H-SERIES FUEL TRANSFER PUMPS

FR1200, FR2400, FR4200, FR4400, FR600, SD1200, SD600

Installation and Operation Manual
 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

Table of Contents

Limited Warranty Policy........................................................................ 2 Thank You!

About This Manual................................................................................ 2 Thank you for your loyalty to the Fill-Rite® brand of fuel transfer pumps.
Your safety is important, so please read and thoroughly understand
Symbols and Definitions....................................................................... 3
the procedures set forth in this manual. In addition, please save these
Before You Begin.................................................................................. 3 instructions for future reference and record the model, serial number,
and purchase date of your fuel transfer pump. Protect yourself as well
Safety Information................................................................................ 4
as those around you by observing all safety instructions and adhering to
Installation........................................................................................... 5 all danger, warning, and caution symbols. Please register your Fill-Rite®
product via info.fillrite.com/product_registration.
12V DC and 24V DC Wiring Instructions................................................ 7
115V AC Wiring Instructions.................................................................10 IMPORTANT RETURN POLICY
Operation Instructions........................................................................ 12 Please do not return this product to the store. For all warranty and product
questions, please contact Fill-Rite Technical Support at 1 (800) 720-5192 or
Security.............................................................................................. 12 via email at FillRiteTech@fillrite.com (M-F, 8 AM – 5 PM ET).
Troubleshooting Guide ........................................................................ 12
Specifications and Models...................................................................14 MODEL#
Performance Curves............................................................................17 SERIAL#
Accessories.........................................................................................19 PURCHASE DATE:

Pump Service Kits............................................................................... 21

Certifications..................................................................................... 22
Motor Tag........................................................................................... 22

Limited Warranty Policy

Fill-Rite Company warrants the goods manufactured shall be free from defects of materials and workmanship. Specific warranty details for individual
products can be found at fillrite.com.

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 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

H-Series Fuel Transfer Pumps Have the Following Features

• Adjustable Electrical Junction Box • Premium Paint Shield

Rotates 180 degrees to provide ease of electrical wiring installation An exemplary corrosion resistant barrier for long field life
in tight quarters no matter the inlet bung location
• Thermally Protected Motor
• Reliable, Heavy-Duty Power Switch Lever Prevents overheating to ensure maximum motor life
Features a cast metal stop that withstands heavy use in the
most rugged environments • Telescoping Inlet Metal Suction Pipe*
Adjustable from 20 to 34 inches in length, allowing for universal
• Locking Bar Defense installation on a multitude of tank sizes and shapes
Elongated bar simplifies the pad locking process to prevent theft *Not included with SD models

• Focused Component Weight Reduction • Intake Strainer Safeguard

Preserves expected heavy-duty performance while Protects the pump by blocking particles created by contamination
improving installation ease
• Certifications – UL, cUL

About This Manual

From initial concept and design through final production, your Fill-Rite fuel transfer pump is built to provide years of trouble-free use. To ensure the safety
of yourself and those around you, it is critical that this manual is read in its entirety prior to attempting to install or operate your new purchase. We strongly
urge that any installer and operator become familiar with the terms, diagrams, and technical data in this manual and pay close attention to warning
symbols and definitions. At Fill-Rite, your satisfaction with our products is paramount. If you have questions or need assistance with your product, please
contact Fill-Rite Technical Support at 1 (800) 720-5192 (M-F, 8am-5pm ET).

Symbols and Definitions

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in moderate or minor injury.

Indicates information considered important but not directly hazard related.

Before You Begin

Fueling Requirements
The Fill-Rite FR1200, FR2400, FR4200, FR4400, FR600 as well as SD1200 and SD600 models are designed and approved for use with the following
flammable and combustible fluids: gasoline and gasoline blends up to 15% or E15, diesel, biodiesel blends up to 20% or B20, kerosene, and mineral spirits.
Please take all necessary precautions when handling flammable liquids.

Power Source Requirements

Depending on the Fill-Rite model, supply line power will either be 12V DC, 24V DC, or 115V AC. The pump motor nameplate located next to the switch lever will
provide detailed electrical information. Please refer to the appropriate electrical instructions found starting on Page 7 (DC power) or Page 10 (AC power).

Items that may be needed for installation:

Steel pipe wrench 14-24", open end wrench or socket (7/16", 11mm), T-25 Torx driver, utility knife, angle grinder or hacksaw (optional), wire cutters, wire
stripper/crimper, and thread sealant (optional).
NOTE: Fill-Rite provides Teflon ® tape for all models as listed on Page 16.

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Safety Information

To ensure a safe installation and proper equipment operation, please read, understand, and adhere to all DANGER/WARNING/CAUTION and other NOTICES.

Never smoke around or near a fuel tank or transfer pump. Open flames or a spark when pumping a flammable liquid will
result in a fire. Improper electrical wiring or installation will result in serious injury or death.

Electrical wiring should ONLY be performed by a licensed electrician in compliance with all local, state, and
national electrical codes (NEC/ANSI/NFPA 30, NFPA 30A, and NFPA 70) as appropriate for the intended use of a
Fill‑Rite fuel transfer pump.
Threaded rigid conduit, sealed fittings, and conductor seal should be used where applicable and as defined by
these codes.
This product must be properly bonded or grounded to avoid the build up of static electricity when handling flammable
products. Static discharge may ignite vapors causing serious injury or death.
Fill-Rite pumps are not suited for use with water or fluids intended for human consumption. Do not use to fuel aircrafts.
To minimize static electricity build up, keep the nozzle in contact with the container being filled at all times during the
filling process. Use only static wire conductive hose when pumping flammable liquid.
Improper mechanical installation or use can result in serious injury or death.

Threaded pipe joints and connections must be sealed with the appropriate sealant or sealant tape to prevent leaks.
All Fill-Rite pump models are equipped with thermal overload protection by which the motor will shut off to prevent heat
damage. If motor is turned off by a thermal overload, turn the switch lever to the OFF position. Once the motor has cooled
sufficiently, turn the switch lever to the ON position to resume fuel transfer.
Some Fill-Rite models will restart automatically if the switch lever is not in the OFF position once the thermal protector
resets. As good practice, always place the switch lever in the OFF position when the motor overheats.

A filter should be used on the pump outlet to avoid contamination into the vehicle or equipment’s fuel tank.
We recommend Fill‑Rite filters for best results.
To prevent fuel storage tanks from shifting or tipping, refer to tank manufacturer’s guidelines on proper anchoring.

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Installation

Your Fill-Rite pump is designed to be mounted on a fuel tank via a threaded inlet flange supplied with the pump. Typical installations are shown in Diagram 1
and 2. Your pump features an integral bypass valve to recirculate the fluid when the pump is operating with the nozzle closed.

Do not use additional check valves or foot valves unless they have a proper pressure relief valve built into them.
Please be aware that additional check valves will reduce flow rates.
A pressure-retaining fill cap can be used to reduce fuel loss through evaporation.
Threaded pipe joints and connections must be sealed with the appropriate sealant to prevent leaks.
Use caution to prevent cross-threading during installation which can cause damage to either or both the inlet flange
as well as storage tank bung.

In all tank applications, be sure the tank is properly secured per tank manufacturer’s guidelines.

Stationary Tank Mobile Tank

For stationary fuel tanks, the pump mounts to the tank bung by way of For mobile fuel tanks, the pump mounts to the tank bung by way
the pump inlet flange. Given the different sizes of stationary fuel tanks, of the pump inlet flange.
a custom suction or inlet pipe may be necessary. We recommend 1” NPT For Telescoping Steel Suction Pipe
black iron pipe that is extended to a length of at least 1-2” from the Allow telescoping tube to extend fully to the bottom of the tank.
bottom of the tank, with the bottom of the pipe cut to an angle between
30-45 degrees for improved flow. For Custom or PVC Suction Pipe
To avoid penetrating the tank, we recommend leaving a minimum of 1-2”
A stationary tank must be equipped with a vent cap. (Diagram 1) of the pipe off the bottom of tank. We further recommend cutting the
suction pipe to a 30-45 degree angle for improved flow.
The mobile tank must be equipped with a vent cap. (Diagram 2)

Diagram 1 Diagram 2

Vent Cap

Vent Cap

1-2"
Min.
1-2"
Min.

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Installation Procedure

Step 1: (Optional) Inlet Flange Removal

Loosen (4) 1/4" bolts using 7/16" wrench or socket. Detach inlet bung Step 2 Step 3
from pump, retain bolts, screen, and gasket.
Step 2: Using either included suction pipe or custom pipe, thread
pipe into inlet bung 1.5 to 2.5 turns past hand tight with pipe wrench.
Use appropriate sealant for fuel transfer.
Step 3: Thread inlet bung with attached suction pipe onto tank 1.5 to
2.5 turns past hand tight. Use appropriate sealant for fuel transfer.
Step 4: (Only if Step 1 utilized) Place screen in screen pocket on the inlet
bung, mount gasket, then place pump on tank bung. Align holes and insert
(4) 1/4" bolts and tighten with 7/16" wrench to 40 in.‑lbs. minimum.
Step 5: Remove junction box cover via (2) T-25 screws and locate wires.
DC Voltage: 2 wires, Black and Red; AC Voltage: 3 wires, Black, White,
and Green which is attached to internal ground screw. Ensure that gasket * Black cable gland only included with DC models
remains in place upon re-attachment of junction box. †
1/2" NPT to cable gland, bronze fitting per ATEX on HE Models

Step 6: Feed wires from power source through NPT opening into junction
†

box. For DC models, use the black cable connector*. For AC models, attach
conduit directly to NPT† opening.
Step 7: Nozzle boot is attached to switch plate via (1) 5/16" bolt torqued to
40 in-lbs. The nozzle boot has two available position placements.

Maintain a minimum 1-2" separation from pipe end to bottom of tank.

Step 4 Step 5 Step 6

(2) T-25 EXTERNAL GREEN JUNCTION
TORX SCREWS GROUND SCREW BOX GASKET

PUMP

SCREEN GASKET
POCKET
SCREEN GASKET
½" NPT
CONDUIT HOLE, EARTH GROUND
INLET TANK (2) T-25 THREADED SYMBOL
FLANGE BUNG SCREWS
JUNCTION BOX CAP
JUNCTION BOX CAP
(CAN BE ROTATED 180°)

Step 7
BOLT POSITION
HOLE POST

5/16" BOLT,
40 IN-LBS

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12V DC and 24V DC Wiring Instructions

FR1200 / FR2400 / FR4200 / FR4400 / SD1200 Series DC Transfer Pump

Electrical wiring should be performed ONLY by a licensed electrician in compliance with local, state, and national electrical
codes (NEC/ANSI/NFPA 30, NFPA 30A, and NFPA 70) as appropriate to the intended use of the pump. Threaded rigid
conduit, sealed fittings, and conductor seal should be used where applicable. The pump must be properly grounded.
Improper installation or use of this pump can result in serious personal injury or death.
Do not connect the positive or negative power to the green ground/earth screw or ground/earth wire as this could
cause a fire.
Do not attempt to power the pump from vehicle wiring smaller than 12 AWG such as the cigarette lighter wire because
these thin wires could overheat and cause a fire.
For wiring up to upfitter switches, please contact Fill-Rite Technical Support at 1 (800) 720-5192 (M-F, 8am-5pm ET).

Fill-Rite DC fuel pumps are designed to operate at the rated nameplate voltage. Series FR1200, FR4200, and SD1200
are rated for 12V DC while FR2400 and FR4400 are rated for 24V DC. Regardless of how supply line power is provided
(i.e. via a battery or hard line), Fill-Rite requires the circuit contain a fuse to prevent against electrical shorts. For 12V
DC, a 30 amp fuse is necessary while for the 24V DC circuit, a 20 amp fuse.
Voltage drop in wiring varies depending on the distance from the battery to the pump and the gauge of the wire used.
If the distance is greater than the supplied 18' 12 AWG power cable*, refer to local, state, and national electrical codes
to ensure the wire is of the correct size for this application.
The following chart is to be used as a reference and is not a substitute for electrical codes:
Maximum Linear Distance (FT) of Stranded Copper Wire Length by Gauge
10 8 6 4 2
27' 44' 69' 110' 175'

*12 AWG power cable not supplied with pump only models

Electrical bonding is the process of connecting metallic parts such as a fuel storage tank or transfer pump which may
be exposed to electrical faults to a grounding conductor to ensure a low-resistance path to the ground. Bonding also
provides a path for static electricity and induced voltages to drain out through the grounding path. The most common
way to bond is with a copper wire.
If the intention is to operate either a 12V or 24V DC fuel transfer pump from a power supply other than a vehicle battery
system, please contact Fill-Rite Technical Support at 1 (800) 720-5192 (M-F, 8am-5pm ET).

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Instructions Before Proceeding with DC Wiring

The pump needs to be electrically bonded to a vehicle frame for mobile tanks or a ground rod for stationary tanks. To electrically bond pump for mobile
application, remove the external factory installed green bonding screw located on the junction box cover (Diagram 3). Insert this screw through eyelet of
furnished green bonding wire assembly and refasten it securely to the junction box. The other end of the wire is to be stripped of insulation and the bare wire
securely bonded to the vehicle or on/off road trailer frame for mobile tanks (Diagram 4). For bonding with stationary tanks, attach a ground wire to a ground
rod and the tank itself (Diagram 5). The distance may be greater than the supplied grounding wire.

Diagram 3 Diagram 4 Diagram 5

(2) T-25 EXTERNAL GREEN JUNCTION

TORX SCREWS GROUND SCREW BOX GASKET

½" NPT
CONDUIT HOLE, EARTH GROUND
THREADED SYMBOL

JUNCTION BOX CAP ATTACH GROUND WIRE

(CAN BE ROTATED 180°) TO GROUND ROD

ATTACH GROUND WIRE TO VEHICLE BODY

DC Wiring Instructions
1. Remove pump’s electrical junction box cover and straighten the red and black wire.
2. Screw the furnished cable connector into 1/2" NPT conduit opening on the junction box.
3. Strip 3" of the outer covering from one end of the furnished electrical supply cable.* Be careful not to damage the black and red wire insulation.
4. Loosen cable connector nut and pass the stripped end of the furnished cable through the cable connector. Tighten the cable connector nut.
5. Strip 1/2" of the insulation from the ends of the red and black cable wires. Using the furnished wire nuts, connect the cable wires to the pump wires
matching the colors.
IMPORTANT: Be sure no bare wire is exposed.
6. Fold wires into junction box and replace, making sure the cover gasket is in place. Make sure all screws are seated so there is no space between the
frame and the junction box (see Step 6 diagram on Page 6).
*12 AWG cable not supplied with pump only models

Mobile Tank Wiring to a Vehicle Electrical System

1. Before electrical installation, place the switch lever into the OFF position to prevent accidental spillage once power is engaged to the motor.
2. Pass the electrical wires to the source of the vehicle power system, supporting as necessary and protecting them from sharp edges, heat, or anything
that could cause damage.
3. To determine if the vehicle electrical system is negative (-) or positive (+) ground, check the battery marking of the terminal that is wired to the vehicle
frame or motor block. The red wire from the pump will connect to positive battery post and the black wire from the pump will connect to negative battery
post. These instructions focus on COMMON negative ground systems. UNCOMMON positive systems are a rare occurrence. Reference the drawing on
Page 9 for information on positive ground systems.
4. Fill-Rite requires installing a fuse holder and fuse (not provided) for protection of the purchased pump. Attach one end of the fuse holder to the end
of the ungrounded wire, making a solid connection. The other end of the fuse holder is then attached to the ungrounded side of the battery, as close
to the battery as possible. Make a solid electrical connection to the grounded side of the battery with the remaining wire. Utilizing a battery terminal
connection (not provided by Fill-Rite) is required for completion of the electrical circuit.
5. Check all connections to make sure they are connected per instructions and all electrical codes. Install fuse (30 amp fuse for 12V DC; 20 amp fuse for
24V DC) into the fuse holder. Installation is now complete.

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Mobile Tank Wiring to a Non-Vehicle System

While rare, there are instances where a 12V or 24V DC Fill-Rite fuel pump does not operate from a vehicle’s electrical system. In these cases, we recommend
calling Fill-Rite Technical Support at 1 (800) 720-5192 (M-F, 8am-5pm ET) to discuss your specific situation. Most of these applications will require equipment
not supplied by Fill-Rite. In addition, we want to ensure that the circuit will be able to handle the necessary power requirements of the pump.

Stationary Tank Wiring

1. Before electrical installation, place the switch lever into the OFF position to prevent accidental spillage once power is engaged to the motor.
2. Fill-Rite requires installing a fuse holder and fuse (not provided) for the protection of the purchased pump.
3. Attach one end of the fuse holder to the red pump wire, as close to the battery or power source as possible. Make a solid connection to the positive
terminal of the power source with the other end of the fuse holder. Make a solid connection with the black pump wire to the negative terminal of
the power source.
4. Check all connections to make sure they are connected per instructions and all electric codes.
5. Install fuse (30 amp fuse for 12V DC; 20 amp fuse for 24V DC) into the fuse holder.
6. The installation is now complete.

Negative Ground System (Common) Positive Ground System (Uncommon)

This electrical system is common within most vehicles utilizing a 12V This electrical system is uncommon within most vehicles utilizing a 12V
DC power source. In this instance, the positive battery terminal supplies DC power source. The chassis of the vehicle is connected to the positive
power to all devices such as the ignition system. The negative (-) terminal (+) terminal of the battery.
is connected to the vehicle’s frame. Fuse to be located outside of hazardous area, as close to the power source
Fuse to be located outside of hazardous area, as close to the power source as possible. If the wiring from the power source to the pump is greater
as possible. If the wiring from the power source to the pump is greater than 18', refer to the applicable Electrical Code (national, international, or
than 18', refer to the applicable Electrical Code (national, international, or local) to ensure the wire is of the correct size for the application.
local) to ensure the wire is of the correct size for the application.

COMMON UNCOMMON

FUSE FUSE
30 amp fuse for 12V DC 30 amp fuse for 12V DC
20 amp fuse for 24V DC 20 amp fuse for 24V DC

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115V AC Wiring Instructions for FR600 / SD600 AC Fuel Transfer Pumps

• All pumps will operate at the rated nameplate voltage.

• AC power should be supplied to the pump from a dedicated circuit with a 15 amp circuit protection. No other
equipment should be powered by this circuit.
• Wiring must be of sufficient size to carry the correct current for the pump.
• Voltage drop will vary with distance to pump and size of wire; refer to the National Electrical Code (NEC) or local codes
for voltage drop compensation to be sure you are using the correct size wire for your application. Undersized wires can
overheat and cause a fire.
• Ensure proper grounding to avoid electrocution.
• Each Fill-Rite motor is labeled as explosion-proof for hazardous locations Class I / Division 1. It is highly recommended
that any repairs be done by an authorized distributor to avoid voiding the warranty. It is very important to maintain the
explosion-proof integrity of the motor and system components.
• Electrical wiring should be performed ONLY by a licensed electrician in compliance with local, state, and national
electrical codes (NEC/ANSI/NFPA 70, NFPA30, and NFPA 30A) as appropriate to the intended use of the pump.
The pump must be properly grounded. Improper installation or use of this pump can result in serious bodily injury or death.

• Ground wire in supply wiring MUST be connected to the ground screw inside the junction box.

Voltage drop in wiring varies depending on the distance from the electrical source to the pump and the gauge of the wire
used. Fill-Rite recommends referring to national, international, or local electrical codes to ensure the wire is of the correct
size for your application. The following chart is to be used as a reference and is not a substitute to electrical codes.

Maximum Linear Distance (FT) of Solid and Stranded Copper Wire Length by Gauge
AWG 16 14 12 10 8 6 4
Solid 39 62 99 158 250
Wire
Stranded 38 61 96 154 245 389 620

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115V AC Wiring Procedure

1. Remove the junction box cover and straighten the wires to make sure the stripped wire ends are accessible outside the junction box.
2. Install rigid conduit and appropriate wiring from power source to the junction box to maintain the explosion-proof integrity.
3. Connect the pump wires to the power supply lines according to the wiring diagram. Be certain to properly insulate the connections with the appropriate
wire nuts or other connectors. NOTE: The ground wire MUST be connected. Ground wire connection is inside the junction box (Diagram 6b).
4. Fold the wires back into the junction box and replace the cover, making sure the cover gasket is in place.

115V AC Pump Junction Box (FR/SD600 Series AC Fuel Transfer Pumps)

Diagram 6a Diagram 6b

INTERNAL GROUND SCREW

115V AC Wiring Diagram

115V AC Wiring Diagram for FR/SD600 AC Fuel Transfer Pumps.

A ground wire must be included within the supply line power cable.
This wire must be connected to the ground screw terminal on the inside
of the junction box surface.

Switch Level Installation Instructions

Effective March 7, 2022, the fuel transfer pump on/off switch lever will need to be installed in the field. Please see Figure 1 for a visual guide on the
proper installation of this lever.

Figure 1

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Operation Instructions

Always keep the nozzle in contact with the container being filled during the filling process to minimize the possibility of
static electricity build up. A spark around flammable vapors will cause an explosion resulting in death or serious injury.

1. If equipped, reset meter to “0” (do not reset while in use as this
will cause damage to the meter). Diagram 7
2. Remove dispensing nozzle from nozzle boot.
3. Move the switch lever to the “ON” position to power the pump NOZZLE BOOT
(Diagram 7).
4. Insert the dispensing nozzle into the container to be filled.
5. Operate the nozzle to dispense fluid; release nozzle when the
desired amount of fluid has been dispensed.
6. Move switch lever to the “OFF” position (Diagram 8) to turn
off the pump.
"ON" Position
7. Remove the dispensing nozzle from the container being filled and
store it in the nozzle boot. SWITCH LEVER

Security
Diagram 8
Your Fill-Rite fuel transfer pump is
equipped with a locking link located next to Diagram 9
the switch lever for security. With the pump NOZZLE BOOT
turned off and the nozzle in the stored
position, a padlock can be inserted through
the locking link and the nozzle handle.
Fill-Rite recommends a commercial grade
laminated steel padlock with an adjustable
shackle (Diagram 9). "OFF" Position

SWITCH LEVER

Troubleshooting

The following troubleshooting guide is provided to offer basic diagnostic assistance in the event you encounter abnormal service from your Fill-
Rite fuel transfer pump. If you have questions, please feel free to contact Fill-Rite Technical Support at 1 (800) 720-5192 (M-F, 8am-5pm ET) or by
email at FillRiteTech@fillrite.com.

Please disconnect all power supply sources from either your AC or DC pump prior to performing any service or maintenance,
as well as relieve any pressure within either the suction tube or discharge hose. Failure to do so can result in damage to the
equipment and personal injury or death.

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Troubleshooting (continued)

Symptom Cause Cure

Suction line problem Check for leaks or restrictions in suction line
Bypass valve open Remove and inspect valve; must move freely and be free of debris
Vanes sticking Check vanes and rotor slots for nicks, burrs, and wear
Pump will not prime
Excessive rotor or vane wear Inspect rotor and vanes for excessive wear or damage; replace if necessary
Automatic nozzle Remove to prime pump
System blockages Check filter and bypass valve for debris; remove nozzle and test flow with pump ON
Excessive dirt in screen Remove and clean screen
Suction line problems Check for leaks or restrictions in suction line
Bypass valve sticking Remove and inspect valve; must move freely and be free of debris
Outlet blocked Check pump outlet hose, nozzle, and filter for blockage
Low capacity Vanes sticking Check vanes and rotor slots for wear; replace if necessary
Excessive rotor or vane wear Inspect rotor and vanes for excessive wear or damage; replace if necessary
Hose or nozzle damage Replace hose or nozzle (Fill-Rite recommends UL-rated hoses and nozzles)
Plugged filter Replace filter
Low fluid level Fill tank
Incorrect voltage Check incoming supply line voltage
Vanes sticking Inspect vanes and rotor slots for nicks, burrs, and wear
Pump runs slowly
Wiring problem Check for loose connections
Motor problem Contact Fill-Rite Technical Support at 1 (800) 720-5192 (M-F, 8am-5pm ET)
Bypass valve sticking Remove and inspect valve; must move freely and be free of debris
Motor stalls, fuse blows, Low voltage Check incoming supply line voltage
thermal protector trips
repeatedly Excessive rotor or vane wear Check rotor and vanes for excessive wear or damage
Debris in pump cavity Clean debris from pump cavity
Transferring high viscosity fluids These fluids can only be pumped for short periods of time (less than 30 minute duty cycle)
Clogged screen Remove inlet and clean screen
Motor overheats Restricted suction pipe Remove and clean pipe
Motor failure Contact Fill-Rite Technical Support at 1 (800) 720-5192 (M-F, 8am-5pm ET)
Pump rotor lock-up Clean and check pump rotor and vanes
No power Check incoming supply line power
Wiring issue Use multimeter to isolate issue with supply line power
Motor inoperable Motor failure Contact Fill-Rite Technical Support at 1 (800) 720-5192 (M-F, 8am-5pm ET)
Locked rotor Clean and check pump rotor; repair as needed with KIT120RG
Incorrect/loose wiring Verify correct wire size with local, state, and national electric codes
Bad O-ring gasket Check and replace all O-ring gaskets (Rotor Cover / Inlet Flange / Bypass Cap)
Dirty/bad shaft seal Replace shaft seal with KIT120SL
Fluid leakage
Incompatible fluid Refer wetted parts list on Page 14 to the fluid manufacturer
Loose fasteners Tighten fasteners

Pump hums but will Motor failure Contact Fill-Rite Technical Support at 1 (800) 720-5192 (M-F, 8am-5pm ET)
not operate Broken rotor key Remove all debris and replace key

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Specifications and Models

A series of fuel transfer pumps with UL/cUL, ATEX, IECEx, CE, EAC, and INMETRO certifications that are compatible with gasoline, diesel fuel, blended fuels
such as biodiesel up to 20%, gasoline with up to 15% ethanol, mineral spirits, and kerosene.

Product Parts Product Materials

Pump Housing Cast Iron

Rotor Powdered Iron
Vane Sintered Bronze
Strainer Mesh Stainless Steel
Wetted Components Buna-N, Fluorocarbon, Ceramic, Cork, Thermoset, Steel, Stainless Steel

Description FR1200 FR4200 SD1200 FR4400 FR2400 FR600 SD600

Voltage, Supply (DC/AC) 12V DC 24V DC 115V AC / 60HZ
Power (HP) 1/4TH 1/6TH
Amps (Full Load) 26 28 26 18 15 2.5
Amps (Rated) 20 19 20 13 10 2.0
RPM 2600 RPM 2000 RPM
Motor

Length 18' 15' 18'

Power Cord* Not Included
AWG 12
Duty Cycle 30 Minutes (on), then 30 Minutes (off)
Thermal Protection (motor) Yes
Required Circuit Protection 30 AMP 20 AMP 15 AMP
*Power cord not included in pump only models

Description FR1200 FR4200 SD1200 FR4400 FR2400 FR600 SD600

Maximum GPM 15 20 13 20 15 13
Bypass Pressure 16 PSI
Minimum Dry Vac 5 IN-HG

At Sea Level Suction Lift 8' Maximum

70° F (21.1° C)
Pump

Outlet Head 37' Maximum

Inlet 1" NPT
Outlet 3/4" NPT* 1" NPT* 3/4" NPT* 1" NPT* 3/4" NPT*
H Models: 2" NPT Bung Adapter with 1" NPT Inlet
Mount HE Pump Only Models: 2" BSPT Bung Adapter with 1" BSPP Inlet
Warranty Limited Lifetime Warranty† 1 Year Limited Lifetime Warranty† 1 Year
†
Warranty details can be found at fillrite.com
*
HE pump only models have BSPP outlets

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 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

FR1200, FR2400, FR4400, FR600, SD1200, and SD600 (Dimensions displayed in inches)

13.0

8.4

2.5

3.4 4.3

11.1

FR4200 (Dimensions displayed in inches)

13.7

8.4

2.5

4.2
4.3

11.8

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 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

H-Series Model Information: FR1200, FR2400, FR4200, FR4400, FR600, SD1200, SD600

Model Number Nozzle Hose Meter Inlet Tube Power Cord Special Voltage Outlet
FR1204H Pump Only Model
FR1210H Manual 12'
FR1210HA Auto Gasoline 12'
FR1210HA1 Auto Diesel 12'
FR1210HARC Auto Arctic 15' Swivel
FR1210HN
FR1211H Manual 12' 807C 12V DC
Metal Telescoping
12 AWG at 18'
FR1211HL Manual 12' 807CL 20" - 34 ½"

FR1211HLN 807CL 3/4"

FR1211HN 807C
FR1219H Manual 12' TT10AN
FR1220HDSQ Auto Diesel 18' Swivel
Swivel
FR1220HDSFQ Auto Diesel 18'
Filter
FR2404H Pump Only Model
FR2410H Manual 12'
Metal Telescoping 24V DC
FR2411H Manual 12' 807C 12 AWG at 18'
20" - 34 ½"
FR2411HL Manual 12' 807CL
FR4204H Pump Only Model
FR4210H Manual 12'
FR4210HARC Auto Arctic 20' Swivel
FR4210HB Ultra Hi-Flow 12' 12 AWG at 18'
FR4210HD Auto Diesel 12'
FR4210HDS Auto Diesel 12' Swivel
10 AWG at 25'
FR4210HBFQ Ultra Hi-Flow 18' Filter
with clamps
FR4210HN Metal Telescoping 12V DC 1"
FR4211H Manual 12' 901C 20" - 34 ½"

FR4211HL Manual 12' 901CL

FR4211HLN 901CL
12 AWG at 18'
FR4211HN 901C
FR4219H Manual 12' TT10AN
FR4220HDSQ Auto Diesel 18' Swivel
Swivel
FR4220HDSFQ Auto Diesel 18'
Filter

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 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

H-Series Model Information: FR1200, FR2400, FR4200, FR4400, FR600, SD1200, SD600 (continued)

Model Number Nozzle Hose Meter Inlet Tube Power Cord Special Voltage Outlet

FR4406H Pump Only Model

24V DC 1"
Metal Telescoping
FR4410H Manual 12' 12 AWG at 18'
20" - 34 ½"
FR604H Pump Only Model

FR610H Manual 12' UL 115V AC

Metal Telescoping
20" - 34 ½"
FR610HA Auto Gasoline 12' UL
3/4"
SD1202H Manual 10' 12 AWG at 15'
PVC, 15 ¼" ‑ 29 ¼" 12V DC
SD1202HA Auto Gasoline 10' 12 AWG at 15'

SD602H Manual 12' UL PVC, 15 ¼" ‑ 43 ¼" 115V AC

HE-Series Model Information: FR1200E, FR2400E, FR4200E, FR4400E

Model Number Nozzle Hose Meter Inlet Tube Power Cord Voltage Outlet
FR1205HE Pump Only Model

FR1210HE Manual 12'

FR1210HEA Auto Gasoline 12' 12V DC

Metal Telescoping
12 AWG at 18'
20" - 34 ½"
FR1211HEL Manual 12' 807CL

FR1211HELA Auto Gasoline 12’ 807CL

3/4"
FR2405HE Pump Only Model

FR2410HE Manual 12'

FR2410HEA Auto Gasoline 12’ 24V DC

Metal Telescoping
12 AWG at 18'
20" - 34 ½"
FR2411HEL Manual 12' 807CL

FR2411HELA Auto Gasoline 12' 807CL

FR4205HE Pump Only Model

FR4210HE Manual 12'

FR4210HEB Ultra Hi-Flow 12’ 12V DC

Metal Telescoping
12 AWG at 18' 1"
20" - 34 ½"
FR4210HEBL Ultra Hi-Flow 12' 901CL

FR4211HEL Manual 12' 901CL

FR4405HE Pump Only Model 24V AC

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 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

1200 Series Performance Curve

2400 Series Performance Curve

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 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

4200 Series Performance Curve

4400 Series Performance Curve

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 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

600 Series Performance Curve

Accessories

METER
STRAIGHT PIPE FILTER HEAD

STREET ELBOW

STRAIGHT PIPE

SWIVEL

NOZZLE

FILTER

HOSE

Proper Accessory Configuration

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 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

Accessories  (continued)

Outlet Size
Accessory Series Notes
3/4" 1"

Manual FRHMAN075S FRHMN1005 Gasoline/Diesel

N075UAU10 N100DAU12 Red Boot

Hi-Flow
N075DAU10 N100DAU12G Green Boot

Nozzle Arctic FRNA075DAU10 FRNA100DAU00 Cold Weather (-40˚F/˚C)

Automatic
N100DAU13 Red Boot

Ultra Hi-Flow N100DAU13G Green Boot

N100DAU13Y Yellow Boot

12', UL Rated 700F3135 300F7773

Gasoline, Diesel,
12' FRH07512 FRH10012 Kerosene, and
Hose
14' FRH07514 FRH10014 Petroleum Oils
compatible
20' FRH07520 FRH10020

807CMK Gallons
800
807CLMK Liters
Mechanical
901CMK4200 Gallons
900
901CLMK4200 Liters

900CD Programmable
Meter 900 Programmable with
900CDP
Integral Pulsar

TT10AB BSPP, Aluminum

Digital
TT10ABC BSPP, Nickel-Plated
TT
TT10AN NPT, Aluminum

TT10ANC NPT, Nickel-Plated

Swivel Multi-Plane S075H1314 S100H1315 360˚ Rotation

Heads 1200KTG9075 (F18 Filters) 700ACCF7017 (F40 Filters)

F1810PMO (10 Micron/18GPM) F4010PM0 (10 Micron/40GPM) Gasoline/Diesel

Filter Particulate
F4030PM0 (30 Micron/40GPM) compatible

Hydrosorb F1810HMO (10 Micron/18GPM)

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 | H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL

Pump Service Kits

# Kit Description Parts

1 KIT120BD* BioDiesel Kit O-ring, inlet and bypass cap seals, bypass valve poppet
2 KIT120RGG Rotor and Vane Kit Rotor cover, rotor, vanes, rotor key, O-ring seal, attaching hardware
3 KIT120JCH Junction Cover Kit Junction cover, seal, fasteners
4 KIT120SL Seal Kit O-ring, shaft seals, retainer clip
5 KIT120BV Bypass Service Kit Bypass valve, valve spring, bypass cap, O-ring seal
6 KIT120NB Nozzle Boot Kit Nozzle boot, attaching hardware
7 KIT120BG Inlet Flange Kit Inlet flange (bung), attaching hardware, inlet seal, screen
8 KIT120SG Inlet Gasket and Screen Gasket for inlet (bung) and screen
9 KIT120SWH Switch Lever Kit Switch lever, mounting hardware
*KIT120BD not called out in diagram above

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Safety Testing Approvals Installation
Pump must be installed in compliance with EN 60079-14 or IEC 60079-14, as
applicable.
The Fill-Rite line of pumps have been safety tested for regulatory compliance. This
product family is approved by UL/cUL. For the “E” series products they are approved to Material of Construction
ATEX, IECEx, INMETRO, EAC, and CE.
Materials of construction of the external surface of the unit: painted steel, painted cast
iron, painted aluminum, zinc plated steel.
Materials of construction of the wetted parts: cast iron, zinc plated steel, 300 series
stainless steel, bronze, carbon, ceramic, polyester, fiber, fluorocarbon, buna.
2809
Repair and Maintenance
Contact the place of purchase for warranty repair and maintenance.
The following standards were used to show compliance in the European Union:
EN IEC 60079-0:2018, Ed 7 “Explosive atmospheres – Part 0: Equipment – Specific Conditions of Use
General requirements” 1. Consult the manufacturer if dimensional information on the flameproof joints is
necessary.
EN 60079-1:2014, Ed 7 “Explosive atmospheres – Part 1: Equipment protection
by flameproof enclosures “d”” 2. ISO Class 4.6, M5 hex-head screws (Yield Stress 240 MPa) shall be used to replace
the DC Motor terminal cover fasteners.
EN ISO 80079-36:2016, Ed 1 “Explosive atmospheres – Part 36: Non-electrical
equipment for explosive atmospheres – Basic method and requirements”
3. ISO Class 8.8, M6 hex-head screws (Yield Stress 640 MPa) shall be used to replace
the DC Motor motor tie-rod fasteners.
EN ISO 80079-37:2016, Ed 1 “Explosive atmospheres – Part 37: Non-electrical 4. An electrically conductive hose and nozzle must be used with flammable liquids.
equipment for explosive atmospheres – Non electrical type of protection To minimize static electricity buildup, always keep the nozzle in contact with the
constructional safety “c”, control of ignition source “b”, liquid immersion “k”” container being filled during the fueling process.
Directive 2014/34/EU – Equipment and protective systems intended for use in
potentially explosive atmospheres. Motor Tag Information
Directive 2011/65/EU – Restrictions of the use of certain hazardous substances in
electrical and electronic equipment. The motor tag on your Fill-Rite pump contains important technical and
performance information. Be certain this label remains affixed to the
The following standards were used to show compliance for IECEx certification:
pump at all times.
IEC 60079-0:2017, Ed 7
IEC 60079-1:2014, Ed 7

Motor Tag Information

The Motor Tag on your Fill-Rite pump II 2 G
contains important technical and Ex db h IIA T5 or T6 Gb
FM19ATEX0019X
performance information. Be certain IECEx FMG19.0013X
this label remains affixed to the pump Ex db IIA T5 or T6 Gb
at all times.

Fill-Rite Company
8825 Aviation Drive
Fort Wayne, Indiana 46809 USA

T 1 (800) 720-5192
1 (260) 747-7524
F 1 (800) 866-4681

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