Tuthill FILL-RITE H Series User manual

MADE IN
USA
H-SERIES FUEL TRANSFER PUMPS
FR1200, FR2400, FR4200, FR4400, FR600, SD1200, SD600
Installation and Operation Manual

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
Table of Contents
Limited Warranty Policy
Tuthill Fort Wayne 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.
MODEL#
SERIAL#
PURCHASE DATE:
Thank You!
Thank you for your loyalty to the Fill-Rite®brand of fuel transfer pumps.
Your safety is important, so please read and thoroughly understand
the procedures set forth in this manual. In addition, please save these
instructions for future reference and record the model, serial number,
and purchase date of your fuel transfer pump. Protect yourself as well
as those around you by observing all safety instructions and adhering to
all danger, warning, and caution symbols. Please register your Fill-Rite®
product via info.tuthill.com/product_registration
IMPORTANT RETURN POLICY
Please do not return this product to the store. For all warranty
and product questions, please contact Tuthill Customer Service at
1-800-634-2695 (M-F, 8am-6pm EST/EDT.)
Limited Warranty Policy........................................................................ 2
About This Manual ............................................................................... 2
Symbols and Definitions ...................................................................... 3
Before You Begin ................................................................................. 3
Safety Information............................................................................... 4
Installation .......................................................................................... 5
12V DC and 24V DC Wiring Instructions ............................................... 7
115V AC Wiring Instructions................................................................10
Operation Instructions ....................................................................... 12
Security ............................................................................................. 12
Troubleshooting ................................................................................. 12
Specifications and Models ..................................................................14
Performance Curves ...........................................................................17
Accessories ........................................................................................19
Pump Service Kits.............................................................................. 21
Certifications..................................................................................... 22
Motor Tag .......................................................................................... 22

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
Before You Begin
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 Tuthill, your satisfaction with our products is paramount. If you have questions or need assistance with your product, please
contact Customer Service at 1-800-634-2695 (M-F, 8am-6pm EST/EDT).
• Adjustable Electrical Junction Box
Rotates 180 degrees to provide ease of electrical wiring installation
in tight quarters no matter the inlet bung location
• Reliable, Heavy-Duty Power Switch Lever
Features a cast metal stop that withstands heavy use in the
most rugged environments
• Locking Bar Defense
Elongated bar simplifies the pad locking process to prevent theft
• Focused Component Weight Reduction
Preserves expected heavy-duty performance while
improving installation ease
• Premium Paint Shield
An exemplary corrosion resistant barrier for long field life
• Thermally Protected Motor
Prevents overheating to ensure maximum motor life
• Telescoping Inlet Metal Suction Pipe*
Adjustable from 20 to 34 inches in length, allowing for universal
installation on a multitude of tank sizes and shapes
*Not included with SD models
• Intake Strainer Safeguard
Protects the pump by blocking particles created by contamination
• Certifications – UL, cUL
Symbols and Denitions
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.
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: Tuthill provides Teflon®tape for all models as listed on Page 16.
H-Series Fuel Transfer Pumps Have the Following Features

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
Safety Information
To ensure a safe installation and proper equipment operation, please read, understand, and adhere to all DANGER/WARNING/CAUTION and other NOTICES.
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.
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.
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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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
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.
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.
Diagram 2
1-2"
Min.
1-2"
Min.
Stationary Tank
For stationary fuel tanks, the pump mounts to the tank bung by way of
the pump inlet flange. Given the different sizes of stationary fuel tanks,
a custom suction or inlet pipe may be necessary. We recommend 1” NPT
black iron pipe that is extended to a length of at least 1-2” from the
bottom of the tank, with the bottom of the pipe cut to an angle between
30-45 degrees for improved flow.
A stationary tank must be equipped with a vent cap. (Diagram 1)
Mobile Tank
For mobile fuel tanks, the pump mounts to the tank bung by way
of the pump inlet flange.
For Telescoping Steel Suction Pipe
Allow telescoping tube to extend fully to the bottom of the tank.
For Custom or PVC Suction Pipe
To avoid penetrating the tank, we recommend leaving a minimum of 1-2”
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)
Vent Cap
Diagram 1
Vent Cap

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
Installation Procedure
Step 1: (Optional) Inlet Flange Removal
Loosen (4) 1/4" bolts using 7/16" wrench or socket. Detach inlet bung
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
remains in place upon re-attachment of junction box.
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.
* Black cable gland only included with DC models
†½" NPT to cable gland, bronze fitting per ATEX on HE Models
Maintain a minimum 1-2" separation from pipe end to bottom of tank.
(2) T-25
SCREWS
JUNCTION BOX CAP
GASKET
Step 5
Step 2 Step 3
PUMP
SCREEN
POCKET
INLET
FLANGE
GASKET
TANK
BUNG
SCREEN
Step 4
½" NPT
CONDUIT HOLE,
THREADED
(2) T-25
TORX SCREWS
EXTERNAL GREEN
GROUND SCREW
JUNCTION
BOX GASKET
JUNCTION BOX CAP
(CAN BE ROTATED 180°)
EARTH GROUND
SYMBOL
Step 6
BOLT
HOLE
POSITION
POST
5/16" BOLT,
40 IN-LBS
Step 7

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
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 Tuthill Customer Service at 1-800-634-2695 (M-F, 8am-6pm EST/EDT).
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), Tuthill 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:
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 Tuthill Customer Service at 1-800-634-2695 (M-F, 8am-6pm EST/EDT).
Maximum Linear Distance (FT) of Stranded Copper Wire Length by Gauge
10 8642
27' 44' 69' 110' 175'
*12 AWG power cable not supplied with pump only models

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
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.
DC Wiring Instructions
Diagram 5
ATTACH GROUND WIRE
TO GROUND ROD
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
ATTACH GROUND WIRE TO VEHICLE BODY
½" NPT
CONDUIT HOLE,
THREADED
(2) T-25
TORX SCREWS
EXTERNAL GREEN
GROUND SCREW
JUNCTION
BOX GASKET
JUNCTION BOX CAP
(CAN BE ROTATED 180°)
EARTH GROUND
SYMBOL
Diagram 3 Diagram 4
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. Tuthill 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 Tuthill) 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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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
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. Tuthill 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.
Positive Ground System (Uncommon)
This electrical system is uncommon within most vehicles utilizing a 12V
DC power source. The chassis of the vehicle is connected to the positive
(+) terminal of the battery.
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
than 18’, refer to the applicable Electrical Code (national, international, or
local) to ensure the wire is of the correct size for the application.
Negative Ground System (Common)
This electrical system is common within most vehicles utilizing a 12V
DC power source. In this instance, the positive battery terminal supplies
power to all devices such as the ignition system. The negative (-) terminal
is connected to the vehicle’s frame.
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
than 18’, refer to the applicable Electrical Code (national, international, or
local) to ensure the wire is of the correct size for the application.
FUSE FUSE
COMMON UNCOMMON
30 amp fuse for 12V DC
20 amp fuse for 24V DC
30 amp fuse for 12V DC
20 amp fuse for 24V DC
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 Tuthill Technical Service at 1-800-634-2695 (M-F, 8am-6pm EST/EDT) to discuss your specific situation. Most of these applications will require
equipment not supplied by Tuthill. In addition, we want to ensure that the circuit will be able to handle the necessary power requirements of the pump.

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
115V AC Wiring Instructions for FR600 / SD600 AC Fuel Transfer Pumps
• Ground wire in supply wiring MUST be connected to the ground screw inside the junction box.
• 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 Tuthill 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.
Voltage drop in wiring varies depending on the distance from the electrical source to the pump and the gauge of the wire
used. Tuthill 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 10 864
Wire
Solid 39 62 99 158 250
Stranded 38 61 96 154 245 389 620

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
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)
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.
Diagram 6a
Diagram 6b
115V AC Wiring Diagram
INTERNAL GROUND SCREW

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
Security
1. If equipped, reset meter to “0” (do not reset while in use as this
will cause damage to the meter).
2. Remove dispensing nozzle from nozzle boot.
3. Move the switch lever to the “ON” position to power the pump
(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.
7. Remove the dispensing nozzle from the container being filled and
store it in the nozzle boot.
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.
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 Tuthill Customer Service at 1-800-634-2695 (M-F, 8am-6pm EST/EDT) or by
email at [e-mail].
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.
"ON" Position
"OFF" Position
Your Fill-Rite fuel transfer pump is
equipped with a locking link located next to
the switch lever for security. With the pump
turned off and the nozzle in the stored
position, a padlock can be inserted through
the locking link and the nozzle handle.
Tuthill recommends a commercial grade
laminated steel padlock with an adjustable
shackle (Diagram 9).
Diagram 7
Diagram 8
Diagram 9
SWITCH LEVER
NOZZLE BOOT
SWITCH LEVER
NOZZLE BOOT

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
Symptom Cause Cure
Pump won’t prime
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
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
Low capacity
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
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 (Tuthill recommends UL-rated hoses and nozzles)
Plugged filter Replace filter
Low fluid level Fill tank
Pump runs slowly
Incorrect voltage Check incoming supply line voltage
Vanes sticking Inspect vanes and rotor slots for nicks, burrs, and wear
Wiring problem Check for loose connections
Motor problem Contact Tuthill Customer Service at 1-800-634-2695 (M-F, 8am-6pm EST/EDT)
Motor stalls, fuse blows,
thermal protector trips
repeatedly
Bypass valve sticking Remove and inspect valve; must move freely and be free of debris
Low voltage Check incoming supply line voltage
Excessive rotor or vane wear Check rotor and vanes for excessive wear or damage
Debris in pump cavity Clean debris from pump cavity
Motor overheats
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
Restricted suction pipe Remove and clean pipe
Motor failure Contact Tuthill Customer Service at 1-800-634-2695 (M-F, 8am-6pm EST/EDT)
Pump rotor lock-up Clean and check pump rotor and vanes
Motor inoperable
No power Check incoming supply line power
Wiring issue Use multimeter to isolate issue with supply line power
Motor failure Contact Tuthill Customer Service at 1-800-634-2695 (M-F, 8am-6pm EST/EDT)
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
Fluid leakage
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
Incompatible fluid Refer wetted parts list on Page 14 to the fluid manufacturer
Loose fasteners Tighten fasteners
Pump hums but will
not operate
Motor failure Contact Tuthill Customer Service at 1-800-634-2695 (M-F, 8am-6pm EST/EDT)
Broken rotor key Remove all debris and replace key
Troubleshooting (continued)

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
Specications and Models
Description FR1200 FR4200 SD1200 FR4400 FR2400 FR600 SD600
Motor
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
Power Cord*
Length 18' 15' 18'
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
Description FR1200 FR4200 SD1200 FR4400 FR2400 FR600 SD600
Pump
Maximum GPM 15 20 13 20 15 13
Bypass Pressure 16 PSI
Minimum Dry Vac 5 IN-HG
At Sea Level
70° F (21.1° C)
Suction Lift 8' Maximum
Outlet Head 37' Maximum
Inlet 1" NPT
Outlet 3/4" NPT 1" NPT 3/4" NPT 1" NPT 3/4" NPT
Mount 2" NPT Inlet Bung
Warranty Limited Lifetime Warranty†1 Year Limited Lifetime Warranty†1 Year
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
†Warranty details can be found at fillrite.com
*Power cord not included in pump only models
A series of fuel transfer pumps with UL/cUL 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.

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
FR4200 (Dimensions displayed in inches)
3.4
4.3
2.5
8.4
13.0
11.1
4.2
8.4
2.5
4.3
11.8
13.7
FR1200, FR2400, FR4400, FR600, SD1200, and SD600 (Dimensions displayed in inches)

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
Model Number Nozzle Hose Meter Inlet Tube Power Cord Special Voltage Outlet
FR1204H Pump Only Model
12V DC
3/4"
FR1210H Manual 12'
Metal Telescoping
20" - 34 ½" 12 AWG at 18'
FR1210HA Auto Gasoline 12'
FR1210HA1 Auto Diesel 12'
FR1210HARC Auto Arctic 15' Swivel
FR1210HN
FR1211H Manual 12' 807C
FR1211HL Manual 12' 807CL
FR1211HLN 807CL
FR1211HN 807C
FR1219H Manual 12' TT10AN
FR2404H Pump Only Model
24V DC
FR2410H Manual 12'
Metal Telescoping
20" - 34 ½" 12 AWG at 18'FR2411H Manual 12' 807C
FR2411HL Manual 12' 807CL
FR4204H Pump Only Model
12V DC
1"
FR4210H Manual 12'
Metal Telescoping
20" - 34 ½"
12 AWG at 18'
FR4210HARC Auto Arctic 20' Swivel
FR4210HB Ultra Hi-Flow 12'
FR4210HD Auto Diesel 12'
FR4210HDS Auto Diesel 12' Swivel
FR4210HBFQ Ultra Hi-Flow 18' 10 AWG at 25'
with clamps Filter
FR4210HN
12 AWG at 18'
FR4211H Manual 12' 901C
FR4211HL Manual 12' 901CL
FR4211HLN 901CL
FR4211HN 901C
FR4219H Manual 12' TT10AN
FR4406H Pump Only Model
24V DC
FR4410H Manual 12' Metal Telescoping
20" - 34 ½" 12 AWG at 18'
FR604H Pump Only Model
115V AC
3/4"
FR610H Manual 12' UL Metal Telescoping
20" - 34 ½"
FR610HA Auto Gasoline 12' UL
SD1202H Manual 10' PVC, 15 ¼" - 29 ¼" 12 AWG at 15' 12V DC
SD1202HA Auto Gasoline 10' 12 AWG at 15'
SD602H Manual 12' UL PVC, 15 ¼" - 43 ¼" 115V AC
H-Series Model Information: FR1200, FR2400, FR4200, FR4400, FR600, SD1200, SD600

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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
METER
STRAIGHT PIPE FILTER HEAD
STREET ELBOW
NOZZLE
FILTER
HOSE
STRAIGHT PIPE
SWIVEL
Proper Accessory Configuration
Accessories

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| H-SERIES FUEL TRANSFER PUMPS INSTALLATION AND OPERATION MANUAL
Accessory Series
Outlet Size
Notes
3/4" 1"
Nozzle
Manual FRHMAN075S FRHMN1005 Gasoline/Diesel
Automatic
Hi-Flow
N075UAU10 N100DAU12 Red Boot
N075DAU10 N100DAU12G Green Boot
Arctic FRNA075DAU10 FRNA100DAU00 Cold Weather (-40˚F/˚C)
Ultra Hi-Flow
N100DAU13 Red Boot
N100DAU13G Green Boot
N100DAU13Y Yellow Boot
Hose
12', UL Rated 700F3135 300F7773
Gasoline, Diesel,
Kerosene, and
Petroleum Oils
compatible
12' FRH07512 FRH10012
14' FRH07514 FRH10014
20' FRH07520 FRH10020
Meter
Mechanical
800
807CMK Gallons
807CLMK Liters
900
901CMK4200 Gallons
901CLMK4200 Liters
Digital
900
900CD Programmable
900CDP Programmable with
Integral Pulsar
TT
TT10AB BSPP, Aluminum
TT10ABC BSPP, Nickel-Plated
TT10AN NPT, Aluminum
TT10ANC NPT, Nickel-Plated
Swivel Multi-Plane S075H1314 S100H1315 360˚ Rotation
Filter
Heads 1200KTG9075 (F18 Filters) 700ACCF7017 (F40 Filters)
Gasoline/Diesel
compatible
Particulate
F1810PMO (10 Micron/18GPM) F4010PM0 (10 Micron/40GPM)
F4030PM0 (30 Micron/40GPM)
Hydrosorb F1810HMO (10 Micron/18GPM)
Accessories (continued)