Toyotomi OPT-91UL Service Manual
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Toyotomi OPT-91UL Service Manual

Fuel lifter pump
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SERVICE MANUAL
FUEL LIFTER PUMP
MODEL OPT-91UL

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Summary of Contents for Toyotomi OPT-91UL

  • Page 1 SERVICE MANUAL FUEL LIFTER PUMP MODEL OPT-91UL...

  • Page 2: Specifications

    SPECIFICATIONS PUMP TYPE Suction (Head or fall type) LIFTING HEIGHT (MAX.) 26 ft. (8m) MAXIMUM HORIZONTAL DISTANCE 131 ft. SUCTION CAPACITY 4 gal./h (15 L/H) at 20 ft. (6m) INLET PIPE SIZE 3/8” O.D. POWER SUPPLY A/C 115V, 60Hz POWER CONSUMPTION SUMP TANK CAPACITY 0.24 gal.

  • Page 3: Component Parts

    COMPONENT PARTS REF # PART # PART NAME REF # PART # PART NAME 20459824 Fuel opening cap 20459882 Drive shaft 20459852 Strainer gasket 20459850 Fuel strainer 20459880 Drain packing 20475535 Power supply cord 20477546 Cover 20459819 Pump assembly 20477529 Mounting plate 20477576 Switch circuit...

  • Page 4: Special Features

    SPECIAL FEATURES Capable of lifting fuel up to a height of 26 ft. (8 m): Equivalent to the height of the third floor of average residences (including multistoried flats and buildings). Fuel sump permits fuel supply without electric power: The fuel sump contains approximately 0.17 gal (0.66 liters) that can be used even though there is a temporary power outage.

  • Page 5: Safety And Reliability

    The following redundant safety features are used to prevent this problem with the Toyotomi Fuel Lifter. A float switch continuously maintains the normal high and low fuel level range. If the lifter malfunctions and the fuel amount exceeds the normal high level, a high limit safety switch stops the motor to prevent the fuel from over-flowing.

  • Page 6: Installation

    INSTALLATION SELECTING LOCATION CAUTION: This lifter is for indoor use only. Check local codes and ordinances for permitted uses. 1. Select a safe and solid place to install the lifter. 2. Select a place easy to inspect and maintain. 3. Do not install the lifter less than six- (6) ft. (2m) from the heating appliance horizontally.
  • Page 7 (b) Height between the floor level of the heater and the bottom of the lifter: 8-1/2 ft. (2.5m) maximum (c) At least 16 in. higher than the heater fuel intake fitting. 2. Max. length of the pipe between the main fuel tank and the lifter: 131 ft.
  • Page 8 6. No more than three oil meters should be used on the outlet line from the lifter. Air inside of the oil meter may expand due to a change in surrounding temperature and possibly cause fuel to flow back to the lifter. CAUTION: If more than four meters are installed on the outline fuel line the lifter may leak fuel and create a hazard.
  • Page 9 4. Install the mounting plate over the mounting rubber cushions using the holes. Slide the mounting plate down. 5. Attach the three (3) screws securely. Be sure not to touch the motor’s cooling fan or the control box with the screwdriver.

  • Page 10: Fuel Supply Line

    FUEL SUPPLY LINE PRECAUTIONS 1. Use 3/8 in. (9.53 mm) outside diameter (O.D.) and not less than 0.032 in. (0.8 mm) thickness copper tubing. Note: some local building inspection authorities may not accept Copper tubing as fuel line. Check local codes and ordinances for permitted use. In these instances, the fuel line may need to be made of wrought iron or steel.
  • Page 11 (a) When installing several lifters with one main fuel tank, install a large diameter horizontal pipe lower than the height of the bottom of the main fuel tank at each point at which the branch vertical pipes are connected to their respective lifters.

  • Page 12: Operation

    FLARING THE TUBING 1. Slide the flare nut provided onto the copper tube. 2. Flare the pipe with a good flaring tool. Note: Be sure the flare is “CLEAN”. 3. Push flared pipes against the joint nut and tighten the flare nut. Fasten the nut securely, but do not over-tighten.
  • Page 13 3. Use the attached funnel to pour about 0.12 gallons (450 cc) of fuel into the fueling mouth. When the fuel sump is filled sufficiently, the green lamp will flash to indicate a normal oil level. CAUTION: Use clean fuel only! Be sure there is no contamination such as dirt, water or particles of metal.

  • Page 14: Maintenance

    6. Remove the funnel from the fueling mouth and store it in a secure place. 7. Plug the hole of the fueling mouth securely with the rubber cap. 8. Replace the cover and attach with cover screw. At this point, the lifter is ready supply fuel automatically to the heater.
  • Page 15 (a) To catch the fuel that will drain out, place a rag or folded paper towel below the strainer cover. (b) Loosen the two (2) screws from the strainer cover and remove it. (c) Remove the fuel strainer and rinse with clean fuel.

  • Page 16: Troubleshooting

    Page 15.) Mark the pipe joints and the nuts and then take them apart. The lifter unit and relevant fuel lines should be covered with a piece of plastic to prevent dust or insects from entering. When using the lifter in the next season: - If the lifter has been stored as installed: Restart the lifter in accordance with the procedures mentioned in the instruction of “When restarting lifter in the next season.”...
  • Page 17 When installing: Red LED lamp is illuminated. Operation Drain the priming oil until green switch OFF. lamp flashes and next turn operation switch ON. Lifter Turn operation switch OFF. is not level. After returning the pump to its vertical position, turn operation switch ON.
  • Page 18 [Note 1] Excessive Operation switch to be turned ON after priming oil turning operation switch is turned OFF and fuel is removed until green LED lamp flashes. Motor connector Operation switch is turned OFF. disconnected Operation switch to be turned ON after connector is inserted.
  • Page 19 Motor drives, but no fuel is pumped. Flow-out valve Turn operation switch OFF to close left open flow-out valve, next repeat oil-priming again, and then turn operation switch ON. Priming oil Turn operation switch OFF, repeat oil- not sufficient priming again, and then turn operation switch ON.
  • Page 20 Drive shaft dislodged Align drive shaft to or broken. its position, or replace it. Pump malfunction Replace pump assy. Fuel pumped, but not fed to the heater. Flow-out valve Flow-out valve to left closed. be opened. Valve of the heater left Valve of the heater to closed.
  • Page 21 Valve of the heater (fuel sump) left Reset fuel sump to closed. make valve in the open state. Insufficient height difference between Correct the pump installation lifter and to make a sufficient height heater difference. Outlet fuel line plugged. Remove stuck substances from the fuel line.
  • Page 22 When using and in the beginning of the season: Red LED lamp illuminates. Operation switch OFF. Operation switch ON. Control box malfunction Replace control box. Pump runs out of fuel during operation All LED lamps illuminated. Float switch connector dis- Yes Float switch connector connected to be inserted properly.
  • Page 23 All LED lamps Flashing Yellow LED lamp flashing All LED lamps Excessive Appropriate number turned off consumption of lifters which of fuel meet fuel consumption rate to be installed. Fuse broken Replace fuse Inlet side Remove stuck sub- piping plugged stances from piping Control box Replace...
  • Page 24 Sufficient amount of fuel is not fed to the heater. Flow valve Open the left closed. flow-out valve. Outlet side Remove stuck piping plugged substances from the piping. Excessive Appropriate number of consumption lifters which meet fuel by heater(s). fuel consumption rate to be installed.
  • Page 25 Large sound High lift Pumping lift to be set lower than 26 ft. (8m). (If two units are connected in series.) Inlet pipe To minimize lifting head, slants upward all horizontal line should be as low as possible. Motor and pump Release four (4) screws on the off center or not cover to adjust for the position of...
  • Page 26 OPERATING PRINCIPLES OF THE PUMP ・ Explanation of the principles: The pump used for the lifter is a rotary vacuum pump. It operates as follows: The motor rotates the rotor to create a vacuum to suck fuel. Fig. 1 illustrates the operation of the pump.
  • Page 27 The operations shown in Fig. 1 to Fig. 3 are called one cycle. At 60Hz approximately 1,690 cycles are repeated by the lifter per minute while approximately 1,410 cycles are repeated at 50Hz. The amount of fuel that the pump sucks during one rotation is constant so the amount of fuel pumped changes as follows between 60Hz and 50Hz.

  • Page 28: Handling Precautions

    HANDLING PRECAUTIONS: The following precautions must be observed when using the pump. (1) No idle operation permitted. The term “idle operation” means that the pump is operated without being filled with fuel. Without fuel, all the components of the pump, such as the rotor, cylinders, and paddle, will rub each other, and may cause excessive friction wear or jamming.

  • Page 29: Electric Components

    ELECTRIC COMPONENTS AND CIRCUITS ELECTRIC COMPONENTS: Pump drive motor: Type: Condenser run single-phase induction motor Power source: 115V/60Hz Condenser: 1.5µF± % 230WV Number of poles: 4 Rated revolution: 1,690rpm ± 5% (60Hz) Temp. fuse operating temp: OFF at 259ºF (126ºC) The condenser motor used for the lifter has a sufficiently large starting torque to pump fuel at any low temperature.
  • Page 30 B: type(SPST)..Normal Close contact point C: type(SPDT)..Common contact point Type A (Normally Open) is used for the OPT-91UL. The A type switch consists of two low magnetic resistive reed elements that are enclosed in the glass tube. The two sections create a center gap and an off-center gap.
  • Page 31 EXPLANATION OF OPERATION OF OPT-91UL The ON and OFF points of the reed switches and their relationship to the oil level are shown in the adjacent diagram. The reed switches are turned ON (closed) when the center of the float ring magnet comes within 1/8 in.
  • Page 32 If the first switch (LS1) is not turned OFF within 15 minutes of operation, the pump will stop and the yellow lamp will flicker. This will prevent idle operation. The lifter may be reactivated by disconnecting and reconnecting the power cord or by turning the operation switch OFF and then ON.

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