FUEL SYSTEM. Table of Contents. Section 3C Oil Injection

Transcription

1 Tle of Contents FUEL SYSTEM Section 3C Oil Injection OIL INJECTION Specil Tools C-2 Oil System Opertion C-2 Oil Pump Output C-2 Oil System Oil Hose Instlltion C-3 Oil Pump Removl nd Instlltion C-4 Engine Oil Reservoir Removl nd Instlltion C-5 Priming the Oil Pump C-6 Priming Procedure Method C-7 Remote Oil Hose Connections C-8 Filling the Oil Tnks C-9 Purging Air From the Engine Oil Reservoir nd Remote Oil Hose C-9 Oil Wrning Systems C-10 Oil System Trouleshooting C-12 Low Oil Wrning System is Activted C-12 3 C JANUARY 2001 Pge 3C-1

2 Specil Tools 1. Gercse Lekge Tester (FT-8950) Oil System Opertion Oil Pump Output Oil in this engine is not mixed with the fuel efore entering the comustion chmer. Oil is stored inside the remote oil tnk in the ot. Crnkcse pressure forces oil from the remote oil tnk into the engine oil reservoir. The engine oil reservoir feeds oil to the oil pump. The oil pump is ECM driven nd controls oil distriution to the crnkcse nd ir compressor. The oil pump hs seven oil dischrge ports. Six of the oil dischrge ports inject oil into the crnkcse through hoses, one hose for ech cylinder. The lst oil dischrge port dischrges oil into the ir compressor for luriction. Unused oil from the ir compressor returns to the top min ering. The ECM is progrmmed to utomticlly increse the oil supply to the engine during the initil engine rek-in period. The oil rtio is douled during the first 120 minutes of opertion whenever engine speed exceeds 2500 RPM nd is under lod; elow 2500 RPM the oil pump provides oil t the norml rtio. After the engine rek-in period, the oil rtio will return to norml :1 t idle to 40:1 t WOT. Using the DDT to ctivte uto prime, the oil pump should dischrge 110 ml (cc) ± 8 ml (cc) during the uto prime time period. To check the oil pump output: Verify the onord oil reservoir is full. Relese ny pressure (loosen cp) from the remote oil tnk in the ot. With engine not running, use the DDT to ctivte the uto prime. Using ml or cc grduted continer, record the mount of oil needed to refill the onord oil reservoir. Retighten cp on the remote oil tnk in the ot. Pge 3C JANUARY 2001

3 Oil System Oil Hose Instlltion OIL INJECTION i j k h g c f e d -Remote Oil Tnk -Engine Oil Reservoir c -Filter d-oil Supply Hose to the Oil Pump e -Oil Supply Hose to Lower Crnkshft Bering f -Oil Pump g-oil Supply Hoses to the Cylinders (6) h-fitting nd Check Vlve (8) i -Oil Supply Hose to Upper Crnkshft Bering j -Oil Supply Hose to the Air Compressor k -Air Compressor JANUARY 2001 Pge 3C-3

4 Oil Pump Removl nd Instlltion REMOVAL 1. Disconnect the wiring hrness from the pump. 2. Disconnect the oil hoses. 3. Remove three olts nd remove pump. e f c d Oil Pump -Bushing (3) c -Ruer Grommet (3) Insert into Hole d-wsher (3) e -Bolt (3) Torque to 12 l. ft. (16 Nm) f -St-Strps Fsten All Hose Ends INSTALLATION 1. Instll pump s shown. 2. Reconnect the oil hoses. Refer to Oil Injection Hose Instlltion for correct loction. Fsten hoses to pump fittings with st-strps. 3. Connect the wiring hrness. 4. Refill the oil system. Refer to Priming the Oil Pump. Pge 3C JANUARY 2001

5 Engine Oil Reservoir Removl nd Instlltion REMOVAL 1. Disconnect the oil hoses. Plug the hoses to prevent spillge. 2. Disconnect the BLUE with BLACK STRIPE wire leds. 3. Remove three olts securing oil tnk to powerhed nd remove tnk. OIL INJECTION j i g c h f e k c d INSTALLATION -Oil Reservoir -Bushing (3) c -Ruer Grommet (3) Insert into Holes d-j-clip e -Decl f -Bolt (3) Torque to 170 l. in. (19 Nm) 1. Instll oil reservoir s shown. 2. Fsten the oil hoses with st-strps. 3. Connect the BLUE with BLACK STRIPE wire leds. 4. Refill the oil system. Refer to Priming the Oil Pump. g-wsher (3) h-wsher i -Screw (Drive Tight) j -Low Oil Switch (Normlly Closed Circuit) k -BLUE/BLACK Leds JANUARY 2001 Pge 3C-5

6 Priming the Oil Pump NOTE: If new powerhed is eing instlled or oil hoses/oil pump hs een removed, it is recommended ll ir e purged from oil pump/oil lines using gercse lekge tester (FT-8950). Connect the lekge tester to the inlet t-fitting on the onord oil reservoir. While clmping off the inlet hose, mnully pressurize the reservoir to 10 psi. Using the Digitl Dignostic Terminl A2, ctivte the oil pump prime sequence. Mintin the 10 psi pressure throughout the uto prime sequence. When the uto prime is completed, remove the lekge tester nd refill the onord oil reservoir Priming the oil pump (filling pump nd hoses using pressure) is required on new or reuilt power heds nd ny time mintennce is performed on the oiling system tht llows ir into the oil system. There re three methods for priming the oil pump: METHOD 1 SHIFT SWITCH ACTIVATION PRIME This method does three things:. Fills the oil pump, oil supply hose feeding pump nd oil hoses going to the crnkcse nd ir compressor.. Activtes rek-in oil rtio. c. Initites new 120 minute engine rek-in cycle. Refer to priming procedure following. METHOD 2 (DDT) DIGITAL DIAGNOSTIC TERMINAL RESET BREAK-IN This method is the sme s Method 1, except the run history nd fult history re ersed from the ECM. Refer to procedure in the Technicin Reference Mnul provided with the Digitl Dignostic Softwre Crtridge Prt. No for Model Yer Use crtridge for Model Yer METHOD 3 (DDT) DIGITAL DIAGNOSTIC TERMINAL OIL PUMP PRIME This method fills the oil pump, oil supply hose feeding pump, nd oil hoses going to the crnkcse nd ir compressor. Refer to procedure in the Technicin Reference Mnul provided with the Digitl Dignostic Softwre Crtridge Prt. No for Model Yer 2000 nd crtridge for Model Yer Conditions Requiring Priming the Oil Pump Condition Priming Procedure New engine Use Method 1 or 2 Reuilt Powerhed Use Method 1 or 2 Pge 3C JANUARY 2001

7 Conditions Requiring Priming the Oil Pump (Continued) New Powerhed Use Method 1 or 2 Oil system rn out of oil Use Method 3 Oil drined from oil supply hose feeding pump Use Method 3 Oil pump removed Use Method 3 Oil injection hoses drined Use Method 3 Priming Procedure Method 1 METHOD 1 SHIFT SWITCH ACTIVATION PRIME PROCEDURE Before strting engine for the first time, prime the oil pump. Priming will remove ny ir tht my e in the pump, oil supply hose, or internl pssges. -Oil Injection Pump -Oil Supply Hose CAUTION To prevent dmge to the fuel pumps, fill the engine fuel system with fuel. Otherwise the fuel pumps will run without fuel during the priming process. Prime the oil injection pump s follows: d. Fill the engine fuel system with fuel. Connect fuel hose to fuel lift pump (). e. Turn the ignition key switch to the ON position. f. Within the first 10 seconds fter the key switch hs een turned on, move the remote control hndle from neutrl into forwrd ger 3 to 5 times. This will utomticlly strt the priming process JANUARY 2001 Pge 3C-7

8 F N NOTE: Audile click from the oil pump will tell you the pump is priming. It my tke few minutes for the pump to complete the priming process. Remote Oil Hose Connections Remove shipping cp from fitting nd connect oil hose (). Fsten hose with st-strp. NOTE: Oil hose with BLUE stripe contins directionl filter which is designed to trp ny deris in the oil efore the oil reches the engine oil reservoir. The filter is mrked with n rrow denoting direction of flow of oil nd should e instlled ccordingly. Should engine oil reservoir oil level drop while remote oil tnk oil level is norml, oil flow through inline filter hs een reduced y deris nd filter must e replced. -Oil Filter -Oil Hose with Blue Stripe Pge 3C JANUARY 2001

9 CONNECTING OIL HOSE WITHOUT BLUE STRIPE OIL INJECTION 1. Remove shipping cp from fitting nd connect hose (). Fsten hose with st-strp. Filling the Oil Tnks -Oil Hose Without Blue Stripe Fill remote oil tnk with the recommended oil listed in the Opertion nd Mintennce Mnul. Tighten fill cp. 2. Remove cp nd fill engine oil tnk with oil. Reinstll the fill cp. 3. Remove ir from remote oil hose. Refer to Purging Air from the Engine Oil Reservoir nd Remote Oil Hose. c -Fill Cp -Engine Oil Reservoir c -Fill Cp Purging Air From the Engine Oil Reservoir nd Remote Oil Hose NOTE: Before strting engine, mke sure the oil pump hs een primed. 1. Strt the engine. Run the engine until ll the ir hs een vented out of the reservoir nd oil strts to flow out of the reservoir. Re-tighten fill cp. -Fill Cp JANUARY 2001 Pge 3C-9

10 Oil Wrning Systems The 200 Jet Drive incorportes n Engine Gurdin System within the ECM to monitor criticl engine functions through sensors on the engine. The opertor cn e notified of impending norml engine conditions udily through wrning horn (4 intermittent eeps) nd/or visully y System Monitor or Smrtcrft guges. LOW OIL LEVEL System Monitor Alrm Low Oil Reserve: The ell nd oil icons re displyed nd the wrning horn egins sounding series of four eeps every two minutes to inform the driver tht the oil level is criticlly low in the engine mounted oil reservoir tnk. When the oil level gets close to empty, the horn egins sounding continuously nd the Engine Gurdin System will strt limiting engine power. The engine mounted oil reservoir tnk long with the remote oil tnk will hve to e refilled. Smrtcrft Guge 6 Alrm Low Oil Reserve: This messge is displyed nd the wrning horn egins sounding series of four eeps every two minutes to inform the driver tht the oil level is criticlly low in the engine mounted oil reservoir tnk. When the oil level gets close to empty, the horn egins sounding continuously nd the Engine Gurdin System will strt limiting engine power. The disply shows percent of reserve oil tht s remining. The engine mounted oil reservoir tnk long with the remote oil tnk will hve to e refilled Pge 3C JANUARY 2001

11 OIL PUMP NOT FUNCTIONING ELECTRICALLY OIL INJECTION System Monitor Alrm Oil Pump Fult: The Bell, Engine nd oil icons re displyed nd the wrning horn egins sounding continuously to inform the driver tht the oil pump hs stopped functioning electriclly. No luricting oil is eing supplied to the engine. Stop the engine s soon s possile. The Engine Gurdin system will strt limiting the engine power. Smrtcrft Guge 7 Alrm Oil Pump Fult: This messge is displyed nd the wrning horn egins sounding continuously to inform the driver tht the oil pump hs stopped functioning electriclly. No luricting oil is eing supplied to the engine. Stop the engine s soon s possile. The Engine Gurdin system will strt limiting the engine power JANUARY 2001 Pge 3C-11

12 Oil System Trouleshooting Low Oil Wrning System is Activted Prolem Prolem Prolem Prolem Low oil level in engine oil reservoir nd in either tnk Oil level is not low lso remote oil tnk Low oil level in engine oil reservoir ut not low in remote oil tnk Note: Oil level in engine oil reservoir should e up to the fill cp Air ws never purged from engine oil tnk Fill cp is leking ir on remote tnk Refill oth oil tnks. Purge ir from engine oil tnk. Refer to procedure Disconnect BLUE/ BLACK wires going to the low oil flot switch in the engine oil reservoir. Check switch for continuity Purge ir from engine oil tnk. Refer to procedure Cps on remote tnk must e seled nd instlled tight Oil leks out of exhust or #6 cylinder Pulse hose nd oil supply hose re reversed Bot oil tnk is mounted higher thn pulse hose fitting on engine nd oil tnk is over-filled Remote oil hoses locked or punctured Check hoses for kink or lekge Restricted oil outlet filter in remote oil tnk Remove filter nd clen Restricted oil inlet filter in oil hose efore engine oil reservoir Replce oil filter Air lek in upper portion on the oil pickup tue Replce tue Fulty pressure check vlve. Locted in engine t end of (lck without lue stripe) remote oil hose Replce check vlve No Continuity Remove engine oil reservoir cp nd use wire to pull flot to top of trvel Continuity Check for open wire etween oil flot switch nd ECU No Continuity Oil Flot switch is fulty. Replce switch Continuity Flot in oil tnk is fulty. Replce oil tnk Pge 3C JANUARY 2001