Stewart Warner 240 Series - User Manual

SERVICE INSTRUCTIONS
240 SERIES ELECTRIC FUEL PUMP
6V & 12V Coil Kits
KIT NO. 426947 (Fig. 2}
(A) 1-425617 Coil, 6 Volt
(B) 1-425651 Base Gasket
(C) 1-425660 Switch Gasket (large)
(D) 1-425655 Switch Gasket (small)
(E) 2-425650 Switch Sleeve
(F) 1-432975 Bowl Gasket
KIT NO. 426948 (Fig. 2)
(A) 1-425664 Coil, 12 Volt
(B) 1-425651 Base Gasket
(C) 1-425660 Switch Gasket (large)
(D) 1-425655 Switch Gasket (small)
(E) 2-425650 Switch Sleeve
(F) 1-432975 Bowl Gasket
1. Insert coil assembly (A) into pump with notch
In contact plate opposite that of switch opening.
When coil is properly indexed and seated, the
terminals and top of coil will be clearly visible
through the switch opening.
2. Replace tension washer with the rounded por-
tion to the coll.
3. Replacenewgasket(B)anduslngtool(T-281843)
screw in coll base until it seats firmly against
gasket.
4. Place "O" ring around protruding portion of
piston tube.
5. Place washer on top of "O" ring.
TOP OF COIL
FIGURE 1
6. Install contact sleeves (E) onto the coll ter-
minals (Figure 1).
7. Trip actuator arm of switch upward (Fig. 3).
8 Insert piston.
9. With finger pressure hold piston to its upper-
most position, then release piston approxi -
mately 1/8". THE PISTON MUST BE IN THIS
POSITION TO INSTALL SWITCH.
f—
/I <MMM
*
FIGURE 2
10. With gaskets (C) and (D) in place, press
switch Into pump body making certain the
switch contacts engage with the contact
sleeves. Due to alignment slot on switch, it
can only be installed one way.
11. Replace switch cover and secure. Note: vent
hole in cover must face downward.
FIGURE 3
12. Insert power spring after piston and replace
the intake valve. Valve must be firmly seat-
ed against washer. Use a wrench but take
care not to over tighten. Do not seat valve
on coil base. .-. -,
13. After inspection or cleaning of sediment bowl,
assemble filter as shown in Figure 4. Make
certain that bowl gasket (F) is properly seat-
ed.
14. Check operation of pump before installation
on vehicle.
IMPORTANT: Always use new gaskets and seal
rings during reassembly.
FIGURE 4
Printed in U.S.A.
P.N. 434357
STEUJRRT-UJflRnER CORPORHTIOH
1826 W. Diversey Parkway
Chicago, Illinois 60614
SER 4750

Summary

Fuel Pump Service Introduction

6 V & 12 V Coil Kits Overview

Details the available 6-volt and 12-volt coil kits for the electric fuel pump.

General Assembly Procedure

Provides a step-by-step guide for assembling the electric fuel pump unit.

Preparation and Disassembly

Preparation and Tools Required

Lists necessary tools and preparation steps before servicing the fuel pump.

Filter Bowl Disassembly

Instructions for removing the filter bowl and its components from the pump.

Intake Valve Disassembly

Details the steps to remove the intake valve from the fuel pump assembly.

Switch Disassembly

Procedure for safely removing the electrical switch assembly from the pump.

Component Disassembly and Service

Piston Disassembly and Service

Procedures for disassembling and servicing the fuel pump's piston component.

Coil Disassembly and Service

Steps to remove and service the pump's electrical coil assembly.

Regulator and Valve Disassembly

Instructions for disassembling the pump's regulator and valve components.

Checking and Repair Procedures

Switch Checking and Repair

Methods to check switch functionality and perform necessary repairs.

Intake Valve Checking and Repair

Procedures for verifying intake valve integrity and performing repairs.

Piston Checking and Repair

Steps to inspect the piston for wear and perform required repairs.

Component Checks and Assemblies

Coil Checking Procedure

How to test the coil for proper operation using a tester.

Regulator and Valve Checking

Procedures for checking the regulator and valve for damage or wear.

Regulator and Valve Assembly

Steps to reassemble the regulator and valve components.

Coil Assembly

Instructions for installing the coil into the pump body.

Switch and Piston Assembly

How to install the switch and piston assembly.

Intake Valve Assembly

Intake Valve Assembly Steps

Detailed steps for correctly assembling the intake valve.

Performance Testing

Establishing Standard Load Test

How to set up and perform standard load tests on the fuel pump.

Pressure Testing Procedure

Steps to test the fuel pump's pressure output.

Volume Testing Procedure

Method for testing the fuel pump's volume delivery.

Regulator Kit Service

Regulator Kit Disassembly

Instructions for disassembling the regulator kit components.

Regulator Kit Assembly

Steps for reassembling the regulator kit components.

Stewart Warner 240 Series Specifications

General

Series	240
Housing Material	Cast Iron
Impeller Material	Bronze
Type	Centrifugal
Power Source	Electric