TOHATSU MFS 9.9 Service Manual
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TOHATSU MFS 9.9 Service Manual

TOHATSU MFS 9.9 Service Manual

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Summary of Contents for TOHATSU MFS 9.9

  • Page 2: Table Of Contents

    This manual has been prepared as a supplement for the "Power Trim & Tilt" section described in the service manual of Tohatsu's 4 stroke gasoline outboard motors' 9.9/15/20C. Please utilize this manual together with the service manual of our outboard motors 9.9/15/20C.

  • Page 3: Outline Dimensions

    PTT Unit 1. Outline Dimensions 1) Outboard Motor Dimensions ITEM TRANSOM UNITS 14.76 27.17 33.07 38.07 16.26 22.13 27.13 14.57 25.79 4.13 17.52 21.26 12.01 30-70 1.18-2.76 17.92 29.73 35.24 1010 39.77 14.37 13.59 12.80 8.27 18.90 5.51 0.59 TRIM ANGLE 4-16 (POSITION) 4st 9.9/15/20 2009...

  • Page 4: 2） Transom Bracket Dimensions

    2) Transom Bracket Dimensions CENTER LINE 76.6mm 76.6mm TOP OF (3.00in) (3.00in) TRANSOM 97.5mm 97.5mm (3.83in) (3.83in) 94.2mm 94.2mm (3.70in) (3.70in) 97mm 97mm (3.81in) (3.81in) 10mm (0.39in) 4st 9.9/15/20 2009...

  • Page 5: Parts Layout

    PTT Unit P/L Fig. 20 2. Parts Layout Bracket (PTT) 24 N·m (17 lb·ft) [2.4 kgf·m] 13 N·m (9.4 lb·ft) [1.3 kgf·m] 13 N·m (9.4 lb·ft) [1.3 kgf·m] Q'ty Q'ty Ref. Ref. Description Remarks Description Remarks 9.9 15 20 9.9 15 20 21 Anode 2 2 - 1 Clamp Bracket (PTT-Right)

  • Page 6: Power Tilt

    P/L Fig. 21 Power Tilt 15 N·m (1.1 lb·ft) [1.5 kgf·m] 5.2 N·m (4 lb·ft) [0.55 kgf·m] Q'ty Q'ty Ref. Ref. Description Remarks Description Remarks 9.9 15 20 9.9 15 20 1 Cap Ass'y 1 1 - 13 O-Ring, 2-62.5 1 1 - Do not reuse.

  • Page 7: Operation Of Power Tilt

    PTT Unit 3. Operation of Power Tilt ・The power tilt system has an electric motor built in the system that drives the hydraulic pump to feed pressurized oil into the tilt cylinder. ・The power trim switch located on the tiller handle or remote control box is used to tilt-up or down the outboard motor. ・The switch is also used for trim operation of the outboard motor during driving at low speed.
  • Page 8 Tilt rod Up-pressure main check valve Cylinder upper chamber Spool valve Piston Cylinder lower chamber Down-pressure main check valve Check valve Gear pump Oil passage Up relief valve Down relief valve Oil reservoir PTT motor Tilt up Operation Pressing "UP" side of PTT switch causes the PTT motor (gear of gear pump) to rotate clockwise. Check valve A opens to cause oil to flow from reservoir toward gear pump and spool valve.
  • Page 9 PTT Unit Tilt rod PTT cylinder Up-pressure main check valve Cylinder upper chamber Spool valve Piston Cylinder lower chamber Down-pressure main check valve Oil passage Check valve Gear pump Up relief valve Down relief valve Oil reservoir Filter PTT motor Tilt down/Trim in Pressing "DOWN"...
  • Page 10 Tilt rod Cylinder upper chamber Shock absorber valve (Open to 129〜169kgf/cm 12.6〜16.6Mpa   〔1835〜2404psi〕 ) Piston Cylinder lower chamber Shock Absorber Valve The PTT unit is provided with a shock absorber that protects the drive unit from an impact in case it hits underwater obstacle during cruising.
  • Page 11 PTT Unit Tilt rod Piston Cylinder lower chamber Thermal valve Thermal Valve Thermal valve protects drive unit from excessive force that attempts to push down tilt rod when the outboard motor is at full tilt up position. The piston rod to which excessive force is applied is pressed into the cylinder, resulting in increasing hydraulic pressure in the lower cylinder chamber over a rated value.

  • Page 12: Removing Ptt Unit

    5. Removing PTT Unit Fully tilt up outboard motor and lock with tilt stopper WARNING Be sure to lock outboard motor with tilt stopper after tilting up. Leaving outboard motor up without locking may lead to accidental descent due to reduction of PTT hydraulic pressure.

  • Page 13: Removing And Repairing Manual Release Valve

    PTT Unit Remove bolt 8 and washer 9, and use a proper punch 0 to remove lower cylinder pin. Be careful not to drop PTT assembly. 6. Removing and Repairing Manual Release Valve Loosen fill cap 1 of power tilt unit slowly, and then remove Fully extend tilt rod when removing fill cap.
  • Page 14 Remove manual valve C ring 2 and turn manual valve 3 counterclockwise to remove. Remove O ring (2 pcs) 4 from manual valve 3, check O ring for damages and deterioration, and replace with new part if necessary. Remove seal washer 5, and replace with new part if necessary.

  • Page 15: Power Tilt Motor

    PTT Unit 7.Power Tilt Motor 1）Removal, Check and Repair of Power Tilt Motor Remove 2 inner hex bolts 1, and then remove motor ass'y 2 from power tilt pump and cylinder ass'y 3. Before disassembling power tilt motor, drain power tilt fluid.

  • Page 16: 3）Inspection Of Motor

    3）Inspection of Motor Replace brush 5 if it is damaged or if gap between brush end in the groove of brush holder 4 and brush holder end is 1.6mm or less. 1.6mm 4）Replacement of Motor Remove 3 screws 3, and remove brush 5 and circuit breaker 7 from motor bracket 8.
  • Page 17 PTT Unit Attach armature 1 while holding brush 3 located in the groove during installation of armature 1 to motor bracket Attach O ring 5 to motor bracket 2. 1Armature 2Motor bracket 3Brush 4Brush 5O ring Attach yoke ass'y 1 by using 2 screws 2. 1Yoke ass'y 2Screw (2) 3Motor bracket...

  • Page 18: Power Tilt Pump

    8.Power Tilt Pump 1）Disassembly of Power Tilt Pump WARNING Contamination of hydraulic system can give damage to the components and circuits, possibly resulting in serious damage to the product. Before inspecting hydraulic circuit and parts, organize working space and tools. Do not use cloth for inspection and servicing of parts.
  • Page 19 PTT Unit Remove UP side relief valve 1, DOWN relief orifice 2 and O ring 3 from power tilt housing. 1Up relief valve component 2Down relief orifice 3O ring Check down side orifice screen 2 and up side relief valve seat face 1.

  • Page 20: 2）Assembling Power Tilt Pump

    2）Assembling Power Tilt Pump Coat new O rings (2) q with oil, and attach it to power tilt housing. Coat new O ring 9 with oil, and attach it to orifice 0. Attach filter 8 and orifice 0. Attach up side relief valve 1 to power tilt pump housing. Recommended PTT Fluid : ATF DEXRON II 1Up relief valve ass'y...
  • Page 21 PTT Unit Attach cleaned screen 1. Attach pump coupling 2 to pump. Install motor ass'y to power tilt pump and cylinder ass'y. Attach wireharness mounting screws. 1Pump filter 2Pump/motor coupler Install motor ass'y 4 to cylinder ass'y and power tilt pump 3 by using screws 5, and tighten screws to specified torque.

  • Page 22: 3）Air-Purging Ptt Unit (Separated From Outboard Motor)

    3）Air-Purging PTT Unit (Separated from Outboard Motor) Turn manual valve 1 clockwise fully. Put PTT unit 2 on the work bench vertically, remove cap 3 and check level of fluid in the reservoir. WARNING Check fluid level with tilt rod fully extended.

  • Page 23: 4）Installation Of Power Tilt Ass'y

    PTT Unit 4）Installation of Power Tilt Ass'y Fully tilt up outboard motor and lock with tilt stopper 1. Install bushing 3 on the tilt cylinder rod 2. 1Power tilt cylinder 2Cylinder rod eye 3Bushing Attach pivot bushings 5 (2) to clamp bracket 1. Place power tilt ass'y 6 between clamp brackets 1.
  • Page 24 Secure earth cord 1 by using screw. Attach electrical cord of power tilt unit to power tilt relay 2, 1Positive terminal (red) 2Up relay terminal (blue) 3Negative terminal (black) 4Down relay terminal (green) Attach bushings (2) 1 to swivel bracket 2. Extend power tilt cylinder rod to align tilt cylinder rod and swivel bracket.

  • Page 25: 5）Inspection Of Ptt Relay

    PTT Unit 5）Inspection of PTT Relay 3 (+)R 3 (+)R This test can be made without removing parts. Disconnect positive and negative cables from battery. 4 (-)B 4 (-)B Remove PTT lead wire socket a from coupler. Check PTT relay wires in accordance with the following table.
  • Page 26 F 9.9C/15C/20C EFT MFS 9.9C/15C/20C EFT CD UNIT CORD ASS'Y Connections decal CONNECTOR PIN LAYOUT WIRE COLOR TERMINAL No. TERMINAL Name TERMINAL No. TERMINAL Name Black IGNITION GND Blue IGNITION(+) BLANK Brown EXCITER(H) Green EXCITER(L) PULSEP(+) Orange TACHO PULSEP(-) LED POWER BLANK White BLANK...
  • Page 27 F 9.9C/15C/20C EPT CD UNIT CORD ASS'Y OPTION Connections decal CONNECTOR PIN LAYOUT WIRE COLOR TERMINAL No. TERMINAL Name TERMINAL No. TERMINAL Name Black VOLTMETER IGNITION GND Blue IGNITION(+) BLANK Brown EXCITER(H) Green EXCITER(L) PULSEP(+) Orange TACHO PULSEP(-) OPTION LED POWER BLANK White BLANK...

This manual is also suitable for:

Mfs 15Mfs 20c

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