Fuelab 42402-c User manual

Model Number 42402-c
Electronic Fuel Pump
Operating and Installation Instructions
This Product is Protected by U.S. Patent 8388322
C
CA AU UT TI IO ON N! !
This product is to be installed only by persons knowledgeable in the repair and modification of vehicle fuel systems
and general vehicle systems modification. Only a qualified technician or mechanic who is aware of applicable
safety procedures and fabrication skills should perform the installation of this product.
This fuel pump utilizes an electronic DC motor system that is not typical of conventional fuel pumps, and therefore
extra precautions must be adhered to as contained in instructions herein.
GASOLINE AND OTHER FUELS ARE FLAMMABLE AND CAN BE EXPLOSIVE!
Perform the installation in a well-ventilated location only to minimize the build up of fuel vapors. NO open flames,
smoking or other sources of ignition are to be present during installation, to prevent fire or explosion that can cause
serious injury or death. Grinding, cutting, and drilling must be performed with care to prevent ignition. Draining and
removal of all fuel and ventilation of vapors in vehicle and fuel system is recommended when performing such
procedures. Proper e
y
e and personal protection are required at all times durin
g
installation.
W
WA AR RN NI IN NG G! !
The Vehicle’s fuel system may be under pressure! Do not loosen any fuel connections until relieving all fuel system
pressure. Consult an applicable service manual for instructions to relieve fuel system pressure safely.
This product is intended for racing, off-road, or marine use only. This fuel system component may not be legal for
sale or use on emission-controlled motor vehicles; consult local, state, and national laws.
Product Contents:
Check the diagram and list of components (right)
to ensure that no components are missing from
box. Contact your Fuelab distributor immediately
for replacement.
42402-c Features and Performance Ratings:
Inlet / Outlet Port Sizes -10
A
N Militar
y
Por
t
Rated Flow Rate 190 GPH @ 45 PSI,13.5V
(
720 LPH
@
3 Bar
)
Maximum Pressure 100 PSI
(
6.8 Bar
)
Operatin
g
Volta
g
e 8-32 Volts
Maximum Current Draw 35
A
mperes
WARNING! Power Supply Voltage must be constant as specified in above specification. Only install fuel
pump on vehicles using between 12 Volt (6 cell lead acid battery) and 24 Volt (12 cell lead acid battery)
systems with or without a normal operating charging system. Pulse-Width Modulation or other means
of reducing input power voltage may result in erratic or non-operational condition. Consult these
instructions on using pulse width modulated signals for means of fuel pump speed control.
Before Installation, Plan Entire Fuel System:
A complete design plan of entire fuel system must be created for the specific application. These instructions are a
guide to help design this plan with respects to integrating this model of fuel pump only. Consult other sources of
information and manufacturer’s instructions for the various components of the fuel system. These instructions are
limited to general topics of fuel pump installation and may not include specific information pertaining to your specific
application. These instructions are written assuming the use of Multi-Point Electronic Fuel Injection using a
standard return (bypass) style fuel pressure regulator. This fuel pump may be integrated in some general
carbureted systems using a bypass system only. Visit our company website (www.fuelab.com) for specific details
pertaining to example fuel systems and other solution ideas. Additional information including advanced
troubleshooting, any special alerts and FAQ’s pertaining to this and other products is also available. A good design
plan for the fuel system must contain consideration for: pressure and flow rate through various components, quality
of components, operating environment (temperature, vibration, shock, general exposure to elements), local area
laws, and racing or track rules. Begin installation of fuel pump only after a complete plan is established to help
avoid fuel system component failure, costly rework, and excessive installation time.
with Rubber
Fuel Pump
(2X) -910 O-rings
Cushions
Electronic
(2X) T-Bolt Style
Mounting Brackets
(3X) 8-32 Nuts
with Washers
110020274-1, Rev E Sheet 1 of 6

Plumbing Planning Notes:
Fuel Pump is recommended for external use only. Inlet Straining Filter may be omitted if fuel system is cleaned,
and only pre-strained fuel is used to fill the fuel tank or fuel cell with great care ensuring debris not to enter tank.
Adequate structural mounting and support is the responsibility of the fabricator and installer. Mount the fuel pump
as low as possible without it being vulnerable to road hazards or debris. Minimize the length of the fuel line feeding
fuel pump. Do not use “cross drilled” style 90° elbow fittings, check valves or other restrictions (other than high flow
fuel filter strainer or shut-off valve) before or upstream of fuel pump. Minimize plumbing restrictions between fuel
tank and fuel pump and regulator for peak performance, use -10AN (5/8”) or -12AN (3/4”). Typically -6AN (3/8”) to -
10AN (5/8”) line is required for the rest of the fuel system, after or upstream of fuel pump. Use of a strainer filter
upstream of fuel pump to reduce risk from foreign object damage. Special Note: Use only Fuelab 828xx or 868xx
Series Filter with 100-Micron Rated Filter Element for -10AN or -12AN Line is recommended. All fuel line used must
handle high pressure. The use of fuel line such as stainless-steel braided line and “AN” style fitting connections are
recommended. The fuel ports (two -10AN Ports) use “AN” or “military” style fittings. This plumbing standard is
commonly used with racing and high-performance applications. See Step 4 on Sheet 4, for additional information
on this port standard. A fuel filter with a 60 micron or lower particle rating is required to be used upstream of
regulator and downstream from fuel pump to protect it and the fuel injectors from foreign object damage. Reference
the Schematic Diagram below for filter locations. Fuel tank must have a modification of an additional sump or use
aftermarket fuel cell as indicated. Use of a “pick-up” tube system is not recommended. Use of a liquid filled gauge
exposed to engine compartment heat is not recommended as the liquid inside the gauge may exert measurement
errors, all mechanical gauges and pressure transducers have amounts of error due to temperature fluctuation, be
aware of inaccurate pressure readings. DO NOT plumb gauge port to any gauge mounted inside the vehicle or in
passenger compartment. A line burst can spill fuel inside passenger compartment and on occupants, possibly
causing serious injury or death. An electronic gauge or pressure transducer system is recommended for readings in
a passenger compartment.
Typical EFI V-8 Fuel System Plumbing Schematic Diagram:
Y-Block or "T" Fitting,
to Split Flow into Two
Fuel Rail System
To Engine Intake Manifold (Air)
EFI Regulator
Fuel Gauge Shown in
Gauge Port, Liquid Filled
Gauge may have Error Due
to Temperature Variations.
Special Note: Use in carbureted systems require a bypass return or relief valve.
Do not "Dead Head" Fuel Pump.
110020274-1, Rev E Sheet 2 of 6
Fuel Filter with 60 Micron or
Lower Particle Rating is Required.
Fuelab Filter with 6, 10 or 40
Micron Rating is Recommended.
Fuelab 828xx Series Recomended
Check Valve Required for Reduced
Vehicle Emissions and Improved
Engine Starting. Fuelab 858xx Series
Filter has Check Valve Assembly
Built in.
(2X) Fuel Rails
with Injectors Fuel Straining Filter Required, Typical Micron
Rating: 75-150, Fuelab 828xx Series or
868xx Series, 100 Micron Filter Recommended.
42402-c Fuel Pump
Fuel Filter and Fuel Pump.
Line Size Required to feed Straining
using -10AN (5/8") Miniumum
Vented Fuel Cell or Fuel Tank.
Tank must be Plumbed
Follow Fuel Cell Manufacturer's
Recommendations for Proper
Cell Vent Plumbing

Electrical Planning Notes:
Reference Sheet 3 and 4 for schematic wiring diagram examples. Use electrical components as described
including electrical connectors that are appropriate for the operating environment of the fuel system, whether its use
in street, racing, or marine applications. Electrical connectors for the power leads must be capable of high current
draw, note all connections, wire, and component rating requirements herein. Solder and use shrink wrap for wire
splices for extra reliability (unless high quality crimping is performed). Use of a check valve in fuel system as
shown in plumbing diagram will maintain fuel pressure at normal levels during engine starting and may be required
depending on the wiring of main relay control circuit. (OEM and some aftermarket ECMs have fuel pump relay
control outputs that will turn off fuel pump during engine starting, requiring check valve use.) If the fuel pressure
does not maintain during engine starting, ensure fuel pump is energized while starting. Main wiring schematic
diagram below shows the control of relay by ignition switch. This source can be changed as described, or by a
toggle switch. Some forms of racing have specific rules regarding electrical switching of fuel pump. Consult
appropriate racing guidelines, rules, and regulations.
MAIN WIRING SCHEMATIC DIAGRAM: (Some electrical components shown are not supplied with kit)
PUMP OPERATES
AT MAXIMUM SPEED
WITH SWITCH POSITION
SHOWN (OPEN).
NO JUMPER WIRE
OR DEVICE
NO
FUSED
NC
+
C
(1-5A)
SWITCH
or ECM
CIRCUIT
(8-10ga)
(16-20ga)
(12-24 Volt System)
-
IGNITION
VEHICLE BATTERY
VEHICLE ELECTRICAL SYSTEM
FUEL PUMP
POWER RELAY
(40+A Rating)
CIRCUIT
BREAKER
or FUSE
(40A)
(16-20ga) Device or Circuit can be used as shown below,
for proper operation.See Speed Control Schematic Diagrams
for wiring of speed control (Yellow Lug).
Fuelab Model:
42402-c
FUEL PUMP
JUMPER WIRE
SPEED CONTROL SCHEMATIC DIAGRAMS:
shown on the pump certification.
Attach no wiring to speed control terminal, to operate
interval use. Use in continuous
specific applications, or short
pump at continuous maximum speed. The performance
See schematic, attach wire between
speed control terminal has greater than 1.65V (Approx), the mode of operation is in continuous maximum speed. A
operating with low engine
maximum speed only while
flow rate at reduced speed is
adequate for application. Using
this mode of operation is
considered continuous duty.
See Examples 3 and 4 for
switching between maximum
Example 3: Switch to Ground Speed Changing
Example 1: Continuous Maximum Speed
Speed”. Use Example 1 for racing
pulsed signal may also be used to control pump speed. See examples below for a method suitable for your application.
terminal has less than 0.25V (Approx) applied to it, the mode of operation is in continuous reduced speed. When the
Example 2: Continuous Reduced Speed
demand for extended periods.
Yellow Lug. Use Example 2 if the
negative terminal (Black Lug) and
The speed control terminal (Yellow Center Lug) can have voltage or a signal applied to it. When the speed control
curve was recorded as shown on the
Pump Certification as “Maximum
and reduced speed.
cooling may be required using
damage fuel pump. Additional
heating and therefore may
maximum speed may cause over-
Attach a jumper wire as shown below, to operate
pump at continuous reduced speed. The reduced
speed is preset, with the performance curve
Attach switch and wiring as shown to the right, to operate pump at
continuous maximum speed while switch is in the open position
(position as shown in diagram). When the switch is in the closed position
(on), the pump will operate in reduced speed mode. To reverse the
desired switch action, refer to Example 4. Switch type can be a relay or
switching based on pressure or other means. Current draw through this
circuit is extremely low (much less than 1 amp), so a very low current rating
for this switch can be used. Use the diagram to the right as a guide to
properly wire this example. Reduced speed is recommended during long
periods of low engine fuel demand conditions to avoid fuel system heat
build-up.
110020274-1, Rev E Sheet 3 of 6

SPEED CONTROL SCHEMATIC DIAGRAMS: (cont.)
Example 4: Switch to Power Speed Changing
When the switching action is in reverse to what can be used as shown Example 3, such as some pressure
switches, the action can be reversed using
a Single Pole Dual Throw (SPDT) relay as
shown to the right. Current draw through
this circuit is extremely low (much less than
1 amp), so a very low current rating for this
relay and switch can be used. Use the
diagram to the right as a guide to properly
wire this example. Reduced speed is
recommended during long periods of low
engine fuel demand conditions to avoid fuel
system heat build-up.
Example 5: Variable Speed
Devices such as an aftermarket ECM can create a pulsed signal (“pulling” voltage to ground at a given
frequency). This signal has a characteristic of dwell time, which is a ratio of on-time vs. off-time (in other words,
the amount of time the signal is “high” vs. “low”). This difference in dwell time percentage will enable the fuel
pump to operate at various speeds or flow rate. A graph demonstrating an example signal created by such a
device is shown below. The example signal is at 66% duty cycle, whereas the amount time that the signal is
above 1.65V voltage is about twice the amount of time at zero volts. When duty cycle is between 5%-20%, the
fuel pump is turned off. A duty cycle between 20%-90% will be variable speed between Minimum and Maximum
Speeds, while duty cycles of 90%-100% are at Full Speed. Frequency range is allowed between 100Hz and
5000Hz. “High” voltage may be as high as the vehicle’s voltage.
Refer to above Example 5, for use with the Fuelab Electronic Fuel Pressure Regulator, Models 52901 and
52902, that creates its own pulsed signal. These regulators automatically control the fuel pump, without the use
of switching means or other components such as described in examples 2 and 3. Refer to instructions for the
Electronic Regulator for proper wiring and installation.
Installation Steps:
1. Disconnect the ground terminal from battery and allow the vehicle’s engine and exhaust system to cool.
Relieve fuel system pressure per applicable service manual. Follow all Warnings, Cautions and Instructions
written on previous pages of these instructions.
2. Modify, remove, or replace other fuel system components as required per established build plan (reference
notes on previous pages and above).
3. Use the supplied brackets attached to the fuel pump, as a drilling template to mark holes for mounting bracket.
Choose a location that minimizes exposure to road hazards and debris, away from engine exhaust pipes, near
fuel tank or cell. Note position and plumbing requirements as stated earlier in these instructions.
4. Install the fuel fittings (not supplied). The threads used on these fuel ports are not tapered or pipe threads. Do
not use Teflonthread tape or thread sealant on these threads, as this can cause leakage or introduce debris
into the fuel system. Fittings to be used with these style of ports require use of the enclosed -910 o-rings for
proper sealing. Use light oil to lubricate the o-rings just prior to installation. Install the O-rings onto the fuel
fitting first. Position the o-ring in the thread relief of the fitting. Thread fitting into fuel pump and tighten
between 5 and 15 ftꞏlbs of torque. ALL fuel line that is internal to tank MUST be fuel compatible both inside
and outside of the line. PTFE based fuel line is recommended for a long service life.
5. Upon installation of fuel tank or cell and installation of all other fuel system components, Inspect fuel system for
any contact of fuel lines or wires with other components that can cause chafing or rubbing. Secure all
components and fuel lines. Ensure that moving components of vehicle are clear.
6. Connect the vehicle’s battery. Perform initial priming: The fuel pump may require priming during initial
operation and for moment after depletion of fuel from fuel tank or cell. This action can be accomplished by
removing fuel line from fuel rail (downstream of fuel pump and filters), allowing the fuel line to empty fluid into
110020274-1, Rev E Sheet 4 of 6
SPDT RELAY
NC
C
(1+A Rating)
AT REDUCED SPEED
SHOWN (OPEN).
NO
WITH SWITCH POSITION
PUMP OPERATES
FROM
FUSED
SOURCE
-3
Input Signal
4
4
Example Square Wave,
* 0 to 3.3 Volts
* Freq. = 1000Hz
2
3
2
1
00
(shown right):
* Dwell Time = 66%
Voltage (v)
Electronic Device,
such as Aftermarket
Engine Control Unit
(Oscilloscope-like
displayshown,
representing incoming
speed control signal).
Time (sec X10 )

fuel safe container. Operate fuel pump until fuel exits fuel line. Attach fuel line back to the fuel rail after priming
fuel pump. After tightening connection, verify leak-free operation while checking fuel rail pressure. If fuel
pressure is not high enough, repeat priming procedure to ensure that fuel pump is receiving fuel from tank.
Turn on fuel pump (typically by bypassing fuel pump relay) without engine operating. ECU or engine
management computer may be controlling the relay. The ECU may only operate pump for a few seconds each
time ignition switch is set to on. The pump will have to operate several seconds (30+) to prime and drive air out
of the fuel system. Reattach fuel rail line. Start fuel system and inspect for leaks. Inspect vehicle for any leaks.
Turn off fuel system and repair any leaks that may be present before continuing.
7. When adjusting pressure, be sure that fuel pump is operating to monitor pressure. Fuelab recommends to use
a “baseline” pressure reference when adjusting the pressure (adjusting the pressure with engine off or pressure
reference line or vacuum line unhooked). The vehicle’s engine may not produce consistent vacuum during idle
to have repeatable readings.
8. After final adjustment of fuel pressure, tighten jam nut. Road test vehicle, and retest pressure upon return to
ensure accurate adjustment. After installation of this fuel pump, verify flow capacity to ensure safe levels of
flow, particularly with reduced levels of pump speed. Having insufficient flow capacity can result in an engine
lean-out condition that can cause severe engine damage. Collecting a given amount of fuel (as measured by
weight or volume) over a measured amount of time can be used to determine capacity. Collect fuel flow from
the return line to measure the amount of fuel capacity at a given operating pressure. A 20+ ampere capacity
battery charger may be used to simulate the charging system of the vehicle while engine is off. If using an
adjustable fuel pressure regulator, for boosted applications, simulate boost by raising the fuel pressure by the
amount of expected maximum boost pressure. Performing these tests will give greater accuracy for capacity
tests.
Fuel System Maintenance Notes:
Periodic inspections and general maintenance are required for longevity and reliability of the fuel system. This
action directly affects the fuel pump's performance and reliability. Included with that are periodic inspection and/or
filter element replacement. The straining filter (upstream of pump) should be checked and cleaned at least every
30,000 miles (more often for off-road operating conditions). Replace or clean downstream filters (after pump) every
year or 15,000 miles (more often for off-road operating conditions). Dirty fuel filters can block flow and adversely
affect fuel system performance as well as can directly damage the fuel pump. Special alert for E85 or Methanol
Users: DO NOT use cellulose (paper) based filter elements! Water can contaminate the fuel and break down the
element, creating debris that can damage injectors and fuel pump. E85 and other oxygenated fuels can absorb
water. Long term storage of this fuel within the fuel tank of vehicle is not recommended and can contribute to
rusting of the fuel pump's tool steel components. Draining the fuel tank and replacement with small amount of
Gasoline or Kerosene (along with operating the fuel system for a small period of time) is recommended for long
term storage of the vehicle.
Troubleshooting Notes:
Problem (Symptom) Possible Causes Possible Solutions
Not operating or slight
"clicking" sound when
turned on.
Faulty fuel pump relay.
Faulty, dirty, or corroded
terminals or improperly sized
wire.
Debris from tank or plumbing
lodged inside pump.
Check voltage to controller, at power terminals. If
voltage is steady and consistent (within 1/2 Volt of
battery) then contact Fuelab for assistance or repair. If
voltage is inconsistent as described, repair or replace
electrical components as required.
Not building up fuel
pressure.
Incorrect fuel system initial
priming procedure.
Pump operating in reverse
direction (see above).
Repeat procedure for proper priming. If condition
continues, check all plumbing upstream (on inlet side) of
fuel pump.
Leakage of fuel at
inlet or outlet fuel
ports.
Improper type of fitting used. If leakage occurs at fitting, be sure that the proper fitting
style is used (AN o-ring seal type ONLY!). Pipe threaded
style fittings are NOT to be used.
Loss of fuel pressure
or erratic pressure
pulsation after several
minutes of operation.
Cavitation (vapor lock) due
to overheating or restricted
inlet.
Look for sources of heat such as exhaust or fuel rail
mountings that could be conducting too much heat.
Check for inlet restrictions such as improperly vented
tank, or debris blocking inlet straining filter. Contact
Fuelab, as pump may be damaged due to improper
operating condition for repair or consultation.
110020274-1, Rev E Sheet 5 of 6

110020274-1, Rev E Sheet 6 of 6
LIMITED LIFETIME WARRANTY
FUELAB, a division of FCP, Inc., having its principal place of business at 1605 Eastport Plaza Drive, Suite 125,
Collinsville, IL 62234, USA ("Manufacturer") warrants its FUELAB products (the "Products") as follows:
1. Limited Lifetime Warranty
Manufacturer warrants that the Products sold hereunder will be free from defects in material and workmanship from the
date of purchase for so long as the original purchaser owns the Products. This Limited Lifetime Warranty does not
extend to any subsequent owner or transferee of the Products. If the Products do not conform to this Limited Lifetime
Warranty during the warranty period (as herein above specified), Buyer shall notify Manufacturer in writing of the
claimed defects and demonstrate to Manufacturer’s satisfaction that said defects are covered by this Limited Lifetime
Warranty. If the defects are properly reported to Manufacturer within the warranty period, and the defects are of such
type and nature as to be covered by this Limited Lifetime Warranty, Manufacturer shall, at its option and own expense,
furnish replacement Products or replacement parts for the defective Products or refund the purchase price. Removal of
Products from vehicle, shipping to Manufacturer and installation of the replacement Products or replacement parts shall
be at purchaser’s expense. (Vehicle means any automotive, bike or marine transportation device powered by an
internal combustion engine to which the Product is attached. This Product is NOT intended or designed for use on
aircraft, experimental or otherwise.)
2. Other Limits
THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
This Limited Lifetime Warranty does not cover any damage due to: (a) transportation; (b) storage; (c) improper use; (d)
failure to follow instructions for the Products or to perform any preventive maintenance; (e) modification; (f) unauthorized
repair; (g) normal wear and tear; or (h) external causes such as accidents, abuse, or other actions beyond
Manufacturer’s reasonable control. This Limited Lifetime Warranty also does not apply to Products upon which repairs
have been effected or attempted by persons other than pursuant to written authorization by Manufacturer. This Limited
Lifetime Warranty is not extended if we repair or replace the Products.
3. Exclusive Obligation
THIS LIMITED LIFETIME WARRANTY IS EXCLUSIVE. The sole and exclusive obligation of Manufacturer shall at its
option be to repair or replace the defective Products in the manner and for the period provided above or to refund the
purchase price. Manufacturer shall not have any other obligation with respect to the Products or any part thereof,
whether based on contract, tort, strict liability or otherwise.
4. Other Statements
ORAL OR OTHER WRITTEN STATEMENTS BY MANUFACTURER’S EMPLOYEES, REPRESENTATIVES AND/OR
RESELLERS DO NOT CONSTITUTE WARRANTIES, SHALL NOT BE RELIED UPON BY BUYER, AND ARE NOT A
PART OF THE CONTRACT FOR SALE OR THIS LIMITED LIFETIME WARRANTY.
5. Entire Obligation
This Limited Lifetime Warranty states the entire obligation of Manufacturer with respect to the Products. If any part of
this Limited Lifetime Warranty is determined to be void or illegal, the remainder shall remain in full force and effect.
6. Warranty Service
How Do You Get Service?
If something goes wrong with your Product, contact FUELAB at 618-344-3300, or send an e-mail with proof of purchase
to: [email protected] for a Return Authorization Number (RMA). After receiving your RMA send the product postage
paid, fully insured, with a brief written description of the problem to:
FUELAB Warranty Department, 1605 Eastport Plaza Drive, Suite 125, Collinsville, IL 62234
We will inspect your Product and contact you within three business days of receipt to give the results of our inspection
and an estimate of the labor and/or parts charges required to fix the Product, if applicable. If covered under this Limited
Lifetime Warranty, Manufacturer will repair or replace the Product and return it to you at no cost or refund the purchase
price. If the Product is NOT covered under this warranty and if you authorize repairs, we will return the repaired Product
to you COD, or prepaid via credit card, within three business days. If we find no issues with the returned product and it
meets all performance specifications, there will be a $25 charge to cover technician labor and inspection time.
Additional return shipping charges will apply. We will return the repaired Product to you COD, or prepaid via credit card,
within three business days.
Limitation of Liability
THE REMEDIES DESCRIBED ABOVE ARE YOUR SOLE AND EXCLUSIVE REMEDIES AND OUR ENTIRE
LIABILITY FOR ANY BREACH OF THIS LIMITED LIFETIME WARRANTY, OUR LIABILITY SHALL UNDER NO
CIRCUMSTANCES EXCEED THE ACTUAL AMOUNT PAID BY YOU FOR THE DEFECTIVE PRODUCT, NOR SHALL
WE UNDER ANY CIRCUMSTANCES BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, SPECIAL OR
PUNITIVE DAMAGES OR LOSSES, WHETHER DIRECT OR INDIRECT.
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL
DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.