Publication T1-728

Dated: April 15, 2002

INSTALLATION AND OPERATING

MANUAL

MODEL: T100-C (60069)

TURBOTWIN Engine Air Starter

AN 02-460 From Tech Development Inc

6800 Poe Ave. ·Dayton OH 45414
Tel: (937) 898-9600 ·Fax: (937) 898-8431
www.tdiairstarters.com
 TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, INC.

TABLE OF CONTENTS

Section Subject Page

1.0 General Information………………….. 1

2.0 Starter Installation………..…………… 1
3.0 Supply Line Installation………………. 5
4.0 Inlet Pressure Port….………………… 5
5.0 Exhaust Piping………………………… 5
6.0 Natural Gas Installation……………. … 5
7.0 Piping System…………………………. 6
8.0 Starter Operation……………………… 6

LIST OF TABLES

Table No. Title Page

1 T100-C Installation Kit………………… 1

2 100-C Tool Kit…………………………. 2

LIST OF FIGURES

Figures Title Page

1 Vane Starter Removal………………… 2

2 Starter Adapter Removal.…..………… 2
3 Locknut Removal……..………………. 2
4 Drive Gear Removal…..…..………….. 3
5 Drive Hub Installation…………………. 3
6 TDI Adapter Installation………………. 3
7 Air Starter Installation.………………… 4
8 Exhaust Hose Installation…………….. 4
9 T100-C Envelope Drawing…………… 7
10 T100-C Performance Curve (Air)……. 8
11 T100-C Performance Curve (Gas)….. 8

Publication T1-728
Issued April 15, 2002
Page: i
 TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

1.0 GENERAL INFORMATION The housing proof pressure is 600 psig and is also shown
on the nameplate. This means the turbine housing will not
The following instructions detail the removal of the two burst when subjected to a static pressure of 600 psig.
existing vane type starter motors and the installation of
the new TDI TURBOTWIN air starter. If there are 2.0 STARTER INSTALLATION
questions not answered in this manual, please contact
your TDI distributor or dealer for assistance. A turbine air starter does not require lubrication in the
supply air. Therefore, if a vane type starter motor is being
The T100 TURBOTWIN starters are designed for replaced, TDI recommends that all lubrication devices and
operation with compressed air or natural gas; materials lines are removed to minimize flow restrictions.
used are compatible with “sour” natural gas and marine
environments. Small amounts of foreign matter or liquid in WARNING
the air stream will not adversely affect TURBOTWIN If a fuel (pulse) lubricator has previously been installed in
starters. As with all other TDI starters, no lubrication is the system, disconnect and plug the line to eliminate
required in the air supply. spraying diesel fuel on the engine.

Please review the rest of this manual before installing the WARNING
T100 TURBOTWIN series air starter. Do not operate this starter unless it is properly connected
to the engine.
WARNINGS, CAUTIONS AND NOTES
CAUTION
Certain types of information are highlighted in this manual
for your attention: Prior to beginning the removal of the existing starter
motors insure the unit is shutdown, post lube has timed
WARNING - used where injury to personnel or off, fuel and start gas are off. Tag out and lock out in full
damage to the equipment is likely. accordance with standard OSHA / Company rules and
regulations.
CAUTION - used where there is the possibility of
damage to the equipment. The starter should be installed with the inlet in a position
between horizontal and straight down. Any condensation
NOTE - used to point out special interest will be restricted to the air lines and not in the starter.
information.
The components listed in the Table 1 (T100C Installation
NOTE Kit) are required to complete starter installation.
Throughout this manual, the term “air” is used to
designate the starter drive medium. Unless other wise QTY PART NUMBER DESCRIPTION
stated, air “ means either compressed air or natural gas. 1 2-28673 Gear Adapter
1 2-28674 Tongue Driver
1.1 PRODUCT IDENTIFICATION 1 2-28676 Exhaust Adapter, Weld
1 9-90001-165 O-ring
The starter nameplate which is attached to the turbine 1 9-90001-228 O-ring
housing contains the following information: model 1 9-90002-041 O-ring
number, serial number, part number, direction of rotation 1 9-90211-029 Woodruff Key
and the maximum rated operating pressure. 1 9-91502-008 Dowel Pin
1 9-92149 Bearing Retainer Nut
The maximum operating pressure is measured at the 1 9-93142 Lock washer
check port on the starter inlet with the starter in operation. 6 14F-25028-012 Screw
4 14F-37516-016 Screw
CAUTION Table 1. T100-C Installation Kit (P/N: T100-28675)
Exceeding the maximum pressure shown on the
nameplate may result in damage to the starter or damage The tools listed in Table 2 (T100-C Tools Kit) are suggested
to the engine. for use when installing the T100-C air starter, and can be
borrowed from TDI to perform starter installation. The

Publication T1-728
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TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

best results can be expected when these tools are used,

however the use of other tools is acceptable.

TOOL DESCRIPTION TDI/PN

¾” Square Drive Socket 2-28724
Gear Puller Pad 2-28722
Gear Puller 2-28720 Adapter Flange
Torque Wrench 2-28719
Anti-rotation Tool 2-28716
Locknut Socket 2-28718
Table 2. T100-C Tools Kit (P/N: T100-28721)

2.1 VANE STARTER REMOVAL

Remove the split flange clamps from the inlet and exhaust
hoses on the starter end of the hoses. Retain the bolts
and clamps to be used later. Discard the o-rings. Figure 2. Starter Adapter Removal

Remove one inlet flange fitting and both exhaust flange Remove the six starter adapter retaining nuts and
fittings from the vane starters. Retain these for later use. washers. Retain these for later reuse. Remove the starter
adapter by gently prying behind the adapter. Slide the
Remove the eight mounting nuts from each vane starter starter adapter off the studs and discard the adapter.
motor mount flange and retain these for later reuse.
Remove the o-ring from the adapter mounting pilot ring.
Remove and discard both the vane starter motors.

Remove the split flange clamps from the oil drain on the
bottom starter adapter. Retain the bolts and clamps for
later reuse.
Drive Gear
½” Flex
hose
Locknut

Split Flange
Clamps
Vane Starters

Figure 3. Locknut removal

Oil Drain Mounting Nuts
Use a small punch or similar tool de-stake the lock
washer on the starter drive gear.

Figure 1. Vane Starter Removal Using the holding tool, special socket and ½" break over
bar loosen the drive gear locknut. Remove and discard
Remove the ½" metal flex hose from the starter gear the locknut & washer.
lubrication jet and disconnect the hose at its origin on the
main oil line. Since this hose is no longer required install a
pressure cap at the main oil line fitting.

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 TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

Install the puller center guide bolt in the threaded hole of Install the new lock washer and locknut supplied with the
the drive gear shaft. Install the puller and remove the kit. Using the holding tool, special socket and a torque
drive gear as shown in figure 4. wrench tighten the nut and torque to 165-175 ft. lbs. (224-
237 Nm). Use caution to align one nut slot with a lock tab
on the washer. Bend the lock tab over and insure it is
locked in the nut.

Place the 3/8" dowel pin supplied with the kit in the hub
piece. Place the hub cover in place on the hub and install
six allen head screws finger tight. Use a soft hammer and
tap the hub cover in place while pressing the dowel pin in
the cover. Torque the allen head screws to 180 in. lbs.
(20.4 Nm).

Remove the TDI starter from the adapter provided in the

kit. Retain the bolts for later reuse.

Install a new o-ring on the adapter mounting pilot ring on

the accessory drive. Install a new o-ring on the oil drain
port of the new TDI adapter.
Figure 4. Drive Gear Removal
Slide the new TDI adapter on the mounting studs. Use
Remove the existing drive key from the gear shaft. Install caution to insure the adapter is installed flat to avoid o-
the new high strength key provided with the kit. ring damage. Install the washers and nuts retained at
removal. Alternately tighten the nuts to guide the adapter
2.2 T100-C AIR STARTER INSTALLATION on to the mounting pilot ring.

NOTE Torque the nuts to 125 ft. lbs. (170 Nm)

All bolts should be lubricated with anti-seize compound
prior to use. All torque specifications contained herein are
for lubricated threads.

Install the new drive hub supplied with the kit until it is
completely seated on the shaft shoulder. Insure the key
and hub slot are aligned.

Figure 6. TDI Adapter Installation

Install the T100-C air starter. Use caution to align the

“drive blade” with the slot in the drive hub cover. Insure
the 2" inlet port is in the left horizontal position. Install the
bolts retained at removal and tighten to 190 in. lbs. (21.5
Nm)
Figure 5. Drive Hub Installation

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TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

NOTE Remove the bolts split flange clamps retaining both

Use of a pipe thread sealer or Teflon tape is lubricators and remove the lubricators.
recommended for the installation of all pipe thread fittings
in the following steps. NOTE
Oil lubricators are not required for TDI starters. However,
Install a 1½" X 2" bushing reducer when required. Install one set of inlet and outlet fittings will be required.
the 1 ½" split flange inlet adapter retained from the vane Remove one set of fittings and discard both lubricators.
motor at removal.
Install one set of lubricator fittings into the 1½" pipe collar
Place a new o-ring on the exhaust manifold flange. Install provided in the kit, and reinstall in one of the previous
the exhaust manifold pointed down on the TDI starter with lubricator locations using a new o-ring. Install the split
the threaded ports facing to the right. Torque the 3/8" flange blank cover and new o-ring, provided in the kit, on
allen screws to 170 in. lbs. (19.26 Nm). the remaining unused lubricator location.

Install the split flange exhaust adapters, retained from the Reinstall the hose end removed earlier with a new o-ring
vane motor at removal in the exhaust manifold of the TDI provided.
starter.
Install both exhaust split flange adapters in the exhaust
NOTE manifold. Install both exhaust hoses using new o-rings
Only one of the two 1 ½" inlet hoses will be required for provided.
the TDI starter. Select the one most suited to the fit of
your new starter system at this time. Disconnect the
unused hose and discard.

CAUTION
Use caution when installing metal flex hoses to avoid any
unnecessary twisting or rub from adjacent hoses,
brackets, or hardware.

Install the inlet hose, and a new o-ring supplied with the
kit, on the starter split flange adapter using the bolts and
clamps retained at removal.

Figure 8. Exhaust Hose Installation

After completion of the installation remove all lock out and

tag out protection in accordance with OSHA / Company
rules and regulations.

During the first start cycle observe operation and soap

check for leaks at all fittings and hoses that were
disturbed during the installation. Repeat this step if
required - no leaks permitted.

Figure 7. Air Starter Installation

Disconnect the opposite end of the inlet hose from the oil
lubricator and retain the bolts and clamps for later reuse.

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 TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

3.0 SUPPLY LINE INSTALLATION the engine has been started, the other system
components may be thawed.
WARNING
Be sure to either bleed the pressurized air reservoir CAUTION
and/or safety the system such as closing all valves prior On new installations, it is strongly recommended to blow
to installing starter supply line. out the supply line with air to remove possible dirt and
welding slag prior to final connection to the TURBOTWIN
Care must be taken to ensure that all inlet supply line starter. Be sure to secure the free end of the supply line
piping is no less than 1.5" and all components used are prior to blowing out the line.
capable of passing the required air flow.
4.0 INLET PRESSURE PORT
NOTE
Valves with a Cv of 40 or higher are recommended. A 1/4" NPT port is located on the air inlet. This port may
be used to check the supply pressure at the starter when
If the supply line must be longer than 20 feet, the inlet the starter is operating. Remove the 1/4" NPT pipe plug
supply line piping should be increased to 2" in diameter to and save for later use. Install a 1/4" minimum size tubing
ensure proper performance by your TURBOTWIN. to the port. Route the tubing away from the starter to a
safe location away from the engine. Install a pressure
Because turbine starters such as the T100 TURBOTWIN gauge on the tubing. This pressure monitoring line/gauge
series are sensitive to flow restrictions, care must be may be permanently installed. Use Loctite Pipe Thread
taken to use uniform hose or tubing and fittings for Sealant or equivalent. Alternately, a pressure transducer
connection of the supply line. Tees, elbows and line may be installed at the pressure check port and electrical
length must be kept to a minimum. TDI recommends that lines routed to a digital display at the operator's station.
hose or flex couplings are installed to eliminate possible This pressure port is invaluable in diagnosing air starter
leakage caused by strain on the supply line. and/or installation problems.

Normally, an air strainer is not required. However, in dirty 5.0 EXHAUST PIPING
environments use of a #40 mesh Y-strainer is
recommended. The T100 TURBOTWIN series is highly The turbine exhaust may be plumbed away from the
tolerant of dirt in the air line, however, starter life can be starter area. All starters using natural gas must be piped
increased with the use of an air strainer. according to industry codes and local regulations.

A pressure regulator is required when the air supply The performance of a turbine starter will be decreased
pressure is great enough to exceed the starter operating because of back pressure when smaller than
pressure (at the inlet port) and/or the maximum torque. recommended exhaust piping is installed. If back pressure
hampers starter performance, compensation can be made
The supply line should be dry-fitted for proper alignment by increasing the supply pressure. Consult your TDI
/location prior to final assembly. All pipe threaded joints distributor for advice.
should be sealed with Loctite Pipe Thread Sealant (TDI
P/N 9-94085) or equivalent for leak tight joints prior to Exhaust piping should be routed downward to help
final assembly. Be sure to tighten all joints to proper prevent any accumulation of condensation in the starter
torque after final assembly. motor.

CAUTION If the overhung section of the starter is not otherwise

In cold weather climates, care should be taken while supported, TDI recommends supporting the exhaust
designing your installation to prevent condensation from piping with a suitable bracket(s).
developing in the starter system. In systems with a
regulator valve or relay valve, there is the possibility of 6.0 NATURAL GAS INSTALLATION
freeze-ups.
The installation of the starter using natural gas is similar
A tee connection with a quick disconnect can be added to to the air installation except all fittings, piping, valves and
the inlet. This will allow an external air source to be used regulators must be compatible with natural gas.
to accomplish a “blow start” if the system freezes. Once

Publication T1-728
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TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

Proper control of natural gas is a major consideration The maximum operating pressure limit is the inlet
when used in the starter system. All starters using natural pressure measured at the starter’s inlet pressure check
gas must pipe the exhaust according to industry codes port. In order to check the starter, a 1/4"NPT pipe tap
and local regulations. connection is provided in the inlet housing to attach a
pressure gauge/transducer). The maximum pressure
There is a natural gas vent port in the turbine housing that assumes an open exhaust (standard turbine exhaust
is plugged for compressed air use. This vent is used to guard). The standard exhaust guard causes no back
remove any natural gas that could leak past the primary pressure.
turbine shaft seal. Remove this 3/8"NPT plug and install a
line to carry gas away from the starter area. The static non-flowing supply pressure will always be
higher than the operating (dynamic) pressure. The
WARNING maximum pressure limit (proof pressure) that the TDI
Do not connect the turbine housing vent line to the turbine TURBOTWIN starter housings may be subjected to is 600
exhaust line. Exhaust gas can pressurize the housing. PSIG (42 BAR). System pressure that exceeds the
maximum operating limit must use a pressure reducing
7.0 PIPING SYSTEM device to ensure that the operating pressure limit to the
TDI TURBOTWIN starter is maintained.
Only type approved metallic hose assemblies are
approved in permanently pressurized compressed air System static pressure that exceeds the 600 PSIG (42
lines of starters. Non-metallic hose assemblies are BAR) limit must, in addition to pressure reducer devices,
allowed only in cases where the piping system will be incorporate a pressure relief valve set below 600 PSIG
emptied after the starting procedure. (42 BAR) in the supply air line.

Pipe unions must be type approved by GL. Downstream All appropriate local pressure codes and pressure
of the pressure regulator a pressure relief valve is to be limitations on other system components must be adhered
provided. to and supersede the guidelines given in this manual.

Consult your TDI distributor if you have exhaust plumbing

8.0 STARTER OPERATION
that creates back pressure and reduces starter
performance. You may be able to increase the supply
Prior to operation, check that all connections are tight and
pressure to restore the lost power.
free from leaks. Check the 1/4" NPT pipe plug or a
pressure gauge/transducer that may be connected to the
Follow the engine manufacturer’s instructions for starting
pressure port on the starter inlet.
the engine.
WARNING
Do not operate the TDI TURBOTWIN starter with air
pressure greater than the pressure rating on the
nameplate. This pressure is measured at the starter inlet
while the starter is running.

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 TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

Figure 9. T100-C Envelope drawing

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TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

TORQUE
T100C Performance Curves POWER
Nm LB-FT HP KW
15 Nozzles, Compressed Air, 9.0 Gear Ratio
680 500 120 90
15
612 450 0p 108 81
s ig
12
544 400 0p 96 72
sig
476 350 84 63
90
408 300 ps
ig
72 54

340 250 60 45
60
272 200 p sig 48 36

204 150 36 27

136 100 24 18

68 50 12 9

0 0 0
0 5 10 15 20 25 30 35 40 45 50

Figure 10. T100-C Performance Curve (Compressed Air)

TORQUE
T100C Performance Curves POWER
Nm LB-FT HP KW
15 Nozzles, Methane Gas, 9.0 Gear Ratio
680 500 150 112
15
612 450 0p 135 101
sig
12
544 400 0 ps 120 90
ig
476 350 105 79
90
408 300 ps
ig 90 68

340 250 75 56
60
272 200 p sig 60 45

204 150 45 34

136 100 30 22

68 50 15 11

0 0 0
0 5 10 15 20 25 30 35 40 45 50 55 60 65

Figure 11. T100-C Performance Curve (Methane Gas)

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