INSTALLATION AND OPERATING

MANUAL

MODEL: T100-C (60057)

TURBOTWIN Engine Air Starter

PRELIMINARY From Tech Development Inc

6800 Poe Ave. ·Dayton OH 45414
Tel: (937) 898-9600 ·Fax: (937) 898-8431
1.0 GENERAL INFORMATION 2.0 INSTALLING THE STARTER

This manual provides instructions for the installation and A turbine air starter does not require lubrication in the
operation of the TDI T100-C TURBOTWIN Air Starter. If supply air. Therefore, if a vane type starter motor is being
there are questions not answered in this manual, please replaced, TDI recommends that all lubrication devices and
contact your TDI TURBOTWIN distributor or dealer for lines removed to minimize flow restrictions.
assistance.

The T100 TURBOTWIN starters are designed for WARNING

operation with compressed air or natural gas; materials If a fuel (pulse) lubricator has previously been installed in
used are compatible with “sour” natural gas and marine the system, disconnect and plug the line to eliminate
environments. Small amounts of foreign matter or liquid in spraying diesel fuel on the engine.
the air stream will not adversely affect TURBOTWIN
starters. As with all other TDI starters, no lubrication is The starter should be installed with the inlet in a position
required in the air supply. between horizontal and straight down. Any condensation
will be restricted to the air lines and not in the starter.
Please review the rest of this manual before installing the
T100 TURBOTWIN series air starter. WARNING
Do not operate this starter unless it is properly connected
WARNINGS, CAUTIONS AND NOTES to the engine.
Certain types of information are highlighted in this manual
The following steps can be used to properly install the
for your attention:
T100-C on the engine:
WARNING - used where injury to personnel or
damage to the equipment is likely. · Remove the entire starting system from the skid.
This includes the motors, starter gearbox pad,
CAUTION - used where there is the possibility of lubricators and inlet manifold. There should be six
damage to the equipment. studs and the female portion of the "slot" drive
remaining on the accessory gear case. The two
NOTE - used to point out special interest 2" exhaust hoses can remain in place. Make note
information. of the "clocking" positions of both the inlet and
exhaust ports of the existing vane motors.
NOTE
· Install a new O-ring around the bearing housing
Throughout this manual, the term “air” is used to
on the accessory gear case.
designate the starter drive medium. Unless other wise
stated, air “ means either compressed air or natural gas.
· Install the O-ring on the overflow hole (lower
small hole) on the face of the T100-C (60057)
housing.
1.1 PRODUCT IDENTIFICATION
· Position the male driver end of the "slot" drive on
The starter nameplate which is attached to the turbine
the starter motor in the vertical position.
housing contains the following information: model
number, serial number, part number, direction of rotation
· Position the female portion of the "slot" drive in
and the maximum rated operating pressure.
the vertical position to match the male end.
The maximum operating pressure is also stamped on the
nameplate. This pressure is measured at the check port · Install the T100-C housing assembly over the
on the starter inlet with the starter in operation. studs being careful not to damage the O-ring.

CAUTION · Reinstall the washers and nuts.

Exceeding the maximum pressure shown on the
nameplate may result in damage to the starter or damage · Remove the hex head screws that secure the TDI
to the engine. motor assembly to the flange casting.

· Without pulling the motor backwards and

The housing proof pressure is 600 psig and is also shown
disengaging the "slot" drive positions, rotate the
on the nameplate. This means the turbine housing will not
motor until the inlet is at the 9 o'clock position or
burst when subjected to a static pressure of 600 psig.
positioned in the original position. Reinstall the
TDI motor screws and tighten.
 · You will have either a threaded or welded The T100 -C air starters come standard with a 2" NPT
manifold for the air inlet that accommodates the female pipe thread for the inlet connection port. The
lubricators and the two 2" inlet hoses at the base supply line consists of the line from the air source, a
of the skid attached to the start gas inlet piping. If pressure regulator (when necessary), a manual or relay
this is welded together use a pipe plug to block off valve, and the connection to the starter inlet. Hard piping
one of the female holes as only one inlet hose will may be used, but a section of flexible tubing should be
be used. installed at the starter to prevent leaks due to engine
vibration.
· If threaded, disassemble and create a manifold
for only one hose from the remaining pieces. Care must be taken to ensure that all inlet supply line
Remove one of the 2" NPT-hydraulic flange piping is no less than 1.5" and all components used are
adapters from the inlet ports of one of the original capable of passing the required air flow.
air motors and install into the TDI motor using
thread sealer. NOTE
Valves with a Cv of 40 or higher are recommended.
· Reconnect the 2" hose from the air inlet at the
base of the skid into the TDI starting motor. If the supply line must be longer than 20 feet, the inlet
supply line piping should be increased to 2" in diameter to
· Remove the socket head screws holding the ensure proper performance by your TURBOTWIN.
exhaust back cover and remove cover.
Because turbine starters such as the T100 TURBOTWIN
· Install TDI PN 2-28676 exhaust manifold (not series are sensitive to flow restrictions, care must be
include in 60057 assy) in the 6 o'clock position. taken to use uniform hose or tubing and fittings for
connection of the supply line. Tees, elbows and line
· Reinstall hex screws with minimal thread locking length must be kept to a minimum. TDI recommends that
compound. hose or flex couplings are installed to eliminate possible
leakage caused by strain on the supply line.
· Remove the exhaust 2" NPT-hydraulic flange
adapters (2) from each of the removed (IR) vane Normally, an air strainer is not required. However, in dirty
motors and install into the installed TDI exhaust environments use of a #40 mesh Y-strainer is
manifold using light thread sealer. recommended. The T100 TURBOTWIN series is highly
tolerant of dirt in the air line, however, starter life can be
· Connect the existing 2" exhaust hoses to the increased with the use of an air strainer.
hydraulic portion of the adapter.
A pressure regulator is required when the air supply
· There is an oil feed tube that lubricates the gear pressure is great enough to exceed the starter operating
case on the original (IR) gear case. Follow this pressure (at the inlet port) and/or the maximum torque.
tube to its source and remove. Cap the hole using
a pipe plug. The supply line should be dry-fitted for proper alignment
/location prior to final assembly. All pipe threaded joints
· There are oil supply lines feeding the lubricators should be sealed with Loctite Pipe Thread Sealant (TDI
for the original vane motors. This supply line P/N 9-94085) or equivalent for leak tight joints prior to
typically comes from the oil reservoir. Depending final assembly. Be sure to tighten all joints to proper
upon the application there could be two of these torque after final assembly.
supply lines. Follow these lines back to their
source and remove them. CAUTION
In cold weather climates, care should be taken while
NOTE designing your installation to prevent condensation from
If the supply lines lead to the base of the engine oil developing in the starter system. In systems with a
reservoir have the pipe plugs ready to install quickly as oil regulator valve or relay valve, there is the possibility of
will rush out from the reservoir. freeze-ups.

A tee connection with a quick disconnect can be added to

3.0 SUPPLY LINE INSTALLATION the inlet. This will allow an external air source to be used
to accomplish a “blow start” if the system freezes. Once
WARNING the engine has been started, the other system
components may be thawed.
Be sure to either bleed the pressurized air reservoir
and/or safety the system such as closing all valves prior
to installing starter supply line.
CAUTION WARNING
On new installations, it is strongly recommended to blow Do not connect the turbine housing vent line to the turbine
out the supply line with air to remove possible dirt and exhaust line. Exhaust gas can pressurize the housing.
welding slag prior to final connection to the TURBOTWIN
starter. Be sure to secure the free end of the supply line 7.0 PIPING SYSTEM
prior to blowing out the line.
Only type approved metallic hose assemblies are
4.0 INLET PRESSURE PORT approved in permanently pressurized compressed air
lines of starters. Non-metallic hose assemblies are
A 1/4" NPT port is located on the air inlet. This port may allowed only in case the piping system will be emptied
be used to check the supply pressure at the starter when after the starting procedure.
the starter is operating. Remove the 1/4" NPT pipe plug Pipe unions must be type approved by GL. Downstream
and save for later use. Install a 1/4" minimum size tubing of the pressure regulator a pressure relief valve is to be
to the port. Route the tubing away from the starter to a provided.
safe location away from the engine. Install a pressure
gauge on the tubing. This pressure monitoring line/gauge 8.0 STARTER OPERATION
may be permanently installed. Use Loctite Pipe Thread
Sealant or equivalent. Alternately, a pressure transducer Prior to operation, check that all connections are tight and
may be installed at the pressure check port and electrical free from leaks. Check the 1/4" NPT pipe plug or a
lines routed to a digital display at the operator's station. pressure gauge/transducer that may be connected to the
pressure port on the starter inlet.
This pressure port is invaluable in diagnosing air starter
and/or installation problems. WARNING
Do not operate the TDI TURBOTWIN starter with air
5.0 EXHAUST PIPING pressure greater than the pressure rating on the
nameplate. This pressure is measured at the starter inlet
The turbine exhaust may be plumbed away from the while the starter is running.
starter area. All starters using natural gas must be piped
according to industry codes and local regulations. The maximum operating pressure limit is the inlet
pressure measured at the starter’s inlet pressure check
The performance of a turbine starter will be decreased port. In order to check the starter, a 1/4"NPT pipe tap
because of back pressure when smaller than connection is provided in the inlet housing to attach a
recommended exhaust piping is installed. If back pressure pressure gauge/transducer). The maximum pressure
hampers starter performance, compensation can be made assumes an open exhaust (standard turbine exhaust
by increasing the supply pressure. Consult your TDI guard). The standard exhaust guard causes no back
distributor for advice. pressure.

Exhaust piping should be routed downward to help The static non-flowing supply pressure will always be
prevent any accumulation of condensation in the starter higher than the operating (dynamic) pressure. The
motor. maximum pressure limit (proof pressure) that the TDI
TURBOTWIN starter housings may be subjected to is 600
If the overhung section of the starter is not otherwise PSIG (42 BAR). System pressure that exceeds the
supported, TDI recommends supporting the exhaust maximum operating limit must use a pressure reducing
piping with a suitable bracket(s). device to ensure that the operating pressure limit to the
TDI TURBOTWIN starter is maintained.
6.0 NATURAL GAS INSTALLATION
System static pressure that exceeds the 600 PSIG (42
The installation of the starter using natural gas is similar BAR) limit must, in addition to pressure reducer devices
to the air installation except all fittings, piping, valves and incorporate a pressure relief valve set below 600 PSIG
regulators must be compatible with natural gas. (42 BAR) in the supply air line.

Proper control of natural gas is a major consideration All appropriate local pressure codes and pressure
when used in the starter system. All starters using natural limitations on other system components must be adhered
gas must pipe the exhaust according to industry codes to and supersede the guidelines given in this manual.
and local regulations.
Consult your TDI distributor if you have exhaust plumbing
There is a natural gas vent port in the turbine housing that that creates back pressure and reduces starter
is plugged for compressed air use. This vent is used to performance. You may be able to increase the supply
remove any natural gas that could leak past the primary pressure to restore the lost power.
turbine shaft seal. Remove this 3/8"NPT plug and install a
line to carry gas away from the starter area. Follow the engine manufacturer’s instructions for starting
the engine.
9.0 PREVENTIVE MAINTENANCE

The TDI TURBOTWIN starters provide distinct

advantages of size and efficiency as compared to electric
motor, vane-type or other turbine-type starters. It is
important to properly install the starter to receive full
benefit of these advantages. Repair technicians or service
organizations without turbine starter experience should
not attempt to repair this starter until they receive factory
approved training from TDI, or its representatives.

Proper operation and repair of your TDI TURBOTWIN

starter will assure continued reliable and superior
performance for many years.

9.1 Every Six (6) Months

Perform the following procedures at six (6) months

intervals if the normal cranking cycle is 0 - 10 seconds.

9.1.1 Check the amount and condition of grease in the

planetary gearbox. If gearbox requires re-greasing, only
use TDI grease. Approximately one (1) pint of grease is
needed to repack the gearbox.

9.1.2 Check the turbine bearing and carrier output

bearings for freedom of rotation without excessive play
between races. If bearings are damaged, replace them
with genuine TDI parts. Refer to TDI Service Manual for
part numbers.

9.2 Every Three (3) Months

Follow the six (6) month procedures if there are severe

starter loading or extended duration crank cycles. Also
perform these procedures every three (3) months when
starter is used for motoring the engine for maintenance or
valve adjustments.

Motoring Crank Cycle: 10 -60 seconds

Extended Crank Cycle: 60 seconds or longer