FORM 1038 (REV. F) 11/04
INSTALLATION INSTRUCTIONS
COMP PUMP® SERIES 250
ELECTRIC FUEL PUMP
PART NOS. 5250 AND 5250A
PARTS INCLUDED IN THIS KIT:
1 COMP PUMP® Series 250 Electric Fuel Pump
3 Fittings, 3/4" - 16 x #8 AN Flare
3 O-rings, Nitrile 0.644ID x 0.087 thickness
NOTE: DO NOT OPERATE THIS PUMP WITHOUT FUEL EXCEPT FOR BRIEF PERIODS WHILE PRIMING
SPECIFICATIONS
Maximum recommended operating pressure: 20 PSI (factory set at approximately 15 PSI)
Maximum dry suction lift: 3 feet. This is maximum distance above the fuel level in the fuel tank that the fuel pump will prime itself.
Oil pressure switch rating: 15 AMP
Fuel pump over current protection: 15 AMP fuse
Fuel application: Part No. 5250, Gasoline; Part No. 5250A, Alcohol / Methanol
GENERAL INFORMATION
The COMP PUMP® 250 Series Electric Fuel Pump is a high volume fuel pump designed for serious racing applications. The pump is factory set to approximately 15 PSI. In all cases, this fuel pump must be used with a fuel pressure regulator. We recommend the following:
Standard Regulator |
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Mallory 4 Port Regulator |
Part No. 4200 |
(gasoline) |
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Part No. 4201 |
(alcohol) |
Return Style Regulator |
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|
Mallory 5 Port Regulator |
Part No. 4300M |
(gasoline) |
|
Part No. 4301M |
(alcohol) |
This fuel system must have a fuel return line going to the fuel tank. We recommend at minimum a #8 AN (1/2") line.
If you use a standard fuel pressure regulator, not a return style, run the fuel return line from the fuel pump’s fuel return port. Use the 3/4"-16 thread x #8 AN flare fitting provided to connect your #8 AN line.
If you use a return style fuel pressure regulator, run a #10 AN fuel return line from the fuel pressure regulator’s fuel return port and install a 3/4"-16 thread plug and o-ring in the fuel pump’s fuel return port. You can find a 3/4"-16 thread plug at most hardware stores. Do not try to adjust the bypass adjustment - pump damage may result.
Be sure to install a suitable fuel filter (maximum 100 micron) between the fuel tank and the fuel pump. Mallory COMP FILTER® Series Part Nos. 3140 or 3500 are recommended. This prevents debris from becoming wedged in the fuel pump’s Gerotor and locking it. An additional filter(s) (maximum 40 micron) should be installed just before
the carb(s).
MALLORY IGNITION |
www.mrgasket.com |
1 |
MOUNTING PROCEDURE
Step 1
Mount the pump as close as possible to the fuel tank in a well ventilated area with minimal exposure to road debris. Avoid exposing the pump and fuel lines to moving parts and hot surfaces, such as the exhaust system.
The pump should be mounted at tank level or below.
NOTE: Increasing distance between pump and tank will decrease pump efficiency.
Step 2
Using the pump mounting bracket as a template, locate mounting holes on a solid member, such as the vehicle chassis. Drill clearance holes for 5/16" bolts. NOTE: To ensure against a potential fire hazard from pump flooding, mount the pump in a vertical position with the motor on top.
See Figure 1.
Step 3
To prolong pump life and efficiency, a high volume fuel filter such as the Mallory COMP FILTER® Series 500 Fuel Filter (Part No. 3500) must be installed between the pump and fuel tank. Connect #8 AN fuel lines as shown in Figure 2 for Standard Regulator or #10 AN lines as shown in Figure 3 for Return (Bypass) Style Regulator.
FIGURE 1
FUEL OUTLET 3/4" - 16 (#8AN)
NITRILE O-RING
RED (+)
BLACK (–)
FUEL INLET 3/4" - 16 (#8AN)
NITRILE O-RING
Step 4
Be sure to install one of the Mallory High Volume Fuel Pressure Regulators between the pump and carburetor. For maximum efficiency, mount the pressure regulator as close as possible to the carburetor. See instructions packaged with the pressure regulator. Make sure all fittings are tight so that air cannot enter the system.
FIGURE 2
FUEL REGULATOR
FILTER
CARB
(WITH STANDARD FUEL PRESSURE REGULATOR)
FUEL RETURN 3/4" - 16 |
BYPASS ADJUSTMENT |
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|
(MUST BE PLUGGED |
NOTE: Bypass pressure above |
WHEN USING A RETURN |
20 psi will make the pump draw |
[BYPASS] STYLE |
more current and significantly |
REGULATOR |
reduce pump life. |
FUEL RETURN
FUEL
PUMP
FUEL
TANK
FUEL RETURN |
|
FUEL |
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||
PORT |
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FILTER |
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FIGURE 3
(WITH REGULAR STYLE FUEL PRESSURE REGULATOR)
2 www.mrgasket.com MALLORY IGNITION
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