User Manuals: Rotax MMH-912 Series Engine Maintenance

Manuals and User Guides for Rotax MMH-912 Series Engine Maintenance. We have 2 Rotax MMH-912 Series Engine Maintenance manuals available for free PDF download: Maintenance Manual

Rotax MMH-912 Series Maintenance Manual (456 pages)

912/914 Series

Brand: Rotax | Category: Engine | Size: 15 MB

Table of Contents

3
- 2 List of Chapters
  
  5
- 3 Index
  
  7
- 4 List of the Valid Pages
  
  11
- 5 Table of Amendments
  
  19
- 6 General Note
  
  21
- 7 Safety Notice
  
  23
  - Repeating Symbols
    23
- 8 Technical Documentation
  
  25
  - Filling in the Dimension Sheets
    25
  - List of Abbreviations
    26
- 9 Classification of Parts for Maintenance/Repair
  
  27
  - Determination of Actual Wear [%]
    30
- 10 Maintenance
  
  33
  - Trouble Shooting
    33
  - Tightening Torques
    33
  - Consumable Materials
    34
  - Auxiliary Tools
    37
  - Measuring Tools
    39
Table of Contents

47
- 2 System Description
  
  49
  - Description of Design
    49
  - Type Description
    50
- 3 Technical Data
  
  57
  - Operating Limits
    57
  - Operating Fluids / Capacity
    57
  - Weights
    57
  - Engine / Components
    58
- 4 Treatment of Corrosion and Surface Damage
  
  61
  - Propeller Shaft
    61
- 5 Preservation and Returning to Service
  
  63
- 6 Maintenance
  
  65
  - Engine Suspension Frame
    65
    
    1) Engine Suspension Frame Disassembly
    65
    
    2) Engine Suspension Frame Inspection
    66
    
    3) Engine Suspension Frame Assembly
    66
  - Temperature- and Pressure Observation
    68
Systems Description/Maintenance

69
- 2 Systems Description
  
  73
  - Propeller Gearbox
    73
  - Hydraulic Governor
    75
  - Vacuum Pump
    76
  - Connections for Instrumentation
    76
    
    1) Mechanical Rev Counter and Hourmeter (Optional)
    76
- 3 Maintenance
  
  77
  - Removal of the Fly Wheel Hub
    77
  - Vacuum Pump Removal and Inspection
    78
  - Governor Removal and Inspection
    78
  - Ignition Housing Removal and Inspection
    79
  - Ignition Housing Fitting
    82
  - Sprag Clutch
    83
    
    1) Sprag Clutch Removal
    84
    
    2) Sprag Clutch Dismantling
    85
    
    3) Sprag Clutch Installation
    86
  - Reduction Gear for Electric Starter
    88
  - Rev Counter Drive
    89
  - Propeller Gearbox
    90
    
    3) Removal of Roller Bearing for - Series 4
    92
    
    4) Propeller Gearbox Disassembly
    96
    
    5) Propeller Shaft Removal
    98
    
    6) Vacuum Pump Drive Removal
    100
    
    7) Propeller Governor Drive Removal
    101
    
    9) Vacuum Pump Drive Installation
    106
    
    10) Gearbox Components Inspection
    107
    
    11) Toothed Shaft Profiles Inspection
    111
    
    12) Gear Set (Gear Wheels) Inspection
    112
    
    13) Propeller Gearbox Reassembly
    117
    
    14) Disc Spring Pre-Tension Adjustment
    119
    
    15) Propeller Gearbox - Installation
    121
  - Cylinder Head - Removal
    123
  - Cylinder Head - Disassembly
    125
    
    1) Cylinder Head and Studs
    127
    
    2) Reworking of the Sealing Surface to the Exhaust Manifold
    129
    
    3) Valve Guides
    130
    
    4) Valve Seats
    131
    
    5) Valves
    132
    
    6) Valve Springs
    135
    
    7) Washers
    137
    
    8) Rocker Arm and Rocker Arm Shaft
    138
    
    1) Rocker Arm with Plastic Bushing
    139
    
    2) Rocker Arm with Pressed Sinter Bushing
    140
    
    3) Rocker Arm Shaft
    140
  - Cylinder Head Reassembly
    141
  - Cylinder and Piston - Removal
    143
    
    1) Checking Pistons
    145
    
    2) Checking the Piston Ring
    147
    
    3) Piston Pin
    148
    
    4) Cylinders Inspection
    149
  - Hydraulic Valve Tappets
    151
  - Pushrods
    153
    
    1) Hydraulic Valve Tappets Fitting
    154
    
    2) Pistons Fitting
    154
    
    Piston and Cylinder Assembly Fitting
    154
    
    3) Cylinders Fitting
    158
    
    4) Cylinder Head Fitting
    160
    
    Intake Manifold and Compensation Tube Assembly
    163
- 4 Wear Limits
  
  165
  - Cylinder Head
    176
- 5 Form Sheets
  
  185
  - Form Sheet for Material Testing ROTAX 912/914 Series
    185
    
    1) Inspection on Cracks
    185
Systems Description/Maintenance

187
- 2 Systems Description
  
  189
  - Fuel System (on 912 Series)
    189
  - Fuel System (on 914 Series)
    191
  - Fuel Filter
    193
  - Fuel Pump (on 912 Series)
    193
  - Fuel Pump (on 914 Series)
    193
  - Fuel Pressure Regulator (Only on 914 Series)
    194
  - Pressure Connecting Lines (Only on 914 Series)
    196
  - BING Constant Depression Carburetor Type 64-3
    198
  - Handling of Fuel
    201
  - Connections for Instrumentation
    202
    
    1) Airbox Air Temperature Display (Only on 914 Series)
    202
    
    2) Boost Pressure Display
    202
  - Carb Heat System and Winter Operation
    202
- 3 Maintenance
  
  203
  - BING-Constant Depression Carburetor Inspection
    207
    
    2) Float Needle Valve Leakage Test
    208
    
    3) Individual Components of the Carburetor (on the 912 Series)73-00-00
    209
    
    4) Individual Components of the Carburetor (on the 914 Series)73-00-00
    210
    
    5) Diaphragm
    211
    
    6) Jet Needle
    211
    
    7) Float Chamber, Floats
    213
    
    8) Float Brackets
    214
    
    9) Carburetor Jets
    215
    
    10) Float Needle Valve Inspection
    216
  - 11) Starting Carburetor (Choke)
    217
  - 12) Carburetor Assembly
    217
  - 13) Carburetor Synchronization
    219
  - 14) Idle Speed Adjustment
    219
  - 15) Throttle Cable and Linkage
    219
  - General Information on the Fuel System
    220
    
    1) Fuel Pressure (on 912 Series)
    221
    
    2) Fuel Pressure (on 914 Series)
    223
    
    3) Carburetor Sockets
    224
    
    4) Fuel Lines (on 912 Series)
    226
    
    5) Fuel Lines (on 914 Series)
    229
    
    6) Fuel Pressure Regulator (Only on 914 Series)
    230
    
    7) Fuel Pump (on 912 Series)
    231
    
    8) Fuel Pump (on 914 Series)
    233
    
    9) Pressure Connecting Lines (Only on 914 Series)
    235
  - Assembly of Carburetor Sockets, Carburetor and Fuel Lines
    239
    
    1) Carburetors and Carburetor Sockets
    239
    
    2) Fuel Lines (on 912 Series)
    241
    
    3) Fuel Lines (on 914 Series)
    244
  - Intake Manifolds Fitting
    246
  - Engaging the Carburetor Support
    246
  - Connecting Fuel Lines (Tank)
    247
Systems Description/Maintenance / Troubleshooting

249
- 2 Systems Description
  
  251
  - Electric System (Alternators, Ignition)
    251
    
    1) Ignition
    254
    
    2) Allocation of Trigger Coils and Ignition Circuits
    256
    
    3) Firing Order
    257
  - Connections for Instrumentation
    257
    
    1) Electronic Rev Counter
    257
- 3 Maintenance / Troubleshooting
  
  259
  - Treatment of Corrosion and Surface Damage
    259
    
    Electric System
    259
  - Checking the Ignition Unit, Trouble Shooting
    259
  - Spark Plugs
    260
  - Spark Plug Connectors and Ignition Cables
    260
  - Electronic Module, Trigger Coil Kit
    262
  - Charging Coil
    263
  - Generator Coils
    264
  - Dual Ignition Coil
    265
  - Cut-In Speed of Ignition
    266
  - Ignition Timing Control
    267
  - Ignition Circuits Inspection (Ignition Check)
    269
  - Measurement Values for the Ignition Unit
    270
  - Wiring Diagrams
    272
    
    1) Engine Internal (on the 912 Series)
    272
    
    Engine Internal (on the 914 Series)
    278
    
    Engine External (on the 914 Series)
    282
  - Ignition Electric Set Removal
    283
  - Ignition Electric Set Dismantling
    285
    
    Dual Ignition Coils Replacement
    285
  - Ignition Electric Set Reassembly
    289
  - Ignition Electric Set Refitting
    291
  - Trigger Coil Kit Replacement
    294
  - Stator Removal and Refitting
    296
  - Fly Wheel Hub
    297
  - Interference Suppression Box (Only on the 912 Series)
    300
    
    1) Interference Suppression Box Dismantling
    300
    
    2) Interference Suppression Box Wiring Diagram
    301
    
    3) Interference Suppression Box Assembly
    302
    
    4) Interference Suppression Box Fitting
    302
  - Rev Counter and Ignition Trigger Coils
    303
  - External Alternator (Optional on 912/914 Series)
    305
    
    1) Vbelt Pulley Assembly
    305
    
    2) Alternator Assembly
    305
    
    3) V-Belt Tension
    307
- 4 Wear Limits
  
  309
- 5 Form Sheets
  
  311
Table of Contents

313
- 2 Systems Description
  
  315
  - Cooling System
    315
  - Connections for Instrumentation
    316
- 3 Maintenance
  
  317
  - Water Pump Removal and Inspection
    318
  - Water Pump Housing - Dismantling and Inspection
    319
  - Fly Wheel Hub Removal
    321
  - Ignition Housing Removal
    321
  - Water Pump Shaft - Removal
    321
  - Rotary Seal - Removal
    322
  - Rotary Seal - Installation
    322
  - Axial Position of the Water Pump Shaft
    324
  - Ignition Housing Assembly
    325
  - Water Pump Housing - Reassembly
    325
  - Coolant Hoses Fitting
    326
  - Spring Band Hose Clamps
    326
  - Radiator (Optional 912/ 914 Series)
    326
  - Cooling Air Duct (Optional 912/ 914 Series)
    326
  - Expansion Tank
    327
  - Overflow Bottle
    327
  - Temperature Measurement System
    327
  - 1) Cylinder Head Temperature Sensor
    327
- 4 Wear Limits
  
  331
  - Water Pump
    331
Systems Description/Maintenance

333
- 2 Systems Description
  
  335
  - Turbocharger Control (Only on 914 Series)
    335
    
    1) Target Pressure Reduction at Overspeeding
    340
    
    2) Target Pressure Reduction
    340
    
    2) Target Pressure Reduction at Excessive Airbox
    341
    
    3) Target Pressure Reduction by Limiting the Compressor
    342
    
    Pressure Ratio
    342
    
    3) Lamp Output Connections on the TCU
    343
    
    4) Three-Way Solenoid Valve
    344
    
    5) PC Interface
    344
- 3 Maintenance
  
  345
  - Control System of the Turbocharger (Only on 914 Series)
    345
    
    1) Checking the Turbocharger Control Unit (TCU) by Means
    345
    
    1) Functions of the Communication Program
    345
    
    2) Required Items
    345
    
    3) Scope of the Communication Program
    347
    
    4) Application of the Communication Program
    349
    
    6) Checking the Throttle Valve Position
    361
    
    7) Recalibration of the Throttle Position
    363
  - 2) Static Check of the Turbocharger Control
    364
    
    1) Turbo Control Unit (TCU)
    364
    
    2) Caution Lamps
    366
    
    3) Wiring Harness
    367
    
    4) Throttle Potentiometer
    369
    
    5) Resistance Thermometer
    374
    
    6) Pressure Sensors
    376
    
    7) Servo Motor
    382
    
    8) Circuit Breaker for Servo Motor
    384
    
    9) Three-Way Solenoid Valve
    385
  - Wiring Diagrams
    386
  - Engine External (on the 914 Series)
    386
- 4 Form Sheets
  
  387
Systems Description/Maintenance

389
- 2 Systems Description
  
  391
- 3 Maintenance
  
  395
Table of Contents

411
- 2 Systems Description
  
  413
  - Lubrication System
    413
  - Main Oil Pump (Engine Lubrication Circuit)
    415
  - Suction Pump (Turbocharger Oil Circuit, Only on 914 Series)
    418
  - Magnetic Plug
    420
  - Drain Plug
    420
  - Connections for Instrumentation
    420
    
    1) Oil Pressure Indication
    420
    
    2) Oil Temperature Indication
    420
- 3 Maintenance
  
  421
  - Oil Pump
    421
    
    1) Oil Pump Removal (Main and Suction Pump)
    421
    
    2) Oil Pump Disassembly
    424
    
    4) Oil Pump Assembly (on 912 Series)
    428
  - Pressure Check Valve (Only on 914 Series)
    430
  - Oil Sump (Only on 914 Series)
    431
  - Oil Tank
    432
  - Oil Lines (Steel Lines)
    433
  - Oil Lines
    435
  - Oil Cooler
    435
  - Purging of Lubrication System
    436
  - Temperature- and Pressure Observation
    436
    
    1) Oil Temperature Sensor
    436
    
    2) Oil Pressure Sensor
    437
- 4 Wear Limits
  
  439
  - Systems Description
    443
    
    Electric Starter
    443
  - Maintenance
    445
    
    Electric Starter Dismantling
    445
    
    1) Standard Starter
    447
    
    Electric Starter - Inspection of Individual Parts
    449
    
    Electric Starter - Reassembly
    451
    
    1) Standard Starter
    452
    
    2) HD Starter
    452
    
    Electric Starter - Installation
    452

Rotax MMH-912 Series Maintenance Manual (464 pages)

For ROTAX Engine Types

Brand: Rotax | Category: Engine | Size: 11 MB

Table of Contents

3
- 2 List of Chapters
  
  5
- 3 Index
  
  7
  - Edition 1 / Rev
    8
  - Edition 1 / Rev
    10
- 4 List of the Valid Pages
  
  11
- 5 Table of Amendments
  
  19
- 6 General Note
  
  23
- 7 Safety Notice
  
  25
  - Repeating Symbols
    25
- 8 Technical Documentation
  
  27
  - Filling in the Dimension Sheets
    27
  - List of Abbreviations
    28
- 9 Classification of Parts for Maintenance/Repair
  
  29
  - Determination of Actual Wear [%]
    32
- 10 Maintenance
  
  35
  - Trouble Shooting
    35
  - Tightening Torques
    35
  - Consumable Materials
    36
  - Auxiliary Tools
    39
  - Measuring Tools
    41
Table of Contents

49
- 2 System Description
  
  51
  - Description of Design
    51
  - Type Description
    52
- 3 Technical Data
  
  59
  - Operating Limits
    59
  - Operating Fluids / Capacity
    59
  - Weights
    59
  - Engine / Components
    60
- 4 Treatment of Corrosion and Surface Damage
  
  63
  - Propeller Shaft
    63
- 5 Preservation and Returning to Service
  
  65
- 6 Maintenance
  
  67
  - 1) Engine Suspension Frame Disassembly
    67
    
    2) Engine Suspension Frame Inspection
    68
    
    3) Engine Suspension Frame Assembly
    68
  - Temperature- and Pressure Observation
    70
Systems Description/Maintenance

71
- 2 Systems Description
  
  75
  - Propeller Gearbox
    75
  - Hydraulic Governor
    77
  - Vacuum Pump
    78
  - Connections for Instrumentation
    78
    
    1) Mechanical Rev Counter and Hourmeter (Optional)
    78
- 3 Maintenance
  
  79
  - Vacuum Pump Removal and Inspection
    79
  - Governor Removal and Inspection
    80
  - Removal of the Fly Wheel Hub
    80
  - Ignition Housing Removal and Inspection
    81
  - Ignition Housing Fitting
    84
  - Sprag Clutch
    85
    
    1) Sprag Clutch Removal
    86
    
    2) Sprag Clutch Dismantling
    87
    
    3) Sprag Clutch Installation
    88
  - Reduction Gear for Electric Starter
    90
  - Rev Counter Drive
    91
  - Propeller Gearbox
    92
    
    1) Removal of Roller Bearing for - Series 2
    97
    
    2) Removal of Roller Bearing for - Series 3
    98
    
    3) Removal of Roller Bearing for - Series 4
    99
    
    4) Propeller Gearbox Disassembly
    100
    
    5) Propeller Shaft Removal
    102
    
    6) Vacuum Pump Drive Removal
    104
    
    7) Propeller Governor Drive Removal
    105
    
    9) Vacuum Pump Drive Installation
    110
    
    10) Gearbox Components Inspection
    111
    
    11) Toothed Shaft Profiles Inspection
    115
    
    13) Propeller Gearbox Reassembly
    121
    
    14) Disc Spring Pre-Tension Adjustment (with Overload Clutch)
    123
    
    15) Disc Spring Pre-Tension Adjustment (with Dog Hub)
    123
    
    16) Propeller Gearbox - Installation
    125
  - Cylinder Head - Removal
    127
  - Cylinder Head - Disassembly
    129
    
    2) Reworking of the Sealing Surface to the Exhaust Manifold
    133
    
    3) Valve Guides
    134
    
    4) Valve Seats
    135
    
    5) Valves
    136
    
    6) Valve Springs
    139
    
    7) Washers
    141
    
    8) Rocker Arm and Rocker Arm Shaft
    142
    
    1) Rocker Arm with Plastic Bushing
    143
    
    Introduction
    143
    
    2) Rocker Arm with Pressed Sinter Bushing
    144
    
    3) Rocker Arm Shaft
    144
  - Cylinder Head Reassembly
    145
    
    Engine
    145
  - Cylinder and Piston - Removal
    147
    
    1) Checking Pistons
    149
    
    2) Checking the Piston Ring
    151
    
    3) Piston Pin
    152
    
    4) Cylinders Inspection
    153
  - Hydraulic Valve Tappets
    155
    
    Lubrication System
    155
    
    Edition 1 / Rev
    157
    
    1) Hydraulic Valve Tappets Fitting
    158
    
    2) Pistons Fitting
    158
    
    Piston and Cylinder Assembly Fitting
    158
    
    3) Cylinders Fitting
    162
    
    4) Cylinder Head Fitting
    164
    
    Crankshaft Inspection
    167
    
    Intake Manifold and Compensation Tube Assembly
    167
- 4 Wear Limits
  
  169

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User Manuals: Rotax MMH-912 Series Engine Maintenance

Rotax MMH-912 Series Maintenance Manual (456 pages)

Table of Contents

Table of Contents

2 List of Chapters

3 Index

4 List of the Valid Pages

5 Table of Amendments

6 General Note

7 Safety Notice

8 Technical Documentation

9 Classification of Parts for Maintenance/Repair

10 Maintenance

Table of Contents

2 System Description

3 Technical Data

4 Treatment of Corrosion and Surface Damage

5 Preservation and Returning to Service

6 Maintenance

Systems Description/Maintenance

2 Systems Description

3 Maintenance

4 Wear Limits

5 Form Sheets

Systems Description/Maintenance

2 Systems Description

3 Maintenance

Systems Description/Maintenance / Troubleshooting

2 Systems Description

3 Maintenance / Troubleshooting

4 Wear Limits

5 Form Sheets

Table of Contents

2 Systems Description

3 Maintenance

4 Wear Limits

Systems Description/Maintenance

2 Systems Description

3 Maintenance

4 Form Sheets

Systems Description/Maintenance

2 Systems Description

3 Maintenance

Table of Contents

2 Systems Description

3 Maintenance

4 Wear Limits

Rotax MMH-912 Series Maintenance Manual (464 pages)

Table of Contents

Table of Contents

2 List of Chapters

3 Index

4 List of the Valid Pages

5 Table of Amendments

6 General Note

7 Safety Notice

8 Technical Documentation

9 Classification of Parts for Maintenance/Repair

10 Maintenance

Table of Contents

2 System Description

3 Technical Data

4 Treatment of Corrosion and Surface Damage

5 Preservation and Returning to Service

6 Maintenance

Systems Description/Maintenance

2 Systems Description

3 Maintenance

4 Wear Limits

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