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MMH-914 Series
Rotax MMH-914 Series Manuals
Manuals and User Guides for Rotax MMH-914 Series. We have
2
Rotax MMH-914 Series manuals available for free PDF download: Maintenance Manual
Rotax MMH-914 Series Maintenance Manual (456 pages)
912/914 Series
Brand:
Rotax
| Category:
Engine
| Size: 15.04 MB
Table of Contents
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
Storage and Preservation Directives for a New Engine
63
Preservation of an Engine Which Has Been in Operation
64
Returning the Engine to Service
64
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
Exhaust System (on the 912 Series)
391
Exhaust System (on the 914 Series)
391
Turbocharger (Only on the 914 Series)
391
1) Exhaust Turbocharger
391
Connections for Instrumentation
393
1) Exhaust Gas Temperature Display (Optional)
393
3 Maintenance
395
Disassembly of the Complete Exhaust System
395
Disassembly of the Complete Exhaust System Incl. Turbocharger
395
Inspection of the Exhaust System and Turbocharger Components
399
(Only on the 914 Series)
399
1) Exhaust Bend and Exhaust Manifold
399
2) Muffler
399
Turbocharger
400
Assembly of the Complete Exhaust System (on the 912 Series)
403
Assembly of the Complete Exhaust System Incl. Turbocharger
403
Owden Cable, Rope Sheave and Spring for Wastegate Control
407
2) Checking of the Components
408
3) Assembly and Adjustment
408
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
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Rotax MMH-914 Series Maintenance Manual (464 pages)
For ROTAX Engine Types
Brand:
Rotax
| Category:
Engine
| Size: 11.73 MB
Table of Contents
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
Storage and Preservation Directives for a New Engine
65
Preservation of an Engine Which Has Been in Operation
66
Returning the Engine to Service
66
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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