Beruflich Dokumente
Kultur Dokumente
1
Dated: April 15, 2006
SERVICE MANUAL
LIST OF ILLUSTRATIONS
WARNING
Failure to properly install the starter or failure to
operate it according to instructions provided byTDI may NOTE
result in damage to the starter or engine, or cause You should always have the starter’s Part Number,
personal injury. DO NOT OPERATE THIS STARTER Serial Number, Operating Pressure, and Direction of
UNLESS IT IS PROPERLY ATTACHED TO AN Rotation information before calling your TDI distributor
ENGINE. or dealer.
2.3 GEARBOX HOUSING ASSEMBLY The carrier shaft is mounted on two ball bearings (41)
in the gearbox housing (58). The retainer nut (48)
secures the carrier shaft in the gearbox housing. The
The gearbox housing assembly, refer to figures 4,
front bearing (41) is secured by a retainer plate (46).
consist of a planet gear carrier and output shaft (35),
The back bearing is preloaded by use of a spring
three planet gears (37), needle bearings (38), spacers
washer (42).
(36), and bearing pins (39).
2.4 BENDIX DRIVE ASSEMBLY The other end of the drive unit is mounted into a needle
bearing (54), which is installed in the nose of the drive
The Bendix drive assembly, refer to figure 8, consists of housing.
an inertial engagement drive or “bendix” (57) and drive
housing (61). The bendix is mounted to the output
shaft with two keys and a retaining set screw (53).
Figure 8. Bendix Drive Assembly (T112B, T121B, T112D, T121D, T109P, T115P)
Do not disassemble the starter any further than Remove the six screws (22). Mark position of bendix
necessary to replace a worn or damaged part pinion opening relative to gearbox housing for
reference during reassembly. Pull drive housing (49)
Always have a complete set of seals and o-rings on from gearbox housing (44). If drive housing is too tight,
hand before starting any overall of a Turbotwin T100 tap it with a mallet to loosen.
series starter. Never use old seals or o-rings.
3.3.2 Removal of Bendix Drive
The tools listed in Table 1 are suggested for use by
technicians servicing the Turbotwin T100 series In loaded spring area of drive (57) remove retaining
starters. The best results can be expected when these ring (51) from set screw (53) slot.
tools are used, however the use of other tools are
acceptable. Remove set screw using a flat head screwdriver,
Figure 9, and pull the bendix assembly from the starter
TOOL DESCRIPTION TDI/PN carrier shaft.
Spanner wrench 52-20134
Spanner wrench 52-21345 Remove spring (52). This spring fits loosely between
Shaft Removal Tool 2-26945 the bendix assembly and carrier shaft. Remove the
Stage 2 Rotor Puller Tool 52-20076 needle bearing (62), if necessary, by simply tapping out
Carrier Shaft Holding Tool 52-20202 the “welch” plug from the front of the drive housing and
press bearing out.
Tool, Bearing Pressing 52-20143
Tool, Bearing/Seal 2-26943
Table 1. T100 Series Service Tools
3.4 DRIVE/GEARBOX HOUSING Remove bearing (65) from shaft by pressing shaft
while supporting inner race of bearing. Remove
(T106F/T112F)
bearing retainer plate (64).
3.4.1 Removal of Drive Housing
3.4.3 Planet Gear Disassembly
Mark position of bendix pinion opening relative to
Remove snap ring (34) from planet shaft (39) using
turbine housing (26) for reference during reassembly.
snap ring pliers and push shaft through holes in
Per Figure 10, remove the six screws (27). Pull drive
assembly.
housing (69) from turbine housing. If drive housing is
too tight, tap it with a mallet to loosen.
Slide the planet gear (37) out from the carrier shaft and
remove the two nylon spacer (36). Unless the needle
roller bearings 38) are damaged, do not remove. If
removal is necessary, simply press bearing out.
Mount the carrier shaft assembly on the TDI holding Remove the six screws (27) and lift the gearbox
tool P/N 52-20202 placing the three holes on the assembly from the turbine assembly. If the gearbox
gearbox over the dow pins. Refer to Figure11. assembly is too tight, tap it with a mallet to loosen).
Place TDI tool P/N 52-21345 (Spanner Wrench) over 3.5.2 Gearbox Disassembly
shaft and into slots of retainer nut (67). Hold down
carrier shaft and remove nut. Mount the gearbox on the TDI holding tool P/N 52-
20202 placing the three holes on the gearbox over the
dow pins. Refer to Figure 11.
Hold the stage 2 rotor (6) and remove the turbine screw
(4) and washer (5).
Remove snap ring (34) from planet shaft (39) and push Figure 13. Turbine Rotor Removal
shaft through holes in assembly.
3.6 Turbine Shaft Removal Separate the stage 2 nozzle assembly (13) from the
turbine assembly (26) by firmly holding the turbine
Using the shaft removal tool P/N 2-26945 per figure 14, assembly, while tapping nozzle 2 with a mallet. If
press on the turbine shaft (33) while supporting the nozzle 2 is too tight, it can be removed by installing two
turbine housing. threaded screws into nozzle 2 and using them as jacks
to separate nozzle 2 from the turbine assembly. Refer
Press the shaft assembly (33) through the aft bearing to Figure 15.
(10) and continue pressing until the shaft assembly is
completely out of the housing (26). Rotate the stage 1 rotor if necessary to allow the jacks
to travel through the large holes in the rotor. The jacks
Remove the woodruff key (16), seal spacer (8), bearing will damage the stage 1 rotor if pressure is applied to
spacer (30), and bearing (10) from the shaft. The them while removing nozzle 2.
bearing can be removed from the shaft by pressing the
shaft through the bearing. Note that if T100 is the The stage 1 rotor (15) may now be removed.
original design (SN: 9501-239 to9611-191), the bearing
will be pressed inside a spacer. Remove the four screws (18) and nozzle 1 (19) from
the turbine assembly. It may be necessary to tap the
screws with a hammer and chisel to loosen.
SECTION 4.0 CLEANING and Clean aluminum parts using the solutions per Table 2;
INSPECTION soak for 5 minutes. Remove parts, rinse in hot water,
and dry thoroughly.
4.2 INSPECTION
Check all bearing bores for wear and scoring. Bearing
Use Table 3 as a guide to check for acceptable bores shall be free of scoring lines, not to exceed
condition of the parts listed. 0.005$ width and 0.005$ depth.
Check all threaded parts for galled, crossed stripped, or Check gear teeth and turbine housing ring gear for
broken threads. wear. In general, visually check for spalling, fretting,
surface flaking, chipping, splitting, and corrosion. If
Check all parts for cracks, corrosion, distortion, scoring, wear is apparent, check the gear teeth dimensions in
or general damage. accordance with Table 4. Nicks and dents that cannot
be felt with a .020 inch radius scribe are acceptable.
5.1 GENERAL
The tools listed in Table 1 are suggested for use by
technicians servicing the T100 Series starters. The
best results can be expected when the proper tools are
used, however, use of other tools is acceptable.
CAUTION
Replace all screws , O-rings, lip seals, and bearings
when the T100 Series starter is reassembled. These
parts are included in the overhaul kits shown in
Section 6.0
NOTE
Always press the inner race of a ball bearing when
installing a bearing on a shaft. Always press the outer
race of a ball bearing when installing into a housing. Figure 18. Pressing Spacer onto Bearing
MATERIALS SOURCE
Petroleum Jelly Commercially Available
Parker-O-Ring Lube Commercially Available
Loctite RC290 Commercially Available
Grease, gearbox TDI P/N 9-94121-001
Table 5. Materials for Assembly
CAUTION
The screws that secure the Containment Ring/ Stage 2
Nozzle must have a drop of Loctite RC290 applied to
the threads before being used.
T100 is the original design (SN: 9501-239 to 9611-
191), press the spacer (31) onto the outer race of the
5.2 TURBINE HOUSING bearing (10) per Figure 18 by supporting the bearing
outer race, and then press the bearing/spacer (10, 31)
5.2.1 Turbine Shaft Installation onto the shaft.
Press the bearing (10) onto the shaft (33) until seated. Press the bearing/shaft assembly, keyway end first,
Support the shaft and press on the inner race only with into bearing housing of the turbine housing. Use press
press tool P/N 2-26943 per Figure 17. Note that if tool P/N 2-26943 if required per Figure 19. Do not
press on the end of the shaft because the load could
damage the balls of the bearing.
Install bearing retainer plate (32) and secure with four Install nozzle 1 onto the turbine housing (26). Orient
screws (18). Torque screws to 30 in-lbs. the nozzles facing the air inlet (23). Install four screws
(18) to secure the nozzle. Do not tighten the screws at
this time.
5.2.3 Rotor 1 Installation
Install the seal spacer (8) onto the shaft. Note the small Press the lip seal (9) into the forward side of nozzle 2
end of the spacer faces the long bearing spacer. with seal lip facing up. Use press tool P/N 2-26943.
5.2.2 Nozzle 1 Installation Install O-ring (14) onto the outer diameter of nozzle 2.
Press the aft seal (17) into nozzle 1 (19) using press Install nozzle 2 (13) onto the turbine housing (26). The
tool P/N 2-26943 per Figure 20 with the lips facing up. three flats of nozzle 2 are always oriented opposite the
turbine housing air inlet (SN 9505-213 to 9611-191).
Install the seal spacer (8) onto the shaft with the small
end facing the aft bearing (10).
Support the sun gear end of the shaft. Press the aft
bearing (10) onto the shaft by pressing onto the inner
and outer race simultaneously. Use press tool per
Figure 21. Press until bearing is seated.
Place the O-ring (24) into the groove on the air inlet
(23).
Install the 2$ NPT air inlet flange (23) and secure with
six screws (22). Tighten the six screws to 170 in-lb.
Press the lip seal (9) into the stage 2 nozzle using
press tool P/N 2-26943 with lip seal facing up.
Install the stage 2 woodruff key (7) into the shaft (33).
Install the stage 2 rotor (6) onto the shaft. Use press
tool P/N 2-26943 if required. Visually inspect that the
key was not pushed out during assembly. Note that
the direction of rotation was oriented properly. This
turbine can be installed backwards.
Install the rotor washer (5) and secure with screws (4).
Tighten screw to 100 in-lb.
Figure 22. Planet Gear Carrier Shaft Assembly
Install the exhaust screen (3) and back plate (2).
Secure with six screws (1). Tighten the screws to 80 in-
lb.
NOTE
Publication T1-701, Rev. 1 Page 17
Issued April 15, 2006
TDI TURBOTWIN!
FROM TECH DEVELOPMENT
NOTE
Make sure anti-rotation pins on shafts are properly
located in the retaining slots of the carrier shafts (63).
Figure 25. Tightening Retainer Nut
5.5.2 Planetary Carrier Bearing Installation
5.4 DRIVE HOUSING Install bearing retainer plate (64) over carrier shaft (63)
(T112B/T121B, T112D/T121D, T109P/T115P)
Press bearing (65) onto shaft making sure pressing
5.4.1 Bendix Drive Installation force is on inner race of bearing only.
Install two woodruff keys (40). Ensure keys are Place carrier shaft assembly onto TDI Tool P/N 52-
properly installed per Figure 26. 20202, see Figure 27. Thread retainer nut (67) onto
shaft (63). Hold carrier assembly down and torque nut
Position bendix assembly (57) on shaft with retainer to 600-800 lb.-in. with spanner wrench, TDI Tool P/N
set screw (53) removed. Install spring ( 52) between 52-21345.
bendix cavity and end of output shaft. Slide bendix
over shaft until set screw hole aligns with set screw
hole in shaft.