T30-M Service Manual - RJ Mann & Associates, Inc
Contents
1. Tn Publication T3 722 Dated April 15 2006 TECH DEVELOPMENT Service Manual T30 M TURBOTWIN Air Motor SY gt gt gt N Ny HAN Pa 4 A amp MG wv JURBO TWIN AIR STARTERS Pigil ar 1222 yy y AU ZN DM ep K wa ANG Vy KG Engine Coutrols amp Danelo Compreaeor Parts 860 North 9th Avenue Brighton CO 80603 Ph 303 659 5139 Fax 303 659 5309 www rjmann com ON i KON a COOND UI BUN O TDI TURBOTWIN FROM TECH DEVELOPMENT TABLE OF CONTENTS Subject Page MUOGUCUON geni eee si se SA a Aud 1 Description of Basic Groups 3 BISASSOMIDIV AA 5 Cleaning and Inspection Jo 7 ASSOMIDIV k be MA ke ht bl nana 10 PAO Na Apa A OR 6 ai a na SN NGA A 12 LIST OF TABLES Table No Title Page 130 Series Service Tool Kits 5 Cleaning Materials and Compounds 1 Parts Inspection Check Reguirements 8 Parts Wear Limits aaa eee 9 Torque Value Sh Kemis Ga dhe atita ia te Das 9 Materials for Assembly 10 LIST OF ILLUSTRATIONS Title Page TDI Turbotwin Nameplate 2 130 Series Part Number Coding 2 Turbine Housing Assembly 3 Gearbox Housing Assembly pp 4 Carrier Shaft Disassembly 5 Turbine Rotor Removal i nse 6 Nozzle 2 Removal oo 6 Turbine2. 1 Removal of Gearbox Housing Remove the four screws 42 and remove the flange 41 from the gearbox assembly 35 Remove four screws 36 and separate the gearbox assembly from the turbine assembly 3 3 2 Gearbox Disassembly Set the gearbox on the gearbox holding tool with the three holes on the gearbox over the dowel pins on the holding tool Install spanner wrench on the bearing retaining nut 38 and turn CCW to remove Apply pressure to the carrier shaft 26 to remove it from the gearbox housing 35 An arbor press and Publication T3 722 Issued April 15 2006 brace may be required Remove spacer 34 and spring washer 32 from carrier shaft Press bearing 37 from gearbox housing 35 by tapping inner race 3 3 3 Carrier Shaft Planet Gear Disassembly Place carrier shaft gear assembly on arbor press with shaft up With carrier shaft 26 supported press each planet shaft 27 out opposite the spline shaft Refer to figure 5 Remove the planet gears 29 and spacers 28 from the carrier shaft 26 Needle bearings 30 may be pressed out if replacement is required Figure 5 Carrier Shaft Disassembly 3 4 TURBINE HOUSING 3 4 1 Stage 2 Rotor Removal Remove seven screws 3 and remove the exhaust elbow 5 from the turbine assembly 16 Hold the stage 2 rotor 9 and remove the turbine screw 7 and washer 8 Install rotor puller tool P N 52 20076 and remove the stage 2 rotor per figure 6
3. 33 Screw External measurement over 38 Retainer Nut two 096 diameter pins 0 952 min Refer to section 6 for part number identification 0 808 min Table 5 Torgue Values 0 670 min Planet Gear External measurement over two 0864 diameter pins 2 3067 min 2 3699 min 2 4359 min Carrier Shaft Bearing Diameter Planet Pin Bore 0 8750 max Ra Bearing Diameter 0 873 min mona Pa Thickness 055 min Table 4 Parts VVear Limits Publication T3 722 Page 9 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT SECTION 5 0 ASSEMBLY 5 1 GENERAL INFORMATION The tools listed in Table 1 are suggested for use by technicians servicing the Turbotwin T30 M air motor The best results can be expected when these tools are used however the use of other tools is acceptable CAUTION Replace all screws o rings lip seals and bearings when the T30 M motor is assembled These parts are included in the overhaul kit shown in the Parts List Section 6 0 NOTE Always press the inner race of a ball bearing when installing a bearing onto a shaft Always press the outer race of a ball bearing when installing into a housing Lubricate all o rings with petroleum jelly or Parker O ring Lube before assembly unless otherwise noted Refer to Table 6 for a list of materials to be used during assembly MATERIALS Petroleum Jelly SOURCE Commercially Available PRESSING TOOL 2 26943
4. 4 1 CLEANING Degrease all metal paris except bearings using a commercially approved solvent Refer to Table 2 NOTE Never vvash bendix assembly or bearings in cleaning solvents It is recommended that the bearings be replaced with new parts Clean aluminum parts using the solutions per Table 2 soak for 5 minutes Remove parts rinse in hot vvater and dry thoroughly Clean corroded steel parts with a commercially approved stripper Clean corroded aluminum parts by cleaning as stated above and then immerse the parts in chromic nitric phosphoric acid pickle solution per Table 2 Rinse in hot water and dry thoroughly MATERIAL or COMPOUND MANUFACTURER Degreasing Solvent Trichloroethylene O T 634 Commercially Available Commercially Available Aluminum Cleaning Solution Steel Cleaner Rust amp Corrosion Chromic Nitric Phosphoric Acid Pickle Solution Diversey Corp 212 W Monroe Chicago IL 60606 Dissolve 5 oz of Diversey 808 per gallon of water at 155 165 F Oakite Products Corp 50 Valley Heights NJ 07992 Rd Berkeley Mix 3 5 Ib of Oakite rust Stripper per gallon of water use at 160 180 F Mix 8lb of chromic acid 1 9 gal of phosphoric acid 1 5 gal of nitric acid with enough water to make a total of 10 gal of solution WARNING Follow all instructions provided with the MSDS sheets on the materials and compounds listed above Table 2 Cleaning Materials and Compounds 4 2 INSP
5. Figure 9 Turbine Shaft Installation Install the bearing retainer 22 onto the turbine housing 21 and secure with four screws 23 Torque to 113 in lbs 5 2 2 ROTOR 1 INSTALLATION Turn the turbine nozzle over exhaust end up and press the square key 10 into the turbine shaft 24 Parker O Ring Lube Commercially Available Loctite RC290 Commercially Available until seated TDI P N 9 94121 001 Table 6 Materials for Assembly Install stage 1 rotor 18 by sliding over turbine shaft 24 while simultaneously aligning the key with the 5 2 TURBINE HOUSING keyway in the rotor 5 2 3 STAGE 2 NOZLE INSTALLATION 5 21 TURBINE BEARING INSTALLATION Slip o ring 6 over stage 1 rotor and into the groove of Press the lip seal 19 onto the large end of he bearing the turbine housing 21 spacer 20 with the lips facing up Install the stage 2 nozzle 16 over the turbine housing 21 and secure with five 17 hex screws Torque to 75 in lb Press the lip seal bearing spacer assembly 19 20 into the stage 1 turbine housing 21 Press the turbine bearing 11 onto the turbine shaft 24 until seated using press tool 2 26943 NOTE The air inlet port on nozzle 2 must be aligned with the casting indentation on the turbine housing Press the turbine bearing shaft assembly 11 24 into 3 3 the turbine housing 21 Use press tool P N 2 26943 if required per figure 9 Do not press on the end of the shaft because the loa
6. Page 5 Remove the sguare key 10 from turbine shaft 24 3 4 2 Turbine Housing Disassembly Remove five screws 17 from the stage 2 nozzle 16 and separate it from turbine housing 21 If turbine housing is too tight it can be removed by installing two threaded screws into nozzle 2 exhaust end and using them as jacks to separate the turbine housing from nozzle 2 Ihe stage 1 rotor may reguire slight rotation to allow the threaded screws to travel through the holes in the rotor Refer to Figure 7 NOZZLE 2 ASSEMBLY 3 8 16 UNC SCREW TURBINE HOUSING 19 Figure 7 Nozzle 2 Removal Page 6 TDI TURBOTWIN FROM TECH DEVELOPMENT Remove the bearing spacer 13 from the turbine shaft Remove turbine bearing 11 and preload spring 12 from nozzle 2 16 Remove four screws 23 and bearing retainer plate 22 from turbine housing 21 Press turbine shaft 24 through turbine housing 21 as shown in figure 8 Remove bearing spacer from turbine shaft Remove the stage 1 rotor 18 and square key 10 Press turbine shaft 24 through bearing 11 to remove bearing from shaft Press the lip seal 19 from the turbine housing by applying pressure to the seal through the housing ARBOR PRESS PRESSING TOOL TURBINE SHAFT TURBINE HOUSING Figure 8 Turbine Shaft Removal Publication 13 722 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT SECTION 4 0 CLEANING and INSPECTION
7. Shaft Removal ii ner 6 Turbine Shaft Installation 10 T30 M Illustrated Parts Breakdown 14 Page Publication 13 722 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT SECTION 1 0 INTRODUCTION 1 1 GENERAL INFORMATION This manual provides information for servicing disassembly and re assembly of the TDI Turbotwin 130 M air motor If there are questions not answered by this manual please contact your local TDI distributor or dealer for assistance Illustrations and exploded views are provided to aid in disassembly and re assembly The TDI Turbotwin T30 M air motor fits a wide range of engine applications up to 20 horsepower One basic design can be used on a broad range of pre lube and post lube pump motors plus extended cycle operations The Turbotwin T30 M air motor is suited to operate within a wide range of inlet pressures and ambient temperatures This motor is designed for operation with either compressed air or natural gas The robust turbine motor design in the Turbotwin T30 M air motor has no rubbing parts and is therefore tolerant of hard and liguid contamination in the supply gas with almost no adverse affects The motor is well adapted to running on sour natural gas As with all TDI air motor products there are no rubbing parts so there is no lubrication required This eliminates failures due to lubricator problems the expense of installing and m
8. of 120 psig 8 BAR 1 4 INSTALLATION AND SERVICE It is important to properly install and operate the T30 M air motor to receive the full benefits of the turbine drive advantages It must be installed in accordance vvith the instructions provided by Tech Development Inc TDI VVARNING Failure to properly install the motor or failure to operate it according to instructions provided byTDI may result in damage to the motor or cause personal injury DO NOT OPERATE THIS MOTOR UNLESS IT IS PROPERLY INSTALLED Repair technicians or service organizations without turbine motor experience should not attempt to repair this motor until they receive factory approved training from TDI or its representatives Proper operation and repair of your TDI Turbotwin will assure continuous reliability and superior performance for many years Page 1 TDI TURBOTWIN FROM TECH DEVELOPMENT 1 5 NAMEPLATE INFORMATION The nameplate located on the turbine housing provides important information regarding the construction of your T30 M air motor refer to Figure 1 The part number coding explanation refer to Figure 2 can help you when talking to your distributor NOTE You should always have the motors Part Number Serial Number Operating Pressure and Direction of Rotation information before calling your TDI distributor or dealer TURBOTWIN PNUEMATIC MOTOR TECH DEVELOPMENT INC 6800 POE AVE DAYTON OH MODEL NO SERIAL
9. ECTION Use Table 3 as a guide to check for acceptable condition of the parts listed Check all threaded parts for galled crossed stripped or broken threads Check all parts for cracks corrosion distortion scoring or general damage Publication 13 722 Issued April 15 2006 Check all bearing bores for wear and scoring Bearing bores shall be free of scoring lines not to exceed 0 005 width and 0 005 depth Check gear teeth and turbine housing ring gear for wear In general visually check for spalling fretting surface flaking chipping splitting and corrosion If wear is apparent check the gear teeth dimensions in accordance with Table 4 Nicks and dents that cannot be felt with a 020 inch radius scribe are acceptable Page TDI TURBOTWIN FROM TECH DEVELOPMENT Description Defective Parts Must Be Replaced 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 pin holes amp keyways not acceptable and keyways Integrity of Scoring on bearing diameter not to knurl connection exceed 005 depth Wear must not exceed limits per Table 4 Wear must not exceed limits per Table 4 Sungear Turbine Cracks scoring wear created Shaft grooves chipped or bro
10. H DEVELOPMENT SECTION 6 0 PARTS LIST When rebuilding the T30 M it is recommended to purchase and completely install the appropriate service The components illustrated and or described in this kit s section are for the Turbotwin T30 M air motor Overhaul Kit T30M 27625 Liz DESCRIPTION PART NUMBER QTY 001 Inlet Adaptor 2 NPT S N Before 9608 001 2 27275 a SS Rs 3 Screw 0000000 M4F 16432 008 7 yo 4 Hollow Hex Plug Exhaust CheckPort 9 93501 002 1 5 Exhaust Adaptor Elbow Before S N 9608 001 2 21248 1 5 Exhaust Elbow 11 2 NPT After SIN 9608 001 2 27555 1 0 6 orn 000000000 peooolo47z 2 Ny 8 Rotorwasher 93o47 1 E E E AA 10 Square Key 1 8 980220050 2 ooo i 12 Bearing PreLoad Sping bi 90439 pa GA Hollow Hex Plug 9 93501 002 1 Ceai da 16 Stage 2 Noz Containment RH 2 27405 00R 14 16 Stage 2 Noz Containment LH 2 27405 00L 1 18 Stage1Rotr o Z o o i la2r229s 1 o 21 Turbine Hsg Stage 1 3 Noz RH 2 27389 03R_ 14 2 urine Hea Stage 1 3 Noz LI 27389 03L 1 21 rurbine Hsg Stage 1 6 Noz RH 39g 22738308 1 o 21 tune Hep Stage 1 6 Nez L P 27389 06L 1 EET Tan Stage 1 S Noz 2 27389 12R 1 21 Turbine Hsg Stage 1 12 Noz LH 2 27389 12L rar 22 BearingRetainer Ci Jos27a0o6 13 o 24 Turbine Shaft 11 4 1 2273910o02 4 CS 25 RingGear O Z O Z o o y y Oena 1 as Cs 25 arr Stat Wad
11. NO T30 M M CW RH CCW LH Ha 9708 105 X PART NUMBER 1306 60016 00L 1 AIR OR NAT GAS USAGE HOUSING PROOF PRESSURE IS 600 PSIG MAX OPERATING INLET PRESS PSIG WARNING po nor OPERATE UNLOADED WITHOUT EXHAST GUARD OR VVITHOUT EXHAUST FITTING Figure 1 TDI TURBOTWIN Nameplate 306 60016 00 NUMBER of NOZZLES DESIGNATES DRAVVING NUMBER for MODEL 60016 T30 M Lube motor 11 4 1 Ratio 41LG type Mount with 900 Elbow 2 NPT PINIONS CODE 00 No pinion motor mount Page 2 Figure 2 T30 Series Part Number Coding Publication T3 722 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT SECTION 2 0 DESCRIPTION OF BASIC GROUPS 2 1 GENERAL The TDI Turbotwin T30 M air motor is a lightweight compact unit driven by a two stage turbine air motor The motor is composed of two basic assembly groups Turbine Housing Assembly and Gearbox Housing Assembly 2 2 TURBINE HOUSING ASSEMBLY The Turbine housing assembly refer to figure 3 consists of a stage one 18 and a stage two turbine rotor 9 mounted on sungear shaft 24 The front bearing 8 is secured by a retainer plate 22 and the aft bearing is pre load by a spring washer 12 The ring gear 25 is installed into the front of the turbine housing 21 and secured by four screws Figure 3 Turbine Housing Assembly Publication 3 722 Issued April 15 2006 Page 3 TDI TURBOTWIN FROM TECH DEVELOPMENT Th
12. aintaining the system and the messy and hazardous oil film around the motor exhaust The motor is factory grease packed for the life of the motor so it requires no maintenance NOTE Throughout this manual the term air is used to donate the motor drive medium Unless otherwise stated air means compressed air or natural gas Please review the rest of this manual before attempting to provide service to the TDI Turbotwin T30 M air motor 1 2 VVARNINGS CAUTIONS amp NOTES Throughout this manual certain types of information vvill be highlighted for your attention Publication T3 722 Issued April 15 2006 WARNING used where injury to personnel or damage to equipmentis likely CAUTION used vvhere there is the possibility of damage to equipment NOTE use to point out special interest information 1 3 DESCRIPTION OF OPERATION The Turbotwin T30 M air motor is powered by a pair of axial flovv turbines coupled to a simple planetary gear reduction set The high horsepovver of the turbine air motor combined vvith the planetary gear speed reducer results in a very efficient and compact unit The Turbotwin T30 M air motor can be used over a wide range of drive pressures from 30 psig 2 BAR to 120 psig 8 BAR and is suitable for operation on either air or natural gas The T30 M vveighs approximately 29 pounds 13KG and is capable of delivering over 25 HP 18 7 kW of cranking povver at the maximum pressure
13. an ran banag a L27 PPlanetshat ot kal Lam Gear ai Ka Page 1 plication T3 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT vera Kit 0 Planet Bearing 991389 Bearing Pre Load Spring 9 90402 023 A Bearing Spacer Gearbox 9 93119 Gearbox Housing 2 21408 36 Hex Bolts Gearbox Attachment Gearbox Bearing Sames as 31 9 91394 1 CD N 39 LipSeal E 40 O Ring 0001 039 1 41 MountingFlange 223976 44 O Ring Gearbox to Turbine Assy Publication 13 722 Page 13 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT Page 14 Publication T3 722 Issued April 15 2006
14. d could damage the balls of the bearings Page 10 122 Publication T3 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT 5 2 4 ROTOR 2 INSTALLATION Slide bearing spacer 13 over turbine shaft 24 Place pre load spring 12 into bearing bore Apply a light coating of oil to the bearing bore in the nozzle 2 containment assembly and press the bearing over the turbine shaft and into the bearing bore Insert key 10 into turbine shaft keyway and install stage 2 rotor 9 onto shaft while simultaneously aligning the key with the keyway in the rotor Secure stage 2 rotor with rotor washer 5 and rotor screw 4 Torque to 180 in lb lf removed Install plug 14 into nozzle 2 containment assembly Hand press ring 25 gear into turbine housing with ring gear holes aligning with holes on gearbox 5 3 GEAR BOX ASSEMBLY 5 3 1 PLANETARY GEAR CARRIER ASSEMBLY If disassembled press needle bearings 30 into planet gear 29 using arbor press Place thrust washer 28 on each side of planet gear 29 and install into carrier shaft 26 slot opening Press planet shafts 27 into the carrier weldment using arbor press 5 3 2 CARRIER SHAFT INSTALLATION Press lip seal 33 into aft side on gearbox housing 35 with lips facing up Press aft bearing 31 onto carrier shaft using arbor press Publication 13 722 Issued April 15 2006 Place wavy washer 32 and bearing spacer on carrier shaft The wav
15. e carrier shaft 26 is mounted on two ball bearings 2 3 GEARBOX HOUSING ASSEMBLY 31 37 in the gearbox housing 35 The retainer nut 38 secures the carrier shaft and the front bearing 37 The gearbox housing assembly refer to figure 4 consist of a planet gear carrier and output shaft 26 iu il aah naag ne a sie 5 three planet gears 29 needle bearings 30 spacers preloaded by use of a spring washer 32 28 and planet shafts 27 Page 4 Publication T3 722 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT SECTION 3 0 DISASSEMBLY 3 1 GENERAL Always mark adjacent parts on the motor housing Nozzle 2 Containment Ring 13 Turbine Housing 19 Gearbox Housing 35 so these parts can be located in the same relative position when the motor is re assembled Do not disassemble the motor any further than necessary to replace a worn or damaged part unless a complete overhaul is being performed Always have a complete set of seals and o rings on hand before starting any overall of a Turbotwin T30 M air motor Never use old seals or o rings The tools listed in Table 1 are suggested for use by technicians servicing the Turbotwin T30 M air motor The best results can be expected when these tools are used however the use of other tools are acceptable TDI PN 2 27272 52 20076 45 25294 Tool Bearing Seal 2 26943 Table 1 T30 Service Tool Kit P N T30 27639 3 2 GEARBOX HOUSING 3 3
16. ken gear teeth galling or scoring on bearing surface of shaft Raised metal on the keyway Wear must not exceed limits per Table 4 Parallelism of end surfaces Ends must be parallel within 0 0005 Spacers 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 gear teeth Wear must not exceed limits per Table 4 Seal Assembly Wear grooves or scratched Wear is not permitted surfaces on carbon ring Seal Spacer No wear permitted Needle Bearings Freedom of needle rollers Replace bearings Ball bearings Freedom of rotation without Replace ae excessive play between races Containment Corrosion erosion cracks kaman and breakage are not ie bl Ring Nozzle and broken nozzle edges Minor surface damage is permitted 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 Table 3 Parts Inspection Check Reguirements Page 8 Publication T3 722 Issued April 15 2006 TDI TURBOTWIN FROM TECH DEVELOPMENT PART DESCRIPTION LIMIT Inches ITEM NUMBER TORQUE Ring gear Turbine Housing Internal measurement 1 Screw between two 084 diameter 5 0890 max pS 14 Screw Sun Gear Turbine Shaft 21 Screw Bearing diameter 0 6690 min
17. y washer should be centered on rear bearing Place carrier shaft assembly on a flat surface and hand press the gearbox housing 35 onto carrier shaft Press forward bearing 37 over carrier shaft and into gearbox housing using arbor press Place carrier shaft assembly on holding tool Install locknut 38 onto carrier shaft Tighten locknut using spanner wrench Torque to 125 in lb 5 4 FINAL ASSEMBLY Temporarily install one screw 36 into ring gear 25 to prevent it from rotating while applying grease Remove screw after grease is applied to ring gear Apply liberal amounts of grease approximately 100 115 grams to planet gears 29 turbine shaft sun gear 24 and ring gear 25 CAUTION The grease used in the planetary system has a shelf life of 2 years Therefore if the starter is NOT installed and operated on the engine for 2 years after the starter is manufactured the grease should be replaced prior to starter operation The manufactured date is reflected in the starter serial number Ex 0602 0567 has a manufactured date of February 2006 Align gearbox assembly with turbine assembly and secure with four screws Press lip seal 39 into mounting flange 41 with lips facing forward Install o ring 40 on mounting flange 41 Install flange 41 on gearbox assembly using four screws 42 Install exhaust elbow 5 using seven screws 3 Torque to 50 in lb Page 11 TDI TURBOTWIN FROM TEC
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