27825-00R

12 Nozzle 2, L.H. (See Note) 2-27825-00L
13 0-ring (2) 9-90001-050 x

14 Seal Spacer 9-93083-001 x

Publication T1-724, Rev. C Page 1

Issued March 15, 2002
 TDI TURBOTWIN™
FROM TECH DEVELOPMENT INC

KEY DESCRIPTION PART OVERHAUL KIT

NO. NUMBER
P/N: T10V-28574

15 Lip Seal (2) 2-26719

x

16 Rotor 1 (See Note) 2-26603

17 Woodruff Key 9-90211-009
18 Screw 14F-31218-016
x

19 Nozzle 1, R.H., 9 Nozzles (See Note) 2-26718-09R

19 Nozzle 1, L.H., 9 Nozzles (See Note) 2-26718-09L
19 Nozzle 1, R.H., 12 Nozzles (See Note) 2-26718-12R
19 Nozzle 1, L.H., 12 Nozzles .. (See Note) 2-26718-12L
- _)
19 Nozzle 1, R.H., 15 Nozzles (See Note) 2-26718-15R
19 Nozzle 1, L.H., 15 Nozzles (See Note) 2-26718-15L
19 Nozzle 1, R.H., 21 Nozzles (See Note) 2-26718-21 R
19 Nozzle 1, L.H., 21 Nozzles (See Note) 2-26718-21 L
20 Pipe Plug 9-93556-004
21 0-ring 9-90001-034 x

22 Screw (6) 14F-31218-016 x

23 Inlet Flange 1-18967

24 0-ring 9-90001-037 x

25 Turbine Housing 2-27869

26 Pipe Plug 9-93501-004
27 0-Ring 9-90001-050 x

28 Ring Gear 2-27870

29 Bearing Spacer 9-93091-001
30 Clamping Plate 2-26750
31 Turbine Shaft 2-27238
32 Retainer Ring (3) 9-92001-001
33 Carrier Shaft (9:1) 2-27798-001
Page 2 Publication T1-724, Rev. C
Issued March 15, 2002
 ) TDI TURBOTWJN'fM
FROM TECH DEVELOPMENT INC.

KEY DESCRIPTION PART NUMBER OVERHAUL KIT

NO.
P/N: T10V-28574

34 Spacer. Gear (6) 9-93004

35 Planet Gear (3) 1-18779
36 Needle Bearing (3) 9-91 004-001
37 Planet Shaft (3) 2P-20182
38 Wood ruff Key 9-90227-025
39 Bearing (2) 9-91003 x
40 Wave Spring Washer 9-90402-025
·.) 41 · Spring Retaining Plate 2-27731
42 Retaining Ring 9-92001-033
43 Bearing Spacer 9-93007-003
44 Housing, Bearing 2-27726
45 Screw (4) 14F-25020-012 x

A.n �P-�r. �n11r 2-27712

47 I .-.. =�
. ,.....,,, ....,r-:...,,, .11,u- 9-Q�nn 1-nn1

48 Locknut, Bearing 9-92127-007

49 Housina. Gearbox 2-27728
50 Screw (6) 71 F-25020-36

:_·. _) 51 Fitting, Filter 2-28270

52 Plug, Pipe (2) 9-93556-004
53 0-Ring, Piston 9-90001-327 x

54 Piston 2-27921

55 Retainer Ring 9-92001-041

56 Bearing 9-91254 x

57 Spline, Helical Shaft, R.H. (See Note 1) 2-27977 -OOR

57 Spline, Helical Shaft, L.H. (See Note 1) 2-27977-00L

Publication T1-724, Rev. C Page 3

Issued March 15, 2002

··-.-···
 TDI TURBOTWJNfM
FROM TECH DEVELOPMENT INC \
/

KEY DESCRIPTION PART NUMBER OVERHAUL KIT

NO.
P/N: T10V-28574

58 Spring, Compression 9-90444

59 Clutch, Helical, R.H. 2-27713
59 Clutch, Helical, L.H. 2-27716
60 Ring, Retainer 9-92001-037
61 Bearinq, Needle Roller 9-91409 x
62 Shaft, Drive Pinion R.H. 2-28169-001
62 Shaft, Drive Pinion L.H. 2-28169-002
63 Washer, Thrust .. 9-93120 x
j
64 Ring, Retainer 2-28051
65 Spring, Compression 9-90447
66 Gearshaft, Spur 2-27711
67 Bearing, Ball 9-91431 x
68 Ring, Retaining 9-92001-036
69 Bearing,Ball 9-91434 x
70 Bearing, Needle Roller 9-91435 x
71 Ring, Retainer 9-92001-042
72 0-Ring 9-90001-158 x
73 Housing, SAE 2-27729
74 Screw 71 F-25020-016 x
75 Fitting, Vent 9-93662-012
76 Seal, Lip 2-22084 x - J
77 Spacer, Pinion 2-28178
78 Pinion, R.H. 6/8P, 12T 2-28167-001
78 Pinion, L.H. 6/8P, 12T 2-28167-002
79 Washer, Pinion 9-93124 x
80 Screw 71 F-50020-016 x
Note: The rotation of the turbine assembly is opposite from the pinion rotation,
therefore the rotors and nozzles must be configured for LH (CCW) rotation if the
pinion rotation is RH (CW), or configured for RH (CW) if pinion rotation is LH (CCW).

Page 4 Publication T1-724, Rev. C

Issued March 15, 2002
 RBOTWJN'fM
TDITECH
TUDEVEL
FRO� OPMENT INC.
---.

\
)

lllustra t e (T1 OO-V TURB OTWIN Air Starters)

d Parts Breakdown

.
Publication Th\-724, Rev. C Page 5
Issued Marc 5 . 2002