OIL RESERVE SYSTEM

OPERATION &
MAINTENANCE
MANUAL
 INDEX

• OIL RESERVE SYSTEM DIAGRAM P1

• OIL RESERVE SYSTEMS P2

- Benefits P2
- Operation - Oil Reserve System P2

• MICRO-GLASS FILTERS P3

• LED MONITOR READINGS P4

- Signals, Oil reserve system - LED in Cab

• ADJUSTMENT OF RUNNING OIL LEVEL P5

• OIL RESERVES P6
- Servicing

• TROUBLESHOOTING P7
- Oil reserve system

• WIRING DIAGRAM P8
- Oil Reserve
- Table connections inside pump units

• PARTS LIST DIAGRAM P9

- Oil Reserve
OIL RESERVE
 OIL RESERVE SYSTEMS

BENEFITS
• Doubles engine oil capacity
• Maintains correct oil level and temperature
• Insurance and unmanned equipment
• Extends oil drain periods (less downtime)
• Guards against overfilling of engine oil
• Early warning system for engine oil loss
• Simplifies daily maintenance

OPERATION - OIL RESERVE SYSTEM

Oil reserve systems are designed to maintain a constant running oil level throughout all types of
conditions, as well as extending oil changed to 500 hours intervals.

Micro-glass filters have been introduced to extend filter life to 500 hours. Standard engine filters
must be changed at 250-hour intervals. (See section on Microglass oil filters, Page 4)

The reserve system works by circulating oil between a remote mounted tank and the engine
sump by using two electrically driven pumps mounted on the reserve tank. The first pump
(Pump 1) runs continuously, withdrawing oil from the sump via a tube set at the correct
operating oil level. When oil is above the bottom of this tube, Pump 1 removes oil from the
sump and delivers it to the reserve tank. Once the oil level drops enough for Pump 1 to start
withdrawing air, the second pump (Pump 2) cuts in and returns oil from the reserve tank to the
sump. The oil level now rises until Pump 1 is no longer withdrawing air, and once again starts
to withdraw oil. Pump 2 now cuts out until Pump 1 starts to draw air again. This process is
repeated constantly, circulating oil between the sump and the tank, as well as maintaining a
close running oil level. The operation of the pumps and oil level is monitored by a LED light
mounted in the cab.

The Oil Reserve system uses an oil pressure switch, which will not allow the reserve system to
run on accessories, draining the battery voltage when the engine is not running. A tank air relief
valve (TRV) is used, as reserve tanks are not vented to atmosphere. The lightly loaded TRV
allows air in the tank, introduced by the withdrawal tube, to be vented into the oil return line.
This eliminates the chance of excessive pressure build-up in the tank. It also acts as an
anti-syphoning valve.
Venturi Combo Filtration.
Cummins recommend the use of micro-glass filters, which are full flow filters and replace
standard cellulose media type filters. These filters use a media formulated from glass fibres.
This technology provides:

• Improved filtration efficiency and longer service life.

• Increased particle retention
• Cold start-up protection due to reduced oil flow restriction
• Superior structural integrity
• Better moisture resistance

The micro glass filter has been introduced in conjunction with the oil reserve and burn systems.
The improved media allows 500 hours between servicing compared to 250 hours with standard
cellulose filters. The table below shows the micro-glass part numbers.

ENGINE VENTURI COMBO CROSS REFERENCE

Cummins XLF1000 LF-670

Caterpillar XLF2000 LF-691 (Fleetguard)
2P-4005 (Caterpillar)
Detroit Diesel XLF4000 LF-3333 (Fleetguard)
PF-911 (AC)

NOTE: Venturi Combo filters replace engine full flow filters, bypass filters are not
available with micro-glass media. However, when used on the oil reserve system
in conjunction with Venturi Combo filters, the life of the bypass filter is extended to
500 hours.
 LED MONITOR READINGS

SIGNALS
OIL RESERVE SYSTEM - LED IN CAB

1. SOLID Pump 1 is running and oil is being transferred

from sump to reserve tank.

2. BLINKING LIGHT (PULSATING) Indicates both pumps are running and oil is
being transferred from reserve tank to
engine sump.

3. ALTERNATION MODE A combination of Solid and Blinking modes.

This indicates that the required oil level
is being maintained.

The above signals should be monitored continuously by the operator. The Alternation Mode
should be constant during normal operating conditions. If the LED signal is only a steady or
blinking mode, this indicates a problem and should be investigated immediately.

NOTE: Steady and blinking modes will occur for short periods of time when there is a
sudden change in working conditions.

ie. Start up and warming of engine

Gradient change
Speed change

A short period of time is needed for the reserve system to restore the correct
running level. This is confirmed when the LED light indicated the Alteration
mode.
 ADJUSTMENT OF RUNNING OIL LEVEL

1. Start the engine and run at high idle until the LED light indicates a stable oil level
had been reached (Alteration mode).

2. After this has occurred, check the running oil level at idle (Caterpillar) or shutdown
the engine and allow the oil to drain back and check the static full mark (Detroit/
Cummins). If oil is not on the full mark, withdrawal tube needs adjusting.

3. To raise the oil level, trim withdrawal tube to the equivalent distance the dipstick was
underfull. To lower the oil level, extend the withdrawal tube the same distance the
dipstick was overfull. When this is complete, carry out Steps 1 - 3 again, unit the
correct oil level is maintained.

4. Check running oil level under all conditions if possible.

NOTE This operation is only necessary during the original fitment of the Oil Reserve
System. Once adjusted only daily checks of the oil reserve tanks should be
necessary.
 OIL RESERVES

SERVICING
IMPORTANT Oil reserve tank is filled 3/4 of total capacity (as marked on sight glass).
Ensure that engine and reserve tanks are not overfilled.

PRE-START (DAILY)

• Check oil before start-up at reserve tank - top up if necessary

• Check engine dipstick as precaution
• Check oil level at least once a shift

DURING OPERATION

• Operator must be familiar with LED signals and is required to report any unusual
operation.

250 HOURS

• Change oil filters if not micro-glass

• Collect engine oil sample for analysis
• Check operation of system

500 HOURS

• Check operation of LED.

• Check electrical connections for tightness and inspect cables.
• Examine hoses for damage, checking tightness of fittings also.
• Drain oil from both engine and reserve system.
• Remove and replace filters on engine and reserve tank (pre-fill filters).
• Refill both engine and reserve tank to correct levels.
 TROUBLESHOOTING

OIL RESERVE SYSTEM

1. Check engine oil is at static full level and oil reserve system is full.

2. Jump oil pressure switch to activate pump

If electric pump or LED light is dead, check battery voltage at pumping unit
terminals
If there is no voltage, the unit has an electrical fault.
If there is power, check operation of pumps.

3. Check Pump 1 (withdrawal pump)

Loosen outlet line (tank return oil line), this line should have a pulsating flow
oil, and the LED will be in the Solid Mode.
If no oil is present, there is a problem with Pump 1.
if oil is present, check operation of Pump 2.

4. Pump 2 is triggered by admitting air into the inlet side of Pump 1.

Remove oil supply (sump withdrawal line) from Pump 1 to induce this.
Pump 2 should begin to deliver oil after this step, check this by removing Pump 2
outlet hose (return oil line to sump). The LED light will now be pulsating (blinking)
If there is no oil coming out of this line, there is a problem with Pump 2.

NOTE: Check operation of the reserve pumps on the oil burn system the same as for
regular reserve systems.
 WIRING DIAGRAM - OIL RESERVE

CONNECTIONS INSIDE PUMP UNIT

R200
UNIT CABLE
RED WHITE
BLACK BLACK
YELLOW GREEN
 OIL RESERVE
PARTS LIST DIAGRAM

OIL RESERVE PARTS LIST

PART NO. DESCRIPTION QTY

1 R2000-24 X X X X X PUMP RESERVE SYSTEM 1
6 FC-15-24N X X X X X DIPSTICK 1
8 4053X X X X X SIGHT GLASS 1
9 LF777 X X X X X BYPASS FILTER RESERVE SYSTEM 1
10 3304173 X X X X X FILTER HEAD (OIL BYPASS) 1
11 TRV-12-6-6 X X X X X TANK RELIEF VALVE 1
13 76575-04 X X X X X MAIN PRESSURE SWITCH 1
14 SL50R X X X X X LED 1
16 FB-6-12 X X X X X SUMP ADAPTOR 1
 CUMMINS

RESERVE OIL SYSTEMS

DIRECTIONS FOR MAINTENANCE

 DAILY INSPECTION.

Check oil level on Engine Dipstick and Oil Tank dipstick, oncer per shift.

NOTE: DO NOT add oil to engine for top up, only ADD oil to tank if top up is required.
(System will automatically top up engine whilst running.)

 OIL/FILTER CHANGE.

 Drain both Engine Oil Pan and Oil Tank

 Replace Filters as necessary
 Connect Oil Supply to WIGGINS Fitting
 Position Oil Supply Valve towards engine and fill to Dipstick high mark
 Turn Oil Supply Valve to Oil Tank and fill to Dipstick high mark
 Reposition Oil Supply Valve to ‘Flow In’ position

 RESERVE SYSTEM DASH LIGHT.

When light is constantly on, Pump 1 is withdrawing oil from Sump and reducing oil level.

When light is pulsing at regular intervals, pump is returning oil to sump and raising oil
level.

If light is pulsing at irregular intervals, oil is at correct running level.