@ nawaye ATTACHED SERVICE MANUAL for the ENGINE AIR STARTERS YANMAR SERVICE NETWORKSINSPECTION INSTRUCTIONS FOR MODEL 45MA AIR STARTER CONTROL MODULE, Before Inspection Be sure to release the air pressure of the eystom before setting about the inspection When the starting power voltage ofthe air starter 45MA is 24VDC, refer to Fig Lbelow. When the voltage is 100VDC refer to Fig2 Control Module fr 24VDC: Part Nusnber 2:24775-005 Yanmar Pat No, 46619-77100 Control Mole for 100VDC: Part Number 2-24775-005-1 Yanmar Part No48613-77210 2 Inspection. 2:1, Trouble: The air starter does not start even with the applicatcn of the normal air pressure. ‘Measure! It is possible that no power is supplied tothe control module, Remove the screws atthe input and output connectors (ee Fig.2 below) and pull thom out from the control module body. Check that the power voltage is supplied to the input side connector lead wire, 2-2, Trouble: Solenoid valve doea not open even when the power is supplicd to the control module, Measure © Check the contra! module bod: Impress the power voltago to the plus (#) and minus © poles of the input terminal and measure the voltage of the output terminal, The fanction is normal when the power valtage as ‘impressed appears. @ Check the solenoid valve Supply 0.2MPa (2kalem®) air pressure to the NC (normal closed) piping of the solenoid valve removed from the control module. Impress DC12V between the terminals (no polarity! of the solenoid valve, open it and check for the fonction. If the solenoid valve is normal, replace the control module ® When the function of the solenoid valve js not normal: YANMAR CO.,LTD. Pogo arr 00a.Remove the elbow, onsen two nuts of the slenotd valve, tars ‘the coil housing (with sealed in Mack resin) counterclockwise for loosening and romove it from the (@lumsinurn) valve boa. Loosen the three screws and check that the valve port is mit clogged with impurities. Fit is clogged, deen the port and check the function of the valve again according to the instruction of © sbove, Bp Madde OVC Power Figs Mota 00006 PowerMODEL 45MA AIR MOTOR SERVICE INSTRUCTIONS FOR YANMAR DIESEL ENGINE MODELS, 6N1S(L), 6 & 8N21(A) ENGINES © Cautions for Disassembly © The dimensions ofthis air motor are represented in the inch unit, @ All boles come with six holes, Apply LOCKTIGHT (serew bonding agent) to the threads, ® Lube oils sealed in the sealing type bearing and the starter dive, Do not swash these items @ Feed 80g specialized grease inside the reduction ges for lubrication, For (O-rings and other items, use ABROSHELL #6 or equivalent geass © Tho air motor can bo disassembled largely into the drive housing (St), gear box housing (68, ring gear (46), contained ring (18) and inlet housing (3) Mark alignment marks on each part before disassembly. YANMAR CO.,LTD. Page aTTDI TURBOSTART TWo~ fron TECH DEVELOPMENTTDI TURBOSTART TWO™ TECH DEVELOPMENT INC. SECTION7.0 PARTS LISTMENOPublication 45-723, Edition 1 Dated: November, 1991 SERVICE MANUAL for the MODEL 45M ENGINE AIR STARTERS TDI TURBOSTART TWO" Engine Air StartersTDI TURBOSTART TWO™ fron TECH DEVELOPMENT INC. SERVICE MANUAL for MODEL 45M AIR STARTERS COMPRESSED AIR USE ONLY CONTACT FACTORY FOR OTHER APPLICATIONS TABLE OF CONTENTS: SECTION 1.0 INTRODUCTION secTON—«SUBIECT Pn ee 1.1 GENERAL INFORMATION Pelenrosucta 2. | | Tasman proves empltensucions tr sen: 20 DESMPRONGr BASICGROUPS % | | iu tetstestconent andreasemy el pelvencsee 2 | | Rida om tote to arsirer tee se £9 Clemo ano nseccrion || qiotons not reno ha rama lease corect aeeoeen 2 | | jurtorrunestot™ athoguretomertorasse 36 Trove sioormecune 12 | | lnc meron ar reed oes Satna ter BE | | Gingaesenscte sumacaorey nore BAe Seno. LIST OF ILLUSTRATIONS “ne Modo 45M wa urine sven ce starter th a pre ee gaan ater ive,Hbst acted Cas! ongoes isuRe ar Page) | ploveaaci (20) Te Moon vi organ oa , ieataton on ees wacune a sae F203 et ousng Note Vave Seat ee Tt Tbe Hang 2 2 slag One Gear Creer ans Genter" one Huse A eee : 3. Tobie Foto: Removal 5 | | ctinetar presses atin teneratres ar conto: 4 iting Tut Housing Up Seat 11.) | ange Fann pressaa 120 Pets gore ns 5 costae nae ‘Shalt Batt a ‘vide reliable starting throughout the Model 45M operat- 6 Installing Turbine Shatt 2 morons 7 isang Geaing wo UeSeat ——13--| | tye nage sti desinad ot peton wih com 8 Model @tu'rarexeynuroes 13. | | pecesar‘Ghan‘aneone Ss oeasteaner iain Iau aly na oroey aes adn Rs at ter Tor eae Mosel ____LIST OF TABLES fe tbtcalon's eaiaedintha sary a aA Taste TLE a FE | | me Madol 45M comes complete wih apt a soe + channels ant | mlcvave insted. The vcsho ol fuosan ‘Comoaunde ? ‘Two™ electronic control module reads output shatt oop Z| | secantstus otartoine ota tet rence ot Bat aeacin 3 | | Stovemeeteossion, sperms neesore 2 |_| ctamtesmeess mn outdone tne saneror | sitecoroessd | You ness tempting fa provise sen Two Model «St low in ast of te rarualbelors at BI Turbosian|1.2 WARNINGS, CAUTIONS, & NOTES ‘Thoghout mis manual, certain types of Infomation vi be ighighed for your atewton WARNING. used wher nur te personne of damage fone equipment is tly CAUTION. used where there is tbe possi (of damage othe equiprent NOTE weedto point out special intarstintor ‘maton, NOTE [THE MODEL «et 15 TO BE SERVICED ONLY BY AUTHORIZED AND PROPERLY TRAINED TDI TURBOSTART™ DISTRIBUTORS, DEALERS, | AND REPAIR STATIONS. DO NOT OPERATE ‘THIS STARTER WITH COMPRESSED AIR UN: LESS 715 PROPERLY ATTACHED TO AN EN: GGINE AND WILL ENGAGE THE FLYWHEEL. ‘The TOITubostant Two™ Model 4M provides distinct fdvaniages of sae and eticiency as compared to Becre motor, vane-yps of ether tutone-ype a stan- (25. lis impsrant ot te operator propery instal ‘he Model 4M to receiv fullbenelé of nese ava: tages. Repar technicians or serve organzatons TDI TURBOSTART TWO™ From TECH DEVELOPMENT without tutine stator expetence should not ater {orepar the machine ut hoy rece factory a>. ‘roves traning from TO), ori eproseratves. Prop fr operabon and repair of yeur TDI Turbostat Two waste continued rele and supenor pert mance for mary years. WARNING “The TOI Turbostart Two™ Mace 45M must be in stalled ard operated in accorcance wih the insta tions gen in the Insaatin and Operating manual Fano to propary insta re stats, tamu oop ‘fae accotcng to thoseinstuctons may resutin Garage tothe starter or egie, or personal ny. SECTION 2.0 DESCRIPTION OF BASIC GROUPS 24 GENERAL “The Model 45M can descripivaly be grouped ino four base sogmenis: (1 It Heung - Nozzle Valve Seal (2) Turbine Housing (9) Slage One Gear Car and (4) Geattor - Deve Housing. Sacion 30 Ds- Sreomby and Sacton 5.0 Aasemaly wll general fl bbw he above mentioned gaupsforinsticion Figure 1, ner Housing - Nozzle / Vabe Seat and Tubing HousingTDI TURBOSTART TW/O™ from TECH DEVELOPMENT INC. 2.2 INLET HOUSING - NOZZLE / VALVE SEAT RelertoFigute 1. The init Housing / Nozzle = Valve ‘Seat area general etdes ams (1) trough (25). You stud note hat some tems such as cotiol ines {nd muir pat, ae asaressed whore they are Dest, femeved and asserted 2.3 TURBINE HOUSING ReferteFigue 1. The Turbine Housing inclu toms (25) trough 38. 2.4 STAGE ONE GEAR CARRIER Felerto Figure 2. Tha Stage Ono Gear Carer aea Ineudes tame (23) rough (47), lus he ng gear pleces (9, 48,50), 25 GEARBOX - DRIVE HOUSING FotertoFigue 2. The Gearbox Drive Housing aroa Inctudes toms (51) tough (3). You shove note hat ome dems, such as anal ines, are adresse snore they are best removed and assembled, SECTION 3.0 DISASSEMBLY 3.4 GENERAL Mark each gaeton of ha sarter ort aezomyy die housing (81), gearbox fing gear (48), coraneent ing (8), ar et housing [B} Hote tne locaton of te long mai elbow (19) in the nozae valve sen (36). Note ha fhe cota! Ine bcvses tole inthe cotsnrgnt ng (18) ane pat irine none ate seat 18) must ie op whan fas Made the turing roto (26) and note ts ection of. Have a complete se of ings, seals, screws, at rscelanaovs hardware avasabe fr assembly. Mod 5k staer averaul i, T01 PIN 45-007 cota al icossary pas CAUTION Tbe notwesh bearings (93, 45, $2, 62) orth starter ] ‘ve (76) ncleaing solvers. i3.2 GEARBOX - DRIVE HOUSING 2.24 General Remove ze wo cottl ine hoses 20,58) and four eons (18,21, Disconnect he solenoid valve (69) om the coroer ‘modula (6), Remove the the serews (62) andthe enol valve (6), move te seven screws (61) andthe conaler module (50), 2.22 Drive Housing WARNING “The dive housing - gearbox housing ls sping load ‘ed. Exergen caution when soparaing te ave ‘aueirg (1 om he gearbow nous (6). Remove the wel screws (83) and separate the ceive housing (8) forthe gearbox ousing (6), “check te canton ofthe roller bearing (82). Press fut damaged or suspect, Remove he compression sing (79) andthe starter ‘hive (70) omthe gearbox routing (8). The two. ‘pitenge (7 wil come ot wi the later aive (7 WARNING [ Hot arag overthaoutpal stat 55) and gearbox | housing (6) stp the pre-engage ison (75). when apoling ow pressure a fo rmeve i rom the gearbox housing (6) ‘Apply tow pressure alo the solenoid pot on he gear box housing (68) force the pre-engage piston (75) ‘out ofthe gearoox housing (66). Referfo the WARN- WG above 3.23 Goarbox Housing Remove te four sorews (67) and separate he gear ‘or housing (28, ring get (45), sage one gear car ‘2r(47}, rine Rousing (2) ad inet housing - nozzle Fave seat, 19), Femave he retainer (73) and two thst washers (72) om he outut sha (5), TDI TURBOSTART TWO™~ fron TECH DEVELOPMENT Remove te goa cari /autput stat (55) rom tne ‘geabox housing (2). Remove the for sirens (64 and he bearing ub (s) Proes out he tp sea (71), ‘check ne conton of ne bance bearing (68). Press cout damaged or suspect Remove te thee serows [57 anc the magnet cap 65) Prose out he tives stage Wo planet gear sha (54) ‘and remove the gears (59) ans gear Spacers (5). Check he condition of the need beatings (52). Press out l damaged or suspect, 3.3 STAGE ONE GEAR CARRIER Remove the two shins (43 om the sun gear. Remove the thee screws (89) andthe stage one plan 1 goa shaft retention plate (40). Press out the tree hats (42) and remove the gears (45) and grease cape (44) (Check he condition f the sees bearings (45. Press out f damaged or suspect 3.4 TURBINE HOUSING Remove the sx sows (29, toe roan pats (24, fd mule retaine (25) Yam the cortaswnent Hg {18), Remove tne tee muta element (22) ands cae, Remove the bine housing assembly (22) forthe ‘containment ng (18). Remove the rotor reterion saw (26) and rotor wash 6r(27) Wom he rine shat (38), NOTE [this suggested that you held the sun gear end of the | fupine shalt (98) 8 sotjawed alumna) vee | wile removig te oor tention srw (25)TDI TURBOSTART TWO™ from TECH DEVELOPMENT INC. Tana a a i i 4 ‘Fgwe 3. Turbine Rotor Removal Remove the ibe oor 28) tom the turbine shat Reterto Figure 3. Holton tothe pull ool wih an ‘open enavrench NOTE instal the tive puter sw Rand ight tthe tue bine oto (29). Belov nstaling Ie puter ool, | check a make sure atthe face af the T-screve is ‘male than he ameter fhe turbine shat 38). Remove the 1/8" key (29) tom th urine shat (28) ress the turhine shat (98 rom the turbine housing (G2). The Bearing spacor (36) should come ot a0. Remove ina bearing sbacar (26 om the turine shat 5). CAUTION ‘Your shal resting ool musibe malar aarster santa turbine at (121 rags tne bal basing (99) tom he turbine ont (35) Remove the compression sping (6) Kom he turing rousing 22). Remove the Oring (27) rom the tine housing (22), Remove the retainer ng (34) tome turbine housing (22) Remove he batlbeare (33) rom (oa) rine nous NOTE ‘Yu should ba able o push the bal bearing (35) ot | ey pressing onthe sel spacer (3) wth your linger ‘The seal spacer (30) wil come ou, also. ‘Suppo the turbine housing (2) and press but the fp sea (3). Use TD pressing fool PN 45:25302, 35 INLET HOUSING - NOZZLE / VALVE SEAT ite threaded ret (24) used, remove the ue serews (1). Remove tne eaded eet (24) tom he inet housing (5) Remove the fou serows (7) and separate t rousing (5 fom the eantanmant 9 (8), et Remove the five screws (6) and separate the nozzle valve seat (16) rom there Pousing (5) WARNING “The spool valve nozzle spingloaded. Exerclse auton when separating tha rit housing (5) rom Remove the sping (10) rom the spool va 12), Re- ‘move the ting eap (11 rom the fp va (12) move the shook dampenet (tom the spool vave 02 Remove and discard the Ovings (3 8.13, 14. 15,17, 37,48, 50,65, 8,70, 74, 75, 0) fom the tread at (2, inlet housing (9), spool valve (12) nose / ‘ave aaa! (18), contanmant ang (9), turbine housing (23). rng gear (28) gearoow house 68), eating mad (6a), pre-engage piston (5), and dive housing 1SECTION 4.0 CLEANING AND INSPECTION 4.1 CLEANING Degrease al metal part excep Bearings anne ster deve (7) using cormercaly azproved so: worts Refer Table Dy pa thorough CAUTION [Nevorwann te are erve 78) or sees bar | [SSS i deanngsovere | Clean aluminum pats using the clearing soluon pet Table; soak for minutes. Remove pats, nse n ot water, are ary thoroughly. Gieancor proved stper. tel pats wi commercaly ap Clean corded aluminum parts by cleaning as stated Stove and then immersing the parts fv aeons MATERIAL or COMPOUND TDI TURBOSTART TW/o~ rom TECH DEVELOPMENT tre-phosphoe ai pickle solution par Table 1. Finse inhot water and ary haroushy. 4.2 INSPECTION Use Tabie2 as agua to check lor aceptabe ond tion of the pats iste check at threaded parts fr gala, erssed, sped, or broken treads ‘Check a pas for racks, corosion, ditorion, sor 19, or general damage, ‘check he nozzles (18) for wear, loping, or boa age, especialy on the wang expos. check he spoot valve (12) and valve seatin th no 2 (16) for wear (Check at bearing bores for wear ane scoring. Beating botesshallbe tre of scoring nes rol to exceed. 005" wath and 005" deh cheek gear test or wear. t woar ls apparont, check {247 teh mensions in accordance wih Table 3. MANUFACTURER Degreasing Solvent (Trchoroetiyiene) (Oreaa) ‘Commercial Avalase ‘estone Commariay Avalae ‘Auminum Gleaning Sottion Diereay Corp. 242 W. Monroe, Gheaga, it 60606 ‘Dissolve Son, of Diversey 808 por talon of water use at 125" 108" ‘ieel Cvaner Rust & Corson Gate Praducie Com, 50 Valiy Ra Berkely Heighs, NJ 07292 ‘Mix Sof Oakto Aust Stippee per (Selon ot water use aB0"= 180 Chromic Nar Phosphorie Adie Pickle Sotion Mix 8, oletvore acd, 48 gal of phosphoric acid 1-5 gal oe acd ttn enough water to mae 2 93 materials and compounds. «WARNING» Follow all instructions provided with the above Table 1. Cleaning Matrils and CompoundsTDI TURBOSTART TWoO™ Fron TECH DEVELOPMENT INC. [parr | oescatrnon onECK FOR ‘REOURENENTS etectve Parte Must Be ee ee ne Sd ees Warbooamee Te owen Scie ee | Sen paapaelopeaio ns faesewt eed ipa ay Taped Sty ‘erie nirces ot mapa Table 2. Pans inspection SECTION 5.0 ASSEMBLY 5. GENERAL ‘ways press tha ine ace of bal bearings when in fling toa shat AWvays press he outer race of! bal bearings nan intaling ne nouSINS ‘The olor retention szrow 25) must be repacedeach time me turns rtor 28) i emoves Degtease alipans (EXCEPT NGS) and clean _aurinum pats; alr o Tablet fo: aaning car pounds NOTE “Tisreorynanedio se HD SUT gaue ona | feat aa booge ite wre wc get Setencone, serps fe wicorentnd Seon peor ou endshganae stg Grip ne een eyeenion ed ate Brning with Patkor OrTDI TURBOSTART TWO™ from TECH DEVELOPMENT i DIMENSIONS PART DESCRIPTION MAX ALLOWABLE ites intr) Mee oe Inches (atimetrs) FuneTao (48805 Mesenret mrta 1b 84.2840 ss os ‘ee Damn Sap} | 037503781 @30-9:26 ome ws: sop asa | osoa-osor vazes-rerm | unm pain TREN SIFT (35) Be nea. ostis-osis psoas | ost (2509 Siowawmess | sses-tresi@m-ani | 11es aa) ‘GEAR TAGE «7 =r Table 3. Pans mensions CAUTION CAUTION [au screw theads are treated athe taco wih a {astene retention compound. Every srew, 14 inch clameter or larger, must have «drop ef Lcite 290, _aplied fo the thas belore being re-used: screws | salir than 1 eh arater rus have Berop oF of vertau he ine el beatings (2) sholé be face he Woe besten (3) shoe teste 222 apo one thease. 0 Table [The turbine housing O-ring (37) must not be hibr- ‘ated. tis tobe istaled dy. For torque vals, Plena 78, on ¢ PatTDI TURBOSTART TWO™ Fron TECH DEVELOPMENT INC. nists ovooti cso Tonave et ae ese, PART DESCRIPTION [pression spring (19) onto the O-ring cap (11). venaery | vm NOTE eee aaa | esc " ‘sua ain the net housing () with bo | eects Patna beep caer aa =e [os es at thou ne rons area : 8 198 valve seat (36). Push together o compress eee eee ee sae) eae Wmeemmaneense Ear Se eee exrgorr [ee | NoTE eaeeecnamarny pa concammensnng (67) | pull, betare tightening all five ©. Saaeee] expat ere 41a 2 pawinosereame 29 Q : im See eee Or “em 12 ub wth Oring be and instal he Ong aa ee eee Table 4 Torque Vales 5.2 INLET HOUSING - NOZZLE VALVE SEAT ube with Aorosnet #5 and itt tenet house 8). ing () 10 Lube with Asrosna #5 ang inta the O ge (19) an (14) toe spot vave (12), Instat shock dampencr (0) noth spoo valve. Lube with O-ing ube andnstatne Og (15) ono thenazae va st (18) Luba the 1D ofthe the spon valve (12) and he 10 ot the nozzle! valve coat (16) win Aerosheli 25. Inset ‘he spool vale (12) ne nazi ae 6235) Push by nana. tt sates NOTE ‘Viel algo the contains aceass hole inthe cortainmant ig (8) wih pot re nozaia/ ale Seat (16), Rete lo Daassamby Sacton (31), ‘tl recommandedo aetna tighen wo oppo | se crows to anure aan pu, before ite | ing al four arews | Insat te ielt mousing (5) ont the containment ng {a}, instal he tur seraws (7) andtorue o 14 Lb-Ft (92 ey, Lua with O-ring ube ang nett ne Ong) no iat nosing), raate mit nse (2) he et housing) neat fo eorews (1) an aru 25 LDF G44 Nm)NOTE [ Ropiy pe tiveas sasant io tings bet saney instal the lng mal elbow (1) it the port the rossi valve cea (16) ard ital he ale etm (21) Tic te nat novsing (3). Be sre to pl ese ino the onaa ports Rete to Disassembly Seaton 31) 5.3 TURBINE HOUSING Instat sea (21) ono the seal spacer (30) by hand. "The ip on the Seal spacer (30) 0 the belo eal pe (83) face up. Press the ip seal/ spacer assembly is he turbine housing (22) und seated. Retorto Figura 4 Instaltne bal bering (29) nto the urine house (Ga) by mand neal fh eine lg (34) eur [She housing (22) to secure tne bearing (3), CAUTION "he turbine ovsing Oving (37) mustrat Be be ated. eo be ntl 3 turine housing (22) TDI TURBOSTART TWO~ From TECH DEVELOPMENT into he ine NOTE ———— resion epg (95) must be shoved past, as ras possible Press te bal eating (3) onto Ie turbine shat (28), Fetarto Figure 5. Install he bearing spacer (36) oe the turbine shat ey Place the turbine housing (22} onto he turtine shal (38) ana pre no postion unseated. Retr fo Fp tee. Inet the "key 29} the bine shat keyway (a CAUTION Be cure o check he lain ofthe starr mo fang he coved inealision oh trie rotor ‘Tortie rotor buckets must flow he eame cee tion athe nezales on he rozzle/ valve seat (18). Be sure o check the alignment ofthe tine rotor (20) are key (23 == eee Figure 5. Istaling urine StatTDI TURBOSTART TWO™ from TECH DEVELOPMENT INC. | a ] ; | | i i iT] J} rote Figure 6, Insaling Tutbine Shan Prass he urine oor 28) ono the turbine shat (98) Unit sates lesa the rotor washer 27) ar rotor retention screw (25) evo he rane shat (3). Torque lo BLDFY (338m) NOTE Use HO 8271S to ghly grease the sx grease cups (44). inal one grease cup (48) on each 82 ofthe thee gears 18) Instaltvaeant-otaon rolling (41) it the throw ‘age one planet gear erat (42) Tap the Bs (1) ino postion wih a small name! Inset the tree gears (46) it he stage one gear car fer (47) and abgn the shah bores. Hangin. the tee gear shat (¢2) tothe gear carte (27 an tap to poston. CAUTION “The gear shats (2) must be inserted om the stage one sun gear (38) se of the gear carcer (47), Be sur to gn me antsctaton pe on the ‘ear shas (42) wih the sts in he gear carer a, ‘Sethe planet gear shat retention plats (20) on the ea” eater (47). Be sure to property aign the sew ois Instat three serews (38): orqe to 45 Lbsn (6.4 Nn CAUTION (Check gear rotation. The gears (26) must tate trea nthe goar ears (7), Tis suggested that you eld the sun gear end ofthe | turbine shat (38) m3 Sot jawes (lumina) ise wie orueing te or eantionserw (25. | 5.4 STAGE ONE GEAR CARRIER Presse si nace be cone panel gers (48) CAUTION reas he bearings (43) intone gears (e@)by |) pressing one inom each ee ol Ne gear. Press ach bearing (45) tush wih se Tare othe Ue —I ing (45) it ho tee a9 Use HO 627M to great he besrings (5) and err between he beans 5.5 GEARBOX - DRIVE HOUSING 551 Gearbox Housing ees he od impregnated bronze baring ($8) ino ‘he Bearing rub (60) ut seated raze te fp cea (71 ito he bearing hb (9) un coated. Rolo rie 7, CAUTION Be eure thatthe ip onthe sea (71) faces down io [iho mod (63, ube with Ong be an the recess on he it ‘ea,foe a0 Seal Peeing Figure 7. rsaling Bearing Hub ip Seal ‘Set the bearing hub (69) nto the goabox housing. ‘Take care to line up the four screw ols. Inetlthe fou srews (640 secure the bearing hu; torque 64 Lbsn 7.2 Nr) CAUTION Be eure 1o hold he bearing Pub (68) andthe gear ‘box housing (6) tml ager while insiang he Seews (64) 1 orcer a prevent the Ong (68) ame shiling out of poston. TDI TURBOSTART TWO™ From TECH DEVELOPMENT Stine gearbox housing (68) ade 5:52 Carrier) Output Shat ross ine tee reece ings (62) eshte nee stage two planet gears (52) CAUTION he bearings 52) ed and a ao end fe cetan fo press agai! he tal end. Press each bearing (62 tush wth the face of the ge (5), Insaltvee antotaton felis (43 notte stage wo planet gear shat (54). Tap the pins (41 nto po ‘ion wh & sma hammer. Place one othe gear spacers (51) on each sie he Stage wo paral gears (53). Insontthe thee gears (53), wih spacers), ne the (gear cari 65) and align he shah boves, and instlhe tree gear shate (4) nt he gear camer ($5) ancip nto postion. CAUTION _ “The gear shat (54) mus be inserted rom te out pul shalt sie ofthe gear carer (8). Ba sure ign he anteaion pins on the gear sas (5) ‘wah ne sats inthe gear carer (5). check gearttaton . The gears (3) must ate ‘rely i the gear cartir 5), Lube with Aeroshell #8 and set the Oxing (70) oxo the bearing hub (3). athe Oving (70) la postion on the beating hub (8), Lube with Asrosnel #6 an insalne O-ing (74) ne (7 om he preengage piston (75) Use Aerosnell 0 grease he inset he gearbox housing (66). and the nie and ouside ofthe pre-e ‘age pon (75). and press the pre-engage piston (7) int the ger box housing (66) and ote tne bearing hub 63), CAUTION Sethe magnet cap (56) onto the gear cate (5), CAUTION “The pon the magnet cap (56) fs overine mag. nets edie nthe gear carr (5) NOTE “The te holes the magnet cap (56) ae rot evenly spaced. Be sure to propery alga he cap (55) an the goa earn 5), Insa the tres serows (67) ato EAN), asoTDI TURBOSTART TWo™ TECH DEVELOPMENT ING. NOTE Cat the bronze bearing (5) wih Rerosnal #5 | grease Inger he sea! pestoning took, TDI PAN 4525956, trvouph ne ip of he 503 (71), Insta the gearbox housing (88) 70 othe gear carer (55), put shat earbox housing (68) nace, remove he 83 postionng tol, TOI PN #5 25336 CAUTION ‘Wile handling the gearbox housing gear cavin, | onal tthe gear cari (5) al out the gear box housing (68) or you wil have to repeat the pre | \weus procedure on the seal (7). fine ip onthe Ip sea (7) becomes reversed curing assemy ot Irate two tt washes (72) ono the ouput shan 35}. Insta tn retane ing (73) ont he output hat (5. Instaltne two epi ngs (7) ont the the starter ie 03, Instat starter dive (78) onto the output shat ($5) andi te re-ongage piston (75). _CAUTION [ss hat the split ings (77) eran in postion so thatthe Starter ve (7) seats tothe pre-engage J Inst ne comoression spring (72) ano tha staner ona (73) piston (75). ress the or bearing (2) roth dive housing (81) unt gated. Use HO 9270S 1 grzase te roar easing (2) Lue wih Aeros #8 and intl he Oving (9) onto the deve using (8), Instatne are housing (82) a0 1 ura hat 5. Holst deve housing (1 iy agains! he gear rousing (68) and instal the wate screws (33). NOTE ‘Align the eve Fousng (81) wine gearbox Rove ing (66) so that component olenaion is creat fo: ‘al assembly and instalation. Refer to Disassem- [py secton 3. NOTE ‘ts recommendado aterratey ighten jo appe- | Ste stews ensure a stag pu etre igten: | ing a wale eave (3, ‘catty ghton the tah sores (2) to ancure that ‘he Oring (0) 8 next. Torque he twelve eorews (89) 10 #2 Lb (16.8 Ni). CAUTION ‘Check he rotation of the gear caver ouput sha (65). The gear carer (55) and gears (53) sould an rotate rey. 5.6 FINAL ASSEMBLY Sette int housing containment ing (5,18) assem by onthe inet housing (3), Insta the turbine assembly (22) no the cont ng (18) iment NOTE ‘Since the major components rust atiach to ach ‘ther, eure te algh the compovon ler both he ropa goeralesrtaton ano sere holes, Lub wih O-ring ube and instal te O-ings ‘nto the ig gear (9). Insta the ng the urine houseg (32). (23,50) (28) on Instat the two shims (43) onto the sn goa pin ofthe ‘lage one gee caver (47) Ons sim 22) oes on SasnendNOTE You can use HO S275 greece t hol these hime 3) postion during 286074, CAUTION ‘Ute HD a27NS to lecally grease te tarot the ring gear (48), the stage one gear carer sec- | ‘nd stage sun gear (47) are the stage two gear car ror 5 Insalthe stage one gear cartier (47) nto the ring gear (49) and onthe trbine eat evn gear (38). Rotts ‘ne cater (47) unl uly seat, Instat the gearbox housing gear cai (65,85) onto ‘a ing gear (29) and ona he sun gear lhe cater (4X), Rotate to uly seat. NOTE FRechosk component oreriaton and sow hole alignment Instat four screws (67 to secure the gearbox housing (6) tough To the content rng (8) NOTE Tis recommendedto atamaty tighten wo oppo: So screws, to ensue a saight pull, before lghton- ing alfour sews (87) ‘cael ohten the tour sezows (67) to ensue hat the Ovings 49,50) on the rng gpa 42) ae not cut Torque the four screns (67) 10 14 LDFt (13.2 Nm) Instal three new muta element (22 no the eon tainment fing (18) Postion the mutter etainr (25) ‘and instal the thee mr etainer lates (24) wath the sc seems (23). Torque te sk srews (29) 1045 Leun(s.1 Nm), TDI TURBOSTART TWoO™ From TECH DEVELOPMENT Irstalthe controler module tet the gearbox reusing (6) CAUTION _ Ensue fal he sped sensor one corto ler module (60) seais to the sourterbore inthe | | gearbox musing (25, Insane seven srews (61) secure he controler module (60). Torque to 15 Lb (1.68 Nm. Lube wth O-ring ube and nstal the Ong (85) onto the gearbox housing (8). Sat Fe solenoid vane ( ‘ort ro gearbox rousing (68) ond secure wth he twee screws (62). Torque fo 8¢Lb-n (7.2 Nr Instal ibe mo male stows (21) One goes into the {gearbox housing (66) ancone goes ins the slenais ave (63), NOTE [aes Install the ielto-solenod hose (59) and i ston to valve Poe (20), ihe thoaded inet 2A) use. instar he O cng (2) Into te trveaded inet (28). Seite treaded int (24) ‘nfo ete inet Rousing (5) ar neta he four ‘SErows (1) Torque to 70 LbF1(08 Nm. ‘tach the solenoid leads tothe cri module (69) terminal stip serows marked SOL. There's no pos! Theor negalve for these leds WARNING Feterto the Model 45M Intalition and Operating Manual for complete instalation nstuctons.TDI TURBOSTART TWO™ Fron TECH DEVELOPMENT INC. SECTION 6.0 TROUBLE SHOOTING GUIDE Se [_TRowsie PROBABLE CAUSE | ‘SOLUTION efoto | A Soles oaingcmah | A Sha x dnaple aman aren cma Ss San wasn aeway | & Sects prank argo Hol Sopra coments Noe SOM sma on pot crgrbsrnny Ca hei aay ‘Selig sate mae a pe'2 YS. si conus cota ee T Baie amhroceeeh | A Lovakpnnnipnin at | Geckar perenne An mS Sonoma ton {so-00PS oe 3 vapanwin elarmaaia | 8 Orn ane sen peg wna aI Spence neha che 7 oom inictenalle, —| ©. Gack hae aria iso pd aa | Sane ep Se be abe poe eae scl mie ‘Sermon cnt mi ADEE ‘Sevan screen toy aon oN ‘Srl en emp ee nti. 7 Aemeameoneprin | BR danape Sie pe Maney Se soonteaae ‘orcpaonepon Chea sone 3 gee kentan cond | A Benmat 1 Plan neo: Haan dante Slovene ‘taco roo no ea Tans Soap | Br 1 Saarenmegeecans | K Umaeipeare Ta as I Sonya 3 Bonito fap le mon | | ©. Sorepdt ate © stain | 0 Bae Belew anie ae pen Ta pesan anise Saeengee [5 amar Kes om [Bimeimeataaneay [8 oe Ave Tampa deayetie | A eemnciowee ipl. | A, Dies gee sae eae | ene aio eso Sparen fesse eso teres tenn os 3 ap apt ans | Seto 6 Sora [0 Sata. “ Release all system air pressure before attempting to work on starter, system componentsTDI TURBOSTART TWO™ view DESCRIPTION ‘vung kt, Moe! 4 Poeagates pane maid ink (reste, HO S27, 1 pt ‘Green, HD S275, alon (iosee, HO S27MI5, 1652 atige Seat Pe Tread Toot Boating Pressing gutine ous) Toot Seal Lip Peston ‘eeuirg mo) ‘Toot Sea Pressing fewrag hb) “Toot Sea Pressing urbe ovens] Too, Son Remavalqune novees) Too, Tune Rtn Pale os Tac) Nanepie Patton Tag iarring Lat PN seoue 9400s sono sseane sees as2emne 52805 S408 954083 334088 from TECH DEVELOPMENT ITEMS NOT SHOWN IN PARTS LIST SOMETAICTDI TURBOSTART TWO™ : ot tc. SECTION7.0 PARTS LISTTDI TURBOSTART TWo™~ From TECH DEVELOPMENTTECH DEVELOPMENT INC.