GENERAL DESCRIPTION

The Fill-Rite Series FR1200C, FR2400C, FR4200D, FR4400, FR600C,

SD1202, and SD602 products are positive displacement, rotary vane
pumps. Their rugged motors are explosion-proof and rain-proof to
FR1200C / FR2400C DC ensure a long life of dependability.
FR4200D / FR4400 DC
ALL PUMPS
SD1202 DC / FR600C / SD602 AC
Use Teflon® Tape on all pipe threads.
FUEL TRANSFER PUMP
Do NOT install additional foot valves or check valves that do
Owner's Operation & Safety Manual not have a pressure relief valve.
for EXPLOSION-PROOF & RAIN-PROOF
DC PUMPS INSTALLATION INSTRUCTIONS
Models FR1205C, FR1210C, FR1211C,
HEAVY DUTY:
FR2410C, FR2411C, FR4210D, FR4211D, 1. Tightly screw suction pipe (1200KTG9099) into inlet flange
FR4410, FR4411, FR610C, FR611C, (1200F6465) of pumping unit.
2. Extend suction pipe into tank or barrel to within 3" of tank bottom.
SD1202, SD602 Do not rest suction pipe on bottom of tank.
3. Screw inlet flange of pump into tank or barrel opening. Inlet flange
must be completely and securely threaded into an undamaged tank
or barrel bung.

STANDARD DUTY:
1. Secure nozzle boot (1200G8521) to motor endplate with the
two supplied bolts (300F7751) as illustrated on Page 3 of
manual.
2. Tightly screw extension pipe (VP1400F7687) into bung adapter.
FR610C (shown) FR1211C (shown) Attach suction pipe (VP1400F7686) to extension pipe in the
same manner.
3. Cut suction pipe at a length that will place its end within 3” of the
SAFETY INSTRUCTIONS container bottom. If a longer suction pipe is required, order
additional extension (VP1400F7687).
To ensure safe and efficient operation, it is essential to read and follow 4. Screw bung/suction pipe assembly securely into container
each of these warnings and precautions. opening.
1. Do NOT smoke near pump or use pump near an open flame.
Fire could result. HEAVY DUTY AND STANDARD DUTY (Electrical)
2. Disconnect power to pump before servicing pump. 1. Install pump. Read and understand all of the electrical wiring
3. Take motors needing service to an authorized repair shop to instructions before proceeding.
maintain “explosion-proof” and “rain-proof” integrity. 2. If pump does not have proper grounding, meaning continuous metal
4. A Fill-Rite filter should be used on pump outlet to ensure that no to metal connection from one component to the next, including tank,
foreign material is transferred to fuel tank. bung, pump, meter, filter, hose and nozzle, the pump needs to be
5. The pump motor is equipped with thermal overload protection. electrically bonded to supply tank or vehicle frame. To electrically
If overheated, it will shut itself off without any damage to the bond pump, remove green bonding screw located next to junction
windings. Move ON / OFF lever to the ‘OFF’ position to reset box cover. Insert this screw through eyelet of furnished green
pump. bonding wire assembly and refasten it securely to the pump. The
6. Tank or barrel should be anchored to prevent tipping in both other end of the wire is to be stripped of insulation and the bare wire
the full and empty conditions. securely bonded to the vehicle frame or skid tank.
7. To minimize static electricity build-up, keep nozzle in contact
with container being filled. CAUTION: Do not connect the positive or negative power to
the green screw or wire as this could cause a fire.

DANGER 3. Remove pump’s electrical junction box cover and straighten the 2
wires to make the stripped wire ends accessible outside of the
Electrical wiring should be done by a junction box.
licensed electrician in compliance with 4. Screw furnished cable connector into ½ inch NPT conduit opening
local, state and national electrical code, in pump junction box.
ANSI/NFPA 70, 30, 30A as appropriate. 5. Strip 6 inches of the outer covering from one end of the furnished
Rigid conduit should be used and a electrical cable being careful not to damage the black and red wire
proper ground must be provided to avoid insulation.
the possibility of electrical shock. Failure 6. Loosen cable connector nut and pass the stripped end of the
to comply with this warning could result furnished cable through the cable connector until 2 inches of the
in serious injury and/or loss of property. unstripped cable is within the cable connector. Tighten the cable
Use only static wire, conductive hose connector nut.
when pumping flammable fluids. 7. Strip ½ inch of the installation from the ends of the red and black
cable wires. Using the furnished wire nuts, connect these wires
to the pump wires matching the colors. Be sure no bare wire is
WARNING exposed.
8. Fold wires into junction box and replace cover making sure the
This product should not be used for fluid transfer into aircraft. This
gasket is in place. Make sure all screws are seated so there is
product is not suited for use with fluids for human consumption or
no space between the cover and the junction box.
fluids containing water.

1
For Vehicle Installation
Follow steps 1 through 8 on Page 1. D. Check all connections to make sure they are connected per
A. Pass the electrical wires to the source of the vehicle power instructions and all electrical codes. Install the 30 amp slow blow
system, supporting the wires as necessary and protecting it from fuse in the fuse holder. The installation is now complete.
sharp edges, heat, and anything that could damage the wires.
B. To determine if the vehicle electrical system is negative (-) or For Skid Mounted Tanks
positive (+) ground, check the battery marking of the terminal that Follow steps 1 through 8 on Page 1.
is wired to the vehicle frame or motor block. The red wire from A. Pass the electrical wires to the power source, supporting the
the pump will connect to positive battery post and the black wire wires as necessary and protecting them from sharp edges, heat
from the pump will connect to negative battery post. and anything that could damage the wires.
C. Attach one end of the fuse holder to the end of the ungrounded B. Attach one end of the fuse holder to the red pump wire. Make a
wire. Make a solid electrical connection with the other end of the solid electrical connection to the positive terminal of the power
fuse holder to the ungrounded side of the battery. Make a solid source with the other end of the fuse holder. Make a solid
electrical connection to the grounded side of the battery with the connection with the black pump wire to the negative terminal
remaining pump wire. The battery terminal or the end of the battery of the power source.
cable is recommended. C. Check all connections to make sure they are connected per
instructions and all electrical codes. Install the 30 amp slow blow
CAUTION: Do not attempt to power the pump from vehicle fuse in the fuse holder. The installation is now complete.
wiring thinner than 12 gage such as the cigarette lighter
wire because these thin wires could overheat and cause a
fire.

AC PUMPS INSTALLATION INSTRUCTIONS

HEAVY DUTY: HEAVY DUTY AND STANDARD DUTY (Electrical):
1. Tightly screw suction pipe (1200KTG9099) into inlet flange 1. Install pump. Read and understand all of the electrical wiring
(1200F6465) of pumping unit. instructions before proceeding. Electrical wiring should be
2. Extend suction pipe (1200KTG9099) into tank or barrel to within done by a licensed electrician in compliance with local, state and
3" of tank bottom. Do not rest suction pipe on bottom of tank. national codes.
3. Screw inlet flange (1200F6465) of pump into tank or barrel opening. 2.` Remove the pump’s electrical junction box cover and straighten the
Inlet flange must be completely and securely threaded into an 3 wires to make the stripped wire ends accessible outside of the
undamaged tank or barrel bung. junction box.
4. Systems should be designed to require a minimum amount of suction 3. Install rigid conduit and wires from the power source to the junction
lift. Maximum "equivalent feet of lift" is 7' (2.1m) for gas and 8' (2.4m) box to maintain explosion-proof integrity. Power to the unit should
for diesel fuel. ("Equivalent feet of lift" is the vertical distance from be supplied from a dedicated 15 amp circuit breaker. No other
the surface of the fluid in the tank to the inlet of the pump, PLUS equipment should be powered from this breaker.
the friction losses through the vertical and horizontal runs of pipe, 4. Connect wires to pump connecting like colored wires together.
all elbows and other fittings.) Ground wire must be connected.
5. Tank or barrel must be properly vented. Use a gasoline and oil proof 5. Fold wires into junction box and replace cover making sure the
pipe compound on all joints. A water separator should be used for gasket is in place. Make sure all screws are seated so there is no
pumping diesel fuel. space between the cover and the junction box. The installation is
now complete.
STANDARD DUTY
1. Secure nozzle boot (700G8828) to motor endplate with the two
supplied bolts (600F2220) as illustrated on Page 3 of manual.
2. Tightly screw extension pipe (VP1400F7687) into bung adapter.
Attach suction pipe (VP1400F7686) to extension pipe in the
same manner.
3. Cut suction pipe at a length that will place its end within 3” of the
container bottom. If a longer suction pipe is required, order
additional extension (VP1400F7687).
4. Screw bung/suction pipe assembly securely into container
opening.

TROUBLESHOOTING (ALL PUMPS)

IF PUMP FAILS TO PRIME: LOW PUMPING CAPACITY:
Check suction line for leaks or obstructions. Check bypass valve Strainer screen clogged, bypass valve not seating properly, obstruc
for dirt. The poppet should slide freely. tion in suction lines. Make sure all 5 vanes slide easily in their slots.

PUMP IS BOUND:
If the motor hums but will not start, the probable cause is a stuck
rotor. Remove rotor cover and check rotor and vanes for dirt.

2
 PARTS LIST
ITM PART ITM PART
NO. NO. DESCRIPTION QTY NO. NO. DESCRIPTION QTY
1 1200F6465 Inlet Flange 1 20 700F3135 3/4" x 12' UL Listed Hose (FR610C, SD602) 1
2 100F0760 Screen 1 FRH07512 3/4" x 12' Hose(FR1200C,FR2400C,SD1202 1
3 100F0790 Inlet Gasket 1 FRH10012 1" x 12' Hose (FR4200D, FR4400) 1
4 1200F2756 Bypass Valve 1 21 1200KTG9099 Suction Pipe Steel (Heavy Duty) 1
5 1200F6455 Bypass Gasket (-121) 1 VP1400F7687 Suction Pipe Extension (Standard Duty) 1
6 1200F2770 Bypass Spring 1 22 VP1400F7686 Suction Pipe PVC (Standand Duty) 1
7 1200F6464 Bypass Cap 1 23 800F3972 3/4" x 2 1/2" Nipple 1
8 1200F6721 1/4-20 x 3/4 HHCS 8 1200F6732 1" X 4" Nipple (FR4211D, FR4411) 1
9 1200G9485 Vane, Bronze 5 24 1200F6470 Fitting Meter 1
10 1200G8881 Rotor, Bronze 1 305F0998 Fitting Meter (FR4211D, FR4411) 1
11 1200F6440 Rotor Key 1 25 800F2300 Screw 5/16-18 x 1 3/4 HHCS 2
12 1200F6435 Rotor Cover 1 900F8649 Screw 1/4-20 x 2 (FR4211D, FR4411) 1
13 1200F6505 Rotor Cover Gasket (-138) 1 26 700F2800 O-ring Custom Buna-N 1
14 1200KTF6446 Seal Assembly 1 27 807C Meter, 3/4" OPT
15 702F3400 3/4" Streel Elbow 1 901 Meter, 1" OPT
800F4400 1" Streel Elbow (FR4200D, FR4400) 1 807CMK Black, 3/4" Meter Kit OPT
16 600F2220 Screw 5/16-18 x 5/8 HHCS 2 28 1200F6721 Screw 1/4-20x3/4 (FR4211D, FR4411) 1
300F7751 Screw 5/16-18x1/2 HHCS (SD1202) 2 29 800G8870 Knob Assembly 1
17 700F6673 Nozzle Cover Red 1 30 304F7885 1" 90 degree Elbow 1
700G8828 Nozzle Cover Yellow (SD602) 1 31 900F8076 Meter Flange 1
1200G8521 Nozzle Cover (SD1202) 1 32 304F7924 1" x 5" Nipple 1
18 6U075 3/4" Manual Nozzle (SD, FR610C ) 1 33 1200R9067 18' Power Cable (12 / 24 V) 1
N075UMN11 3/4" Manual Nozzle non UL 1 34 1200G9038 Junction Box Gasket 1
N100UMN11 1" Manual Nozzle non UL 1 35 1200G8999 Junction Box Cover 1
19 N075UAU10 3/4" Automatic Nozzle OPT 36 VP1400F8823 Screw #10-32 x 3/4 PHMS 4
300F7801 1" Automatic Nozzle OPT
**For more information go to www.fillrite.com

Included in 30

FR4211D, 32
31
FR4411
Included in FR4211D, FR4411
26
27

29
24
Included in FR1211C, 27

FR2411C,
uded inFR611C
FR1211C,
26 29 25
411C, FR611C 20

24 17 SD1202
23 ONLY 16
28
25
SD1202
ONLY
15 17
16
23 4
6 3/4-14 NPT ID
5 1-11 1/2 NPT ID
7
12/24V ONLY
33

Date of Manufacture can be found Representative

on the motor nameplate. Illustration
14
11
10
9
13
12
REPAIR KIT 4200KTF8739 8
36

Includes Items 3 34
35
2,3,4,5,6,9,10,11,12,13,14 2
21

1 21
2-11 1/2 NPT OD
19
8

22
1-11 1/2 NPT ID

3
 FR1210C FR2410C FR4210D FR4410 FR610C SD1202 SD602
Warranty Two Years Two Years Two Years Two Years Two Years One Year One Year
Motor HP 1/4 HP 1/4 HP 1/4 HP 1/4 HP 1/4 HP 1/4 HP 1/4 HP
Motor Volt 12V DC 24V DC 12V DC 24V DC 115V AC 12V DC 115V AC
Amp 20 10 22 13 1.5 20 1.5
Certified Rainproof yes yes yes yes yes yes yes
57 LPM 57 LPM 76 LPM 76 LPM 57 LPM 49 LPM 49 LPM
Flow with manual nozzle 15 GPM 15 GPM 20 GPM 20 GPM 15 GPM 13 GPM 13 GPM
Meter 807C 807C 901 901 807C 807CMK 807CMK
Static Guard Hose 3/4" x 12' 3/4" x 12' 1" x 12' 1" x 12' 3/4" x 12' UL 3/4" x 10' 3/4" x 12' UL
Dimensions without meter 12" wide 12" wide 13" wide 12" wide 12" wide 9" wide 12" wide
9" high 9" high 12" high 12" high 9" high 9" high 9" high
9" deep 9" deep 9" deep 9" deep 9" deep 7.5" deep 9" deep
Dimensions with meter 14" wide 14" wide 14" wide 14" wide 14" wide 14" wide 14" wide
14" high 14" high 14" high 14" high 14" high 14" high 14" high
9" deep 9" deep 9" deep 9" deep 9" deep 9" deep 9" deep
Duty cycle 30 min. 30 min. 30 min. 30 min. 30 min. 30 min. 30 min.
Max.Operating Temp °F 150° 150° 150° 150° 150° 130° 130°
Min.Operating Temp °F minus 15° minus 15° minus 15° minus 15° minus 15° minus 15° minus 15°
Minimum suction lift gasoline 7' 7' 10' 10' 7' 7' 7'
Minimum suction lift diesel 8' 8' 15' 15' 8' 8' 8'
Maximum outlet pressure 12 psi 12 psi 14 psi 14 psi 12 psi 12 psi 12 psi
Minimum dry vacuum 10" mercury 10" mercury 12" mercury 12" mercury 6" mercury 6" mercury 6" mercury
Outlet 3/4" F NPT 3/4" F NPT 1" F NPT 1" F NPT 3/4" F NPT 3/4" F NPT 3/4" F NPT
Threaded tank adapter 2" M NPT 2" M NPT 2" M NPT 2" M NPT 2" M NPT 2" M NPT 2" M NPT
Inlet suction port 1" F NPT 1" F NPT 1" F NPT 1" F NPT 1" F NPT 1" F NPT 1" F NPT
Automatic nozzle Opt. Opt. Opt. Opt. Opt. Opt. Opt.
Thermal overload protection yes yes yes yes yes yes yes
Integral inlet screen yes yes yes yes yes yes yes
Pump UL and cUL listed — — — — yes — yes
Motor UL and cUL listed yes yes yes — yes yes yes
Screen yes yes yes yes yes yes yes
Ball Bearing construction yes yes yes yes yes yes yes
Security Padlocking Padlocking Padlocking Padlocking Padlocking Padlocking Padlocking
Fluid Compatibility Diesel Diesel Diesel Diesel Diesel Diesel Diesel
Gasoline Gasoline Gasoline Gasoline Gasoline Gasoline Gasoline
Kerosene Kerosene Kerosene Kerosene Kerosene Kerosene Kerosene
Mineral Spirit Mineral Spirit Mineral Spirit Mineral Spirit Mineral Spirit Mineral Spirit Mineral Spirit

PRODUCT WARRANTY
Tuthill Transfer Systems (“Manufacturer”) warrants to each consumer constitute the sole recourse of the Buyer against Manufacturer for
buyer of its Fill-Rite products (the “Buyer”), from the date of invoice or breach of warranty. IN NO EVENT SHALL MANUFACTURER’S
sales receipt, that goods of its manufacture (“Goods”) will be free from LIABILITY ON ANY CLAIM FOR DAMAGES ARISING OUT OF THE
defects of material and workmanship. Duration of this warranty is as MANUFACTURE, SALE, DELIVERY, OR USE OF THE GOODS EXCEED
follows: THE PURCHASE PRICE OF THE GOODS. The foregoing warranties
• Heavy Duty Products - Two years will not extend to Goods subjected to misuse, neglect, accident or
• Standard Duty Products – One year improper installation or maintenance, or which have been altered or
• Economy Duty Products – One year repaired by anyone other than Manufacturer or its authorized
• Cabinet pumps, Parts, and Accessories - One year representative. THE FOREGOING WARRANTIES ARE EXCLUSIVE
Manufacturer’s sole obligation under the foregoing warranties will AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY,
be limited to either, at Manufacturers’ option, replacing or repairing FITNESS FOR PURPOSE OF ANY OTHER TYPE, WHETHER EXPRESS
defective Goods (subject to limitations hereinafter provided) or OR IMPLIED. No person may vary the foregoing warranties and
refunding the purchase price for such Goods theretofore paid by remedies except in writing signed by a duly authorized officer of
the Buyer, and Buyer’s exclusive remedy for breach of any such Manufacturer. Warranties or remedies that differ from the foregoing
warranties will be enforcement of such obligations of Manufacturer. shall not otherwise be binding on Manufacturer. The Buyer’s
If Manufacturer so requests the return of the Goods, the Goods will acceptance of delivery of the Goods constitutes acceptance of the
be redelivered to Manufacturer in accordance with Manufacturer’s foregoing warranties and remedies, and all conditions and limitations
instructions F.O.B. Factory. The remedies contained herein shall thereof.
8825 Aviation Drive
Fort Wayne, Indiana USA 46809
Tel 260 747-7524 Fax 260 747-3159

www.tuthill.com

4 1200G9918 REV. 0