Publication T30-706, Rev.

1
Dated: May 9, 2001

INSTALLATION AND OPERATING

MANUAL

MODEL: T30-I
TURBOTWIN Engine Air Starter

AN96-419 From Tech Development Inc

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

1.0 GENERAL INFORMATION 1.2 INSTALLATION and SERVICE

This manual provides instructions for the The TDI TurboTwin™ T30 Series starters
installation and operation of the TDI provide distinct advantages of size and
TurboTwin™ Model T30-I air starters. If efficiency compared to electric motor, vane-
there are questions not answered by this type, or other turbine-type air starters. It is
manual, please contact your TDI important to properly install the starter to
TurboTwin™ distributor or dealer for receive full benefit of these advantages.
assistance. Repair technicians or service organizations
without turbine starter experience should not
The T30-I model is a turbine driven air attempt to repair this machine until they
starter with inertia engaged drive. They are receive factory approved training from TDI,
best suited for diesel engines up to 20 Liters or its representatives. Proper operation of
(1220 CID) or gasoline engines up to 28 your TDI TurboTwin™ T30 Series starter will
assure continued reliable and superior
Liters (1709 CID). The T30-I is designed
performance for many years.
for installation on engines which use an SAE
3 mounting pad.
WARNING
The T30 Series starters are suited to The TDI TurboTwin™ T30 Series starter
operate within a wide range of inlet air must be installed and operated in
pressures and ambient temperatures. The accordance with the instructions given in this
engine size and parasitic loading will manual. Failure to properly install the
determine the exact minimum pressure that starter, or failure to operate it according to
will ensure reliable starting. these instructions may result in damage to
the starter or the engine, or cause personal
The T30 Series starters are designed for injury.
operation with compressed air or natural
gas. Moderate amounts of foreign matter or
liquid in the air stream will normally not
NOTE
THIS STARTER IS TO BE SERVICED ONLY BY
adversely affect T30 Series starters. As with AUTHORIZED TDI TURBOTWIN™ DISTRIBUTORS,
all other TDI TurboTwin™ models, no DEALERS, AND REPAIR STATIONS. DO NOT
lubrication is required in the supply air. OPERATE THIS STARTER UNLESS IT IS PROPERLY
ATTACHED TO AN ENGINE.
You need to review the rest of this manual
before installing your TDI TurboTwin™ T30 2.0 ORIENTATION OF THE
Series starter. STARTER
1.1 WARNINGS, CAUTIONS, & NOTES If the factory orientation of the starter’s
Throughout this manual, certain types of mounting flange (drive housing) assembly,
information will be highlighted for your or optional exhaust port does not fit your
attention: engine installation, these components can
be re-oriented.
WARNING - used where injury to
personnel or damage to the
2.1 MODEL T30-I ORIENTATION
equipment is possible.

CAUTION - used where there is the A. Determine the required orientation of the
possibility of damage to the mounting flange assembly and any optional
equipment. exhaust port.

NOTE - used to point out special B. Note that the mounting flange assembly
interest information. can be rotated to twelve different positions
relative to the gearbox and the gearbox
housing assembly can be rotated to four
Publication T30-706, Rev. 1 Page 1
Issued May 9, 2001
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

positions relative to the inlet port. TDI recommends mounting the air piloted
Additionally, the optional exhaust housing relay valve no more than 3 meters (10 feet)
can be rotated to eight positions relative to from the starter’s inlet port, and as close to
the inlet port. the starter as possible. If the starter is being
installed on a vehicle where the air tank is
within 3 meters (10 feet) of the starter, then
CAUTION the relay valve may be mounted on the tank.
All screw threads are treated at the factory
with a fastener retention compound. Every A turbine driven starter does not require
screw and tapped hole must be clean and lubrication in the supply air. Therefore, if a
have a drop of Loctite 290 applied to the vane-type starter motor is being replaced,
threads before being reinstalled. TDI recommends that all lubrication devices
and lines be removed to minimize flow
2.1.1 Drive Housing / Mounting Flange restrictions.
Re-Orientation

Remove the twelve mounting flange

WARNING
attachment socket head cap screws. If a fuel (pulse) lubricator has previously
been installed in the system, disconnect and
Rotate the mounting flange to the desired plug the line to eliminate spraying diesel fuel
position and reinstall the twelve socket head on the engine.
cap screws. Torque the twelve screws to
9.4 Lb-Ft. (12.7 Nm). Liberally grease the starter’s pinion teeth
with chassis lube and then mount the T30
Series starter on the engine. Tighten all
CAUTION mounting hardware as appropriate.
Ensure that the O-ring on the drive housing
remains in position and is not cut. After mounting the starter to the engine,
attach the supply air line from the tank, any
WARNING control air lines, and solenoid to the ignition
Do not remove the five radial screws that system and/or palm valve to the air piloted
connect the inlet and turbine housing. The relay valve.
inlet and turbine housing assembly must
remain in the same position relative to each TDI recommends installation of a “Glad
other. Hand” / quick disconnect for auxiliary
pressurization of the air tank.

3.0 INSTALLING THE Because turbine starters are sensitive to

STARTER flow restrictions, care must be taken to use
uniform sized hose or tubing and fittings for
The T30 Series installation is shown in connection of the supply air line. Tees,
Figures 2 & 3. The components illustrated elbows, and line length must be kept to a
may vary in shape, but there must at least minimum. TDI recommends that hose or
be a start initiation switch, air supply, and a flex couplings be installed to eliminate
starter relay valve to correctly install and possible leakage caused by strain on the
operate a T30 Series starter. supply air line.

Normally an air strainer is not required. In

NOTE dirty environments, use of a #40 mesh
Mounting the air piloted relay valve on the Y-strainer is recommended.
starter is preferred in installations where the
space is available. Only type approved metallic hose
assemblies are approved in permanently
pressurized compressed air lines of starters.

Page 2 Publication T30-706, Rev. 1

Issued May 9, 2001
 TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

Non-metallic hose assemblies are allowed System pressure that exceeds the 300 PSIG
only in case the piping system will be (20.7 Bar) limit must, in addition to a
emptied after the starting procedure. pressure reducer device, incorporate a
pressure relief valve, set below 300 PSIG
Pipe unions must be type approved by GL. Bar (20.7), in the supply air line.
Downstream of the pressure regulator a
pressure relief valve is to be provided. All appropriate local pressure codes and
pressure limitations on other system
components must be adhered to and
WARNING supersede guidelines given in this manual.
Recheck all connections for tight fit.
Follow the engine manufacturer’s
Fill the air system tank. The T30 Series instructions for starting the engine.
starter is now ready to operate.

4.0 STARTER OPERATION WARNING

Do not engage the starter while the engine
is running.
The maximum operating pressure limit is
that pressure measured at the starter inlet
pressure check port during the crank cycle. If the starter fails to function properly when
In order to check the starter inlet pressure, first operated, or its performance
an 1/8" NPT pipe tap connection is provided deteriorates with use, refer to the Operator’s
just below the main inlet for attaching a Trouble Shooting Guide, Section 6.0. If you
pressure gauge. Refer to Figure 1. IN NO cannot solve the problem, or repair is
CASE SHOULD INLET OPERATING necessary, contact your local TDI
PRESSURE EXCEED 10.3 BAR (150 TurboTwin™ distributor or dealer.
PSIG).

WARNING
Do not operate the TDI TurboTwin T30
Series air starter with air pressure greater
than the pressure rating on the nameplate.
This pressure is to be measured at the
starter inlet while the starter is running.

The static supply pressure will always be

higher than the operating pressure. As a
guideline, the maximum pressure limit (proof
pressure) that the T30 Series starter may be
subjected to is 300 PSIG (20.7 Bar).

System pressure that exceeds the maximum

operating limit must use a pressure reducer
device to ensure operating pressure limit to
the T30 Series starter is maintained.

Publication T30-706, Rev. 1 Page 3

Issued May 9, 2001
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

5.0 WARRANTY
TDI TURBOTWIN ENGINE STARTER WARRANTY
Tech Development Inc. (TDI) warrants to the original user of the TDI TurboTwin™ Model T30
Series air starters to be free from defects in material and workmanship for a period of one year
from date of purchase by such user. The warranty period shall begin on the actual delivery date
to the original user or twelve (12) months from the date of shipment from TDI, whichever comes
first. The conditions of this warranty are: a) TDI is notified within this period by return of such
product to TDI or its authorized distributor or dealer, transportation prepaid by user; b) such
product has been installed according to TDI’s specifications; c) such product has not been
misused, abused or improperly maintained by user; d) the defect is not the result of normal wear
and tear; and e) such starter product has not been repaired with parts not manufactured or
authorized by TDI, and TDI installation and repair procedures as outlined in the appropriate
manual were properly followed.

Tech Development Inc. shall, at its option, either repair or replace, without charge, any such
starter product found by TDI’s examination to be defective, or by mutual agreement, refund the
user’s purchase price in exchange for such starter product. Repairs or replacements are
warranted for the remainder of the original warranty period.

Tech Development Inc. makes no other warranty, and IMPLIED WARRANTIES INCLUDING ANY
WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE
HEREBY DISCLAIMED.

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

Page 4 Publication T30-706, Rev. 1

Issued May 9, 2001
 TDI TURBOTWINÔ
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. Control valve not sealing, C. Check control valve and replace
pressure remains in APP port of if necessary.
relay valve.
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. from nozzles.
4. Starter does not run. Normal A. Excessive bends in the A. Shorten length or straighten
air flow from exhaust. supply line. supply air line.
5. Pinion does not engage A. Air pressure is too low A. Increase air pressure to 40 -150
psig.
B. Damaged pinion teeth. B. Replace pinion or starter drive
as necessary.
6. Starter runs but engine cranks A. Air pressure too low A. Increase air pressure to 40 -150
slowly or not at all. psig.
B. Excessive back pressure. B. Increase inlet pressure or
reduce back pressure.
C. Worn or broken starter drive. C. Replace starter drive.
D. Worn Starter Drive D. Replace Starter Drive
E. Nozzle blocked or damaged. D. Remove blockage or replace
damaged parts.
7. Starter continues to operate A. Control valve is not sealing A. See 1C. above
after start button is released. correctly.
B. Relay valve is not sealing B. See 1B. above
correctly.
8. Air tank pressure decays after A. Air connections are too tight. A. Tighten loose fittings. Repair or
extended shut down. replace damaged fittings.
B. Damaged air lines: crushed, B. Replace damaged lines.
frayed, kinked.
C. Relay valve is not sealing C. See 1B. above
correctly.
D. Control valve is stuck open. D. See 1C. above

Publication T30-706, Rev. 1 Page 5

Issued May 9, 2001
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

Figure 1. T30-I TurboTwin Air Starter Envelope Drawing

Page 6 Publication T30-706, Rev. 1

Issued May 9, 2001
 TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

Figure 2. T30-I TurboTwin Air Starter Installation Diagram (Mechanical)

Publication T30-706, Rev. 1 Page 7

Issued May 9, 2001
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

Figure 3. T30-I TurboTwin Air Starter Installation Diagram (Electrical)

Page 8 Publication T30-706, Rev. 1

Issued May 9, 2001
 TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, Inc

T306 Performance Curve

TORQUE 6 Nozzles, Compressed Air, 11.4:1 RATIO POWER
Nm LB.FT HP KW

12 Inlet Pressure SCFM Nm3/h

0p
170 125 sig 120 PSIG 478 813 25 18.6
90 PSIG 365 621
60 PSIG 255 434

136 100 20 14.9

90 p
s ig

102 75 15 11.2
60 p
sig

68 50 10 7.5

34 25 5 3.7

0 0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500

TORQUE
T306 Performance Curve POWER
6 Nozzles, Methane Gas, 11.4:1 RATIO
Nm LB.FT HP KW
Inlet Pressure SCFM Nm3/h 35 26.1
12
0 ps 120 PSIG 600 1020
ig
170 125 90 PSIG 465 791
60 PSIG 330 561 30 22.4

136 100 90 25 18.6

psig

20 14.9
102 75
60 p
sig
15 11.2
68 50
10 7.5

34 25
5 3.7

0 0 0 0
0 5 10 15 20 25 30 35 40 45 50 55
Publication T30-706, Rev. 1 Page 9
Issued May 9, 2001