Mercury OptiMax: No Oil Flow From Main to Under-Cowling

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Author Topic:   Mercury OptiMax: No Oil Flow From Main to Under-Cowling

Livingwater posted 05-12-2006 02:39 PM ET (US)
So far I have run my [Mercury 150-HP OptiMax engine] only twice. Each time I had to bleed air out of the [under-cowling] oil tank in order for the system to fill the [under-cowling] oil tank and start drawing oil from the [remote] tank. If I don't bleed out the air at the [under-cowling oil] tank the system will continue to draw oil only from the [under-cowling oil tank]. My main oil tank is approximately 95/100th-Full.
dr john posted 05-12-2006 08:53 PM ET (US)
I have a similar problem with a pair of 2002 Mercury OptiMax 225 motors. The dealer has not fixed it in multiple attempts. I end up adding oil to [the under-cowling oil tank in order] to stop the alarms. This has become a real problem
bsmotril posted 05-15-2006 10:23 AM ET (US)
Oil is moved from the main tank to the under-cowling tank by air which pressurizes the main tank. If your main tank is not holding air pressure, you'll never fill the under cowling tank. With the motor running for about four minutes, remove the cap to the main tank. You should hear a hiss as the air pressure leaks out. If no hiss, there's your problem. Your main tank or its cap is leaking, or the air pressure system is leaking or not generating air pressure. It's not rocket science, just basic troubleshooting. BillS
Livingwater posted 05-21-2006 11:43 AM ET (US)
Ran the Optimax 150 yesterday and to my delight I didn't have a reserve oil alarm. Last thing I did to the 190 Nantucket was tighten down on the oil fill cap.
Also, can't help but comment on how easily the Optimax starts.
jimh posted 05-21-2006 12:35 PM ET (US)
It sounds like Mercury is using the same oil supply system in the OptiMax as they did in earlier motors. This system is described in detail in the REFERENCE section. See:
Mercury Oil Injection System
http://continuouswave.com/whaler/reference/mercuryOilInjection.html
The article includes advice on how to diagnose problems with the oil supply system. As you have noted, the system uses a pressurization of the remote oil tank to force oil flow to the motor. There is a procedure given for how to bleed air from the system.
dr john posted 05-22-2006 09:33 AM ET (US)
Any other thoughts as to why this problem continues to occur on a pair of Mercury OptiMax 225 motors? I have good pressure, no leaks and after three hours running I get the oil reserve alarm and oil is being depleted from the reservoir despite a full remote tank. I top off the reservoir to get rid of alarm; the problem reoccurs again over time. Dealer can't fix it and last week, I watched the port engine blow smoke and empty the reservoir [to half-full] while at idle in four minutes. I hope this latest development will help the dealer. Thank you in advance for any help.
bsmotril posted 05-22-2006 10:29 AM ET (US)
Oil flow is electronically controlled by the engine computer, and the frequency of the pulses it sends to the electric oil pump. If it is drawing oil so fast that you can watch it go down in the under-cowling tank there is something wrong with the control system to regulate oil flow. But, before you start looking at the expensive oil pump and computer, I'd do one more diagnostic test first. Try this:
Remove the oil hose (not the air hose) from the remote tank. Start the motor, and see if you get oil coming out the fitting on the remote tank where you removed the hose. If you don't you have some kind of obstruction in the tank pickup. The pickup has a very fine mesh filter screen and it gets surprisingly dirty and clogged with a thickened film of who knows what. I clean mine annually. If all looks good and oil flows out that fitting, then put the hose back on and go ahead and remove it inside the engine cowl where it attaches to the under cowl tank. Plug the fitting where you removed the hose, start the motor, and see if after a few minutes you get oil out the hose. If yes, then I would suspect some kind of problem with the ECU and Pump. If no, then something under the deck is obstructing the hose. BillS
SebastianFL posted 05-22-2006 11:27 PM ET (US)
I have a pair of 2001 OptiMax 225-HP motors. On the last fishing trip on way back in I received a SmartCraft warning on the starboard tachometer. Happened coming through rough inlet with large standing waves (not sure if this had anything to do with triggering alarm). Warning message stated 'RESERVE - 100% Oil Remaining' and beeped intermittently. I checked engine reserve tank and it was full. Remote tank had about two gallons. I suspected the reserve low-oil sensor may be faulty so I purchased a new one for troubleshooting purposes, along with a maintenance manual. What did I find out? I did a continuity check on suspect sensor (with it still installed) and it was an open circuit (not good according to manual for a 2001 model). So I installed new one and did same continuity check and same results (not what I was expecting if sensor was bad). So what could it be, after all tank is full. Puzzled, I decided to check port side engine sensor for comparison and it checked out just fine. Note: Port and starboard side engine oil tank levels are about the same. I then tested both the suspect (starboard) and new sensor(s) in the port oil resevoir; they both check out fine. As I slowly pulled the sensor(s) out of the port tank, the continuity state changes when the top of the sensor is raised 1/4-inch up out of its seat. However, this does not happen on the starboard side. I physically left sensor connected to multi-meter and raised it out of starboard tank (where it doesn't work) and placed it into port tank and it checks out fine. The only thing changed was the tank location. Is there something in the sensor receive housing or sensor seat that could be bad? Why do all three (port, starboard, and new) sensors check out in port tank but not in starboard tank? I topped off tank to ensure it was full and still same results. What in the suspect starboard tank is different from the good port tank? Any help would greatly appreciated. Thanks in advance-Jeff
dr john posted 05-23-2006 10:55 AM ET (US)
My problem started out with 100% reservoir oil alarm without under-cowling tank level decrease only to have this problem worsen with time. There is a check valve between the tanks and this can go bad. [Made reference to other resource but did not give uniform resource locator.] The dealer is back this week and I will let you know. If the reservoir continues to stay full it may be the sensor but your problem may just be beginning.
SebastianFL posted 05-23-2006 11:03 PM ET (US)
I have an update: I talked to my mechanic and described my troubleshooting results. My partial diagnosis was any good low oil sensor would work in my port engine oil reserve tank but not in my starboard tank. So I concluded there must be something wrong with the starboard tank since the sensor checked out good in other tank. Final diagnosis (after talking to my mechanic)is the low oil sensor "receive housing" (the hole or sleeve that sensor drops into) has a magnetic float built into it and if the magnetic float gets stuck in down position then the magnet can't move up with oil level to trip the sensor, and a false low oil event occurs. If the sensor checked out good with a continuity check (with sensor inserted into full tank with a working magnetic float in the sensor receive housing of that good tank), then the only thing left is the other half of the sensor assembly in the suspect tank, and that is the magnetic float. Unfortunately the housing that the sensor fits into is not removable from the tank so you have to buy a new tank. So that is the solution. Remember, the low oil sensor has two pieces to it: the sensor probe that you remove from the tank, and the mating magnetic float which is built into the oil tank sensor housing. Without this magnet, sensor doesn't work. In fact, what makes the sensor trip is simply a magnetic field. If you remove the probe from tank and move a magnet close to it, while having the two sensor leads connected to multi-meter for continuity check, you will be able to hear the sensor trip by moving the magnet to and from sensor. What moves the magnet in the oil tank? It is simply the oil that floats the magnet up and down as oil level changes. And as I have learned, if that magnetic float gets stuck in the down position, then a false low oil condition occurs. My mechanic says he has seen this before so be on the look out next time you get a low oil alarm and your tank is full. Hope this helps others in their troubleshooting efforts. Thanks-Jeff
SebastianFL posted 05-23-2006 11:09 PM ET (US)
[Says he found the other article which was not identified by a uniform resource locator.] I learned some more important diagnostic information from reading the thread. Thanks again and good luck with your troubleshooting. Jeff
rsess1 posted 05-24-2006 09:13 AM ET (US)
That is very important information regarding the magnetic float. Thank you for sharing this. I think anyone with SmartCraft gauges (including myself) has seen this LOW OIL alarm once in a while and its a pain in the "ss. I used to get CHECK PITOT also. I think Jim is right in other posts about the lack of information in the owner's manual about SmartCraft. The system is fantastic when you need it but the false alarms are a nuisance. In my case the false alarms have not caused loss of [engine speed] and always reset so it is only an inconvenience. I love the safety factor of the system, and know it will improve in years to come.
njwhaler posted 08-07-2008 10:38 PM ET (US)
I am having similar problems with my 2002 Mercury OptiMax 135. The alarm went off with four beeps every two mininutes, and my reservoir was full. Actually, I filled the oil reservoir, ran the boat for 10 minutes, then the alarm began to sound.
I called Mercury and the representative on the phone said BEEP BEEP BEEP BEEP (four beeps) can only be the sensor at the cap. He told me to tighten the cap. If that didn't work, then all I needed was a new cap and sensor.
I asked him if it could be anything else because I am worried about oil not getting to the motor. He said, "no, if you have oil in the tank, then you are good to go."
After reading the posts, I am concerned whether this guy has given me accurate information.
jimh posted 08-08-2008 08:15 AM ET (US)
In any alarm system, the alarm can only respond to input from the sensors available. So far in this discussion the only sensor identified has been the magnetically operated float level switch in the under-cowling oil tank assembly. When the oil level is low (or if the float mechanism becomes stuck) the sensor--a magnetically operated switch--operates and causes an alarm which is apparently signaled by sounding of four beeps.
No other sensor has been mentioned in the oil system monitoring. I do not have good information about the OptiMax oil monitoring system. Perhaps some Mercury mechanics can contribute additional information to this discussion.
The question at hand: Are there any other sensors in the Mercury OptiMax which monitor the oil flow or oil level?
bluewaterpirate posted 08-08-2008 03:47 PM ET (US)
There is a small inline filter in the oil line bewteen the primary on boat tank and the on motor oil tank. That filter should be replaced every year. Also, enusre all your oil fittings are securely connected and secured with plastic cable ties.
In the picture follow the oli line to the left to you see white pencil size inline oil fliter. I replaced the oil sensor on the motor at 2000 hours.
http://cdn-2-service.phanfare.com/images/4892322_2159335_31001591_Web_4/ Image-4892322-31001591-2-Web_0_91059f20c309fe4ec1b0bc9def8399c8_1
jross036 posted 08-09-2008 03:16 AM ET (US)
The only other oil warning you should hear is if the pump fails , then the ecm will recognize this. Magnetic float problem is common, especially on the older ones. I just replaced both my tanks.

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Author	Topic: Mercury OptiMax: No Oil Flow From Main to Under-Cowling
Livingwater	posted 05-12-2006 02:39 PM ET (US) So far I have run my [Mercury 150-HP OptiMax engine] only twice. Each time I had to bleed air out of the [under-cowling] oil tank in order for the system to fill the [under-cowling] oil tank and start drawing oil from the [remote] tank. If I don't bleed out the air at the [under-cowling oil] tank the system will continue to draw oil only from the [under-cowling oil tank]. My main oil tank is approximately 95/100th-Full.
dr john	posted 05-12-2006 08:53 PM ET (US) I have a similar problem with a pair of 2002 Mercury OptiMax 225 motors. The dealer has not fixed it in multiple attempts. I end up adding oil to [the under-cowling oil tank in order] to stop the alarms. This has become a real problem
bsmotril	posted 05-15-2006 10:23 AM ET (US) Oil is moved from the main tank to the under-cowling tank by air which pressurizes the main tank. If your main tank is not holding air pressure, you'll never fill the under cowling tank. With the motor running for about four minutes, remove the cap to the main tank. You should hear a hiss as the air pressure leaks out. If no hiss, there's your problem. Your main tank or its cap is leaking, or the air pressure system is leaking or not generating air pressure. It's not rocket science, just basic troubleshooting. BillS
Livingwater	posted 05-21-2006 11:43 AM ET (US) Ran the Optimax 150 yesterday and to my delight I didn't have a reserve oil alarm. Last thing I did to the 190 Nantucket was tighten down on the oil fill cap. Also, can't help but comment on how easily the Optimax starts.
jimh	posted 05-21-2006 12:35 PM ET (US) It sounds like Mercury is using the same oil supply system in the OptiMax as they did in earlier motors. This system is described in detail in the REFERENCE section. See: Mercury Oil Injection System http://continuouswave.com/whaler/reference/mercuryOilInjection.html The article includes advice on how to diagnose problems with the oil supply system. As you have noted, the system uses a pressurization of the remote oil tank to force oil flow to the motor. There is a procedure given for how to bleed air from the system.
dr john	posted 05-22-2006 09:33 AM ET (US) Any other thoughts as to why this problem continues to occur on a pair of Mercury OptiMax 225 motors? I have good pressure, no leaks and after three hours running I get the oil reserve alarm and oil is being depleted from the reservoir despite a full remote tank. I top off the reservoir to get rid of alarm; the problem reoccurs again over time. Dealer can't fix it and last week, I watched the port engine blow smoke and empty the reservoir [to half-full] while at idle in four minutes. I hope this latest development will help the dealer. Thank you in advance for any help.
bsmotril	posted 05-22-2006 10:29 AM ET (US) Oil flow is electronically controlled by the engine computer, and the frequency of the pulses it sends to the electric oil pump. If it is drawing oil so fast that you can watch it go down in the under-cowling tank there is something wrong with the control system to regulate oil flow. But, before you start looking at the expensive oil pump and computer, I'd do one more diagnostic test first. Try this: Remove the oil hose (not the air hose) from the remote tank. Start the motor, and see if you get oil coming out the fitting on the remote tank where you removed the hose. If you don't you have some kind of obstruction in the tank pickup. The pickup has a very fine mesh filter screen and it gets surprisingly dirty and clogged with a thickened film of who knows what. I clean mine annually. If all looks good and oil flows out that fitting, then put the hose back on and go ahead and remove it inside the engine cowl where it attaches to the under cowl tank. Plug the fitting where you removed the hose, start the motor, and see if after a few minutes you get oil out the hose. If yes, then I would suspect some kind of problem with the ECU and Pump. If no, then something under the deck is obstructing the hose. BillS
SebastianFL	posted 05-22-2006 11:27 PM ET (US) I have a pair of 2001 OptiMax 225-HP motors. On the last fishing trip on way back in I received a SmartCraft warning on the starboard tachometer. Happened coming through rough inlet with large standing waves (not sure if this had anything to do with triggering alarm). Warning message stated 'RESERVE - 100% Oil Remaining' and beeped intermittently. I checked engine reserve tank and it was full. Remote tank had about two gallons. I suspected the reserve low-oil sensor may be faulty so I purchased a new one for troubleshooting purposes, along with a maintenance manual. What did I find out? I did a continuity check on suspect sensor (with it still installed) and it was an open circuit (not good according to manual for a 2001 model). So I installed new one and did same continuity check and same results (not what I was expecting if sensor was bad). So what could it be, after all tank is full. Puzzled, I decided to check port side engine sensor for comparison and it checked out just fine. Note: Port and starboard side engine oil tank levels are about the same. I then tested both the suspect (starboard) and new sensor(s) in the port oil resevoir; they both check out fine. As I slowly pulled the sensor(s) out of the port tank, the continuity state changes when the top of the sensor is raised 1/4-inch up out of its seat. However, this does not happen on the starboard side. I physically left sensor connected to multi-meter and raised it out of starboard tank (where it doesn't work) and placed it into port tank and it checks out fine. The only thing changed was the tank location. Is there something in the sensor receive housing or sensor seat that could be bad? Why do all three (port, starboard, and new) sensors check out in port tank but not in starboard tank? I topped off tank to ensure it was full and still same results. What in the suspect starboard tank is different from the good port tank? Any help would greatly appreciated. Thanks in advance-Jeff
dr john	posted 05-23-2006 10:55 AM ET (US) My problem started out with 100% reservoir oil alarm without under-cowling tank level decrease only to have this problem worsen with time. There is a check valve between the tanks and this can go bad. [Made reference to other resource but did not give uniform resource locator.] The dealer is back this week and I will let you know. If the reservoir continues to stay full it may be the sensor but your problem may just be beginning.
SebastianFL	posted 05-23-2006 11:03 PM ET (US) I have an update: I talked to my mechanic and described my troubleshooting results. My partial diagnosis was any good low oil sensor would work in my port engine oil reserve tank but not in my starboard tank. So I concluded there must be something wrong with the starboard tank since the sensor checked out good in other tank. Final diagnosis (after talking to my mechanic)is the low oil sensor "receive housing" (the hole or sleeve that sensor drops into) has a magnetic float built into it and if the magnetic float gets stuck in down position then the magnet can't move up with oil level to trip the sensor, and a false low oil event occurs. If the sensor checked out good with a continuity check (with sensor inserted into full tank with a working magnetic float in the sensor receive housing of that good tank), then the only thing left is the other half of the sensor assembly in the suspect tank, and that is the magnetic float. Unfortunately the housing that the sensor fits into is not removable from the tank so you have to buy a new tank. So that is the solution. Remember, the low oil sensor has two pieces to it: the sensor probe that you remove from the tank, and the mating magnetic float which is built into the oil tank sensor housing. Without this magnet, sensor doesn't work. In fact, what makes the sensor trip is simply a magnetic field. If you remove the probe from tank and move a magnet close to it, while having the two sensor leads connected to multi-meter for continuity check, you will be able to hear the sensor trip by moving the magnet to and from sensor. What moves the magnet in the oil tank? It is simply the oil that floats the magnet up and down as oil level changes. And as I have learned, if that magnetic float gets stuck in the down position, then a false low oil condition occurs. My mechanic says he has seen this before so be on the look out next time you get a low oil alarm and your tank is full. Hope this helps others in their troubleshooting efforts. Thanks-Jeff
SebastianFL	posted 05-23-2006 11:09 PM ET (US) [Says he found the other article which was not identified by a uniform resource locator.] I learned some more important diagnostic information from reading the thread. Thanks again and good luck with your troubleshooting. Jeff
rsess1	posted 05-24-2006 09:13 AM ET (US) That is very important information regarding the magnetic float. Thank you for sharing this. I think anyone with SmartCraft gauges (including myself) has seen this LOW OIL alarm once in a while and its a pain in the "ss. I used to get CHECK PITOT also. I think Jim is right in other posts about the lack of information in the owner's manual about SmartCraft. The system is fantastic when you need it but the false alarms are a nuisance. In my case the false alarms have not caused loss of [engine speed] and always reset so it is only an inconvenience. I love the safety factor of the system, and know it will improve in years to come.
njwhaler	posted 08-07-2008 10:38 PM ET (US) I am having similar problems with my 2002 Mercury OptiMax 135. The alarm went off with four beeps every two mininutes, and my reservoir was full. Actually, I filled the oil reservoir, ran the boat for 10 minutes, then the alarm began to sound. I called Mercury and the representative on the phone said BEEP BEEP BEEP BEEP (four beeps) can only be the sensor at the cap. He told me to tighten the cap. If that didn't work, then all I needed was a new cap and sensor. I asked him if it could be anything else because I am worried about oil not getting to the motor. He said, "no, if you have oil in the tank, then you are good to go." After reading the posts, I am concerned whether this guy has given me accurate information.
jimh	posted 08-08-2008 08:15 AM ET (US) In any alarm system, the alarm can only respond to input from the sensors available. So far in this discussion the only sensor identified has been the magnetically operated float level switch in the under-cowling oil tank assembly. When the oil level is low (or if the float mechanism becomes stuck) the sensor--a magnetically operated switch--operates and causes an alarm which is apparently signaled by sounding of four beeps. No other sensor has been mentioned in the oil system monitoring. I do not have good information about the OptiMax oil monitoring system. Perhaps some Mercury mechanics can contribute additional information to this discussion. The question at hand: Are there any other sensors in the Mercury OptiMax which monitor the oil flow or oil level?
bluewaterpirate	posted 08-08-2008 03:47 PM ET (US) There is a small inline filter in the oil line bewteen the primary on boat tank and the on motor oil tank. That filter should be replaced every year. Also, enusre all your oil fittings are securely connected and secured with plastic cable ties. In the picture follow the oli line to the left to you see white pencil size inline oil fliter. I replaced the oil sensor on the motor at 2000 hours. http://cdn-2-service.phanfare.com/images/4892322_2159335_31001591_Web_4/ Image-4892322-31001591-2-Web_0_91059f20c309fe4ec1b0bc9def8399c8_1
jross036	posted 08-09-2008 03:16 AM ET (US) The only other oil warning you should hear is if the pump fails , then the ecm will recognize this. Magnetic float problem is common, especially on the older ones. I just replaced both my tanks.