Fill-Rite BD4200D User Manual

SERIES BD1200C / BD4200D

DC FUEL TRANSFER PUMPS FOR

BIODIESEL B21-B100

(Biodiesel must conform to ASTM D6751 Standard)

W ARNING

This product should not be used for fluid transfer into aircraft. This
product is not suited for use with fluids for human consumption or
fluids containing water.

GENERAL DESCRIPTION

The Fill-Rite Series BD1200C/BD4200D products are positive
displacement, rotary vane pumps. Their rugged motors are explosion­proof and rain-proof to ensure a long life of dependability.

Owner's Operation & Safety

Manual

BD1210C (shown)

CAUTION

Not for use with Gasoline, Diesel Fuel or Biodiesel less than B21.
Use the Fill-Rite® Series FR1200 and FR4200 pumps to dispense
gasoline & diesel fuel.

SAFETY INSTRUCTIONS

To ensure safe and efficient operation, it is essential to read and follow
each of these warnings and precautions.

1. Do NOT smoke near pump or use pump near an open flame.
Fire could result.

2. Disconnect power to pump before servicing pump.

3. Take motors needing service to an authorized repair shop to
maintain “explosion-proof” and “rain-proof” integrity.

4. A biodiesel compatible filter should be used on pump outlet to
ensure that no foreign material is transferred to fuel tank.

5. The pump motor is equipped with thermal overload protection.
If overheated, it will shut itself off without any damage to the
windings. Move ON / OFF lever to the ‘OFF’ position to reset
pump.

6. Tank or barrel should be anchored to prevent tipping in both
the full and empty conditions.

7. To minimize static electricity build-up, keep nozzle in contact
with container being filled while filling container.

DANGER

Electrical wiring should be done by a
licensed electrician in compliance with
local, state and national electrical code,
ANSI/NFPA 70, 30, 30A as appropriate.
Rigid conduit should be used and a
proper ground must be provided to avoid
the possibility of electrical shock. Failure
to comply with this warning could result
in serious injury and/or loss of property.
Use only static wire, conductive hose
when pumping flammable fluids.

MECHANICAL INSTALLATION INSTRUCTIONS

Do NOT install additional foot valves or check valves unless
they have a pressure relief valve.

1. Use Teflon® Tape on all pipe threads

2. Tightly screw suction pipe (21) into inlet flange (1) of pumping unit.

3. Extend suction pipe into tank or barrel to within 3" of tank bottom.
Do not rest suction pipe on bottom of tank.

4. 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.

ELECTRICAL INSTALLATION INSTRUCTIONS

1. Install pump as described in Mechanical Installation Instructions.

Read and understand all of the electrical wiring
instructions before proceeding.

2. Remove pump’s electrical junction box cover and straighten the 2
wires to make the stripped wire ends accessible outside of the
junction box.

3. Screw furnished cable connector into ½ inch NPT conduit opening
in pump junction box.

4. Strip 6 inches of the outer covering from one end of the furnished
electrical cable being careful not to damage the black and red wire
insulation.

5. Loosen cable connector nut and pass the stripped end of the
furnished cable through the cable connector until 2 inches of the
unstripped cable is within the cable connector. Tighten the cable
connector nut.

6. 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
exposed.

7. Fold wires into junction box and replace cover making sure the
gasket is in place. Make sure all screws are seated so there is
no space between the cover and the junction box.

For Vehicle Installation

Follow steps 1 through 7 above.

A. Electically ground the pump to the vehicle (fuel tank pump is

mounted on must also be grounded). To electrically ground
pump, remove green grounding screw located next to junction
box cover. Insert this screw through eyelet of furnished green
grounding wire assembly and refasten it securely to the pump.
The other end of the wire is to be stripped of insulation and the
bare wire securely bonded to the vehicle frame.

CAUTION: Do not connect the positive or negative power to

the green screw or wire as this could cause a fire.

B. Pass the electrical wires to the source of the vehical power

system, supporting the wires as necessary and protecting them
from sharp edges, heat and anything that could damage the wires
and insulation.

C. Attach one end of a 30 amp, slow-blow fuse holder to the red

pump wire. Make a solid electrical connnection with the other end

1

Definition: Biodiesel is a clean burning fuel made from vegetable oil or animal fat that has been processed to meet the requirements of

ASTM D6751 standard. Only biodiesel that meets the ASTM D6751 standard are to be used with Fill

-Rite Series BD1200C and BD4200D
pumps. Unprocessed or recycled vegetable oil are not biodiesel and are not to be used with the Fill-Rite Series BD1200C or BD4200D
pumps.

Biodiesel can be used as a pure fuel, but is often blended with petroleum diesel fuel. When blended, the resulting fuel is known by the
percentage of biodiesel in the blend; ie. a 20% biodiesel blend with 80% petroleum diesel is know as B20. Pure biodiesel is B100, also know
as “Neat” biodiesel. Blends with 20% biodiesel or less (B1-B20) are generally treated like petroleum diesel fuel.

The Fill-Rite Series BD1200C and BD4200D Transfer Pumps are designed to handle biodiesel blends of B21–B100 (21%-100% biodiesel).
Users who wish to dispense blends with lower concentrations of biodiesel (B1-B20) should use the Fill-Rite Series FR1200C or FR4200D
fuel pumps.

Temperature Limitations: B100 (100% biodiesel) that meets ASTM D6751 has a “gel” point of 38°F (3.3°C). If B100 gets colder t han 40°F
(4.4°C), the Fill-Rite Series BD1200C and BD4200D Transfer Pumps may not operate properly due to the thickness of the fluid. In some
situations, tank manufactures may be able to supply tank and pipeline heaters that are safe to use and can keep the temperature of the B100
above 40°F.

Cleaning Properties of Biodiesel: Biodiesel has solvent properties that give it scrubbing and cleaning properties that tend to loosen rust,
varnish, and dirt in storage tanks, piping, and equipment. The resulting debris can clog filters and screens, or damage equipment. It is
important to understand this and take precautions to prevent problems when first using biodiesel.

Shelf Life of Biodiesel: It is recommended that biodiesel be used within 6 months for best performance. Microbial growth may occur if
biodiesel is stored for longer periods.

For more information on biodiesel, go to www.biodiesel.org.

of the fuse holder to the postive side of the battery. Make a solid
connection with the black pump wire to the negative battery
terminal or the end of the negative battery cable.

CAUTION: Do not attempt to power the pump from vehicle
wiring thinner than 12 gage such as the cigarette lighter
wire because these thin wires could overheat and cause a
fire.

D. Check all connections to make sure they are connected per

instructions and all electrical codes. Install the 30 amp, slow-blow
fuse in the fuse holder. The installation is now complete.

CAUTION: Do not connect the positive or negative power to
the green screw or wire as this could cause a fire.

B. Pass the electrical wires to the power source, supporting the

wires as necessary and protecting them from sharp edges, heat
and anything that could damage the wires and insulation.

C. Attach one end of a 30 amp, slow-blow fuse holder to the red

pump wire. Make a solid electrical 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.

For Skid Mounted or Mobile Tanks

Follow steps 1 through 7 on Page 1.

A. Electically ground the pump to the Tank. To electrically ground

pump,remove green grounding screw located next to junction
box cover. Insert this screw through eyelet of furnished green
grounding wire assembly and refasten it securely to the pump.
The other end of the wire is to be stripped of insulation and the
bare wire securely bonded to the tank.

TROUBLESHOOTING

IF PUMP FAILS TO PRIME:

• Check suction line for leaks or obstructions.

• Check bypass valve for dirt. The poppet should slide freely.

• Check electrical connections. Pump will run backwards if the black

and red wires are reversed.

• Open nozzle to allow air to be removed from the system

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.

BIODIESEL NOTES

CAUTION: Do not attempt to power the pump from vehicle
wiring thinner than 12 gage such as the cigarette lighter
wire because these thin wires could overheat and cause a
fire.

D. Check all connections to make sure they are connected per

instructions and all electrical codes. Install the 30 amp, slow-blow
fuse in the fuse holder. The installation is now complete.

LOW PUMPING CAPACITY:

• Strainer screen clogged.

• Bypass valve not seating properly

• Obstruction in suction lines.

• Make sure all 5 vanes slide easily in their slots.

2

PARTS LIST

1 1200F6465 Inlet Flange 1
2 100F0760 Screen 1
3 100F0792 Inlet Gasket Flurocarbon 1
4 1200F2763 Bypass Valve Flurocarbon 1
5 1200G9290 Bypass Gasket Flurocarbon (-121) 1
6 1200F2770 Bypass Spring 1
7 1200F6464 Bypass Cap 1
8 1200F6721 1/4-20 x 3/4 HHCS 4

9 4200G9807 Vane, Carbon 5
10 1200G8881 Rotor 1
11 1200F6440 Rotor Key 1
12 1200F6435 Rotor Cover 1
13 1200F6538 Rotor Cover Gasket Flurocarbon (-138) 1
14 1200KTF6446 Seal Assembly 1
15 702F3400 3/4" Streel Elbow (BD1210) 1

800F4400 1" Street Elbow (BD4210) 1

BD901MK

1" Meter with mechanical register for

BD4210

PART#

BD807CMK

DESCRIPTIO N

3/4" Meter with mechanical register for

BD1210

16 600F2220 Screw 5/16-18 x 5/8 HHCS 2
17 700F6673 Nozzle Cover 1
18 BDH0709 1" Manual Nozzle 1

18b 6F3095 3/4 x 1 Reducer Bushing 1

19 BDH0707 3/4" Automatic Nozzle

OPT

BDH0708 1" Automatic Nozzle

OPT

20 BDH0659 3/4" x 12' (BD1210) 1

BDH0660 1" x 12' (BD4210) 1
21 1200KTG9099 Suction Pipe Steel 1
33 1200R9067 18' Power Cable 1
34 1200G9038 J unction Box Gasket 1

35 1200G8999 Junction Box Cover

1

36 VP1400F8823 Screw #10-32 x 3/4 PHMS 4

2 NPT OD

1 NPT ID

8

12

9

13

10

8

2

1

3

33

11

14

5

7

15

6

4

21

16

17

34

35

36

ITM PART
NO. NO. DESCRIPTION QTY

For more information go to www.fillrite.com

ITM PART
NO. NO. DESCRIPTION QTY

Optional Bio Diesel Meter Kits

Date of Manufacture can be

found on the motor nameplate.

XX XX

Week year

REPAIR KIT BD1210KTH0710

Includes Items

2,3,4,5,6,9,10,11,12,13,14

19

3

Tel [phone] Fax [phone]

Fort Wayne, Indiana USA 46809

8825 Aviation Drive

www.tuthill.com

BD1210C BD4210D

Warranty

Two Years

Two Years

Motor HP

1/4 HP

1/4 HP

Motor Volt

12V DC

12V DC

Amp 2530

Rainproof

yes

yes

Flow with manual nozzle

57 LPM

15 GPM

76 LPM

20 GPM

Hose with static wire

3/4" x 12'

1" x 12'

Dimensions

12" wide

13" wide

9" high

12" high

9" deep

9" deep

Duty cycle

30 min.

30 min.

Max.Operating Temp

150°F

150°F

Min.Operating Temp

40°F*

40°F*

Minimum suction lift Bio Diesel B21­B100

6' 6'

Maximum outlet pressure

12 psi

14 psi

Minimum dry vacuum

5" mercury

5" mercury

Outlet

3/4" F NPT

1" F NPT

Threaded tank adapter

2" M NPT

2" M NPT

Inlet suction port

1" F NPT

1" F NPT

Thermal overload protection

yes

yes

Integral inlet screen

yes

yes

Motor UL and cUL listed

yes

yes

Ball Bearing construction

yes

yes

Security

Padlocking

Padlocking

Fluid Compatibility

Biodiesel

B21-B100

Biodiesel

B21-B100

* Bio Diesel B100 gel temperature is 38ºF. (Bio Diesel that conforms to

ASTM D6751 Standard

PRODUCT WARRANTY

Tuthill Transfer Systems (“Manufacturer”) warrants to each consumer
buyer of its Fill-Rite products (the “Buyer”), from the date of invoice or
sales receipt, that goods of its manufacture (“Goods”) will be free from
defects of material and workmanship. Duration of this warranty is as
follows:

• Heavy Duty Products - Two years

• Standard Duty Products – One year

• Economy Duty Products – One year

• Cabinet pumps, Parts, and Accessories - One year
Manufacturer’s sole obligation under the foregoing warranties will
be limited to either, at Manufacturers’ option, replacing or repairing
defective Goods (subject to limitations hereinafter provided) or
refunding the purchase price for such Goods theretofore paid by
the Buyer, and Buyer’s exclusive remedy for breach of any such
warranties will be enforcement of such obligations of Manufacturer.
If Manufacturer so requests the return of the Goods, the Goods will
be redelivered to Manufacturer in accordance with Manufacturer’s
instructions F.O.B. Factory. The remedies contained herein shall

constitute the sole recourse of the Buyer against Manufacturer for
breach of warranty. IN NO EVENT SHALL MANUFACTURER’S
LIABILITY ON ANY CLAIM FOR DAMAGES ARISING OUT OF THE
MANUFACTURE, SALE, DELIVERY, OR USE OF THE GOODS EXCEED
THE PURCHASE PRICE OF THE GOODS. The foregoing warranties
will not extend to Goods subjected to misuse, neglect, accident or
improper installation or maintenance, or which have been altered or
repaired by anyone other than Manufacturer or its authorized
representative. THE FOREGOING WARRANTIES ARE EXCLUSIVE
AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY,
FITNESS FOR PURPOSE OF ANY OTHER TYPE, WHETHER EXPRESS
OR IMPLIED. No person may vary the foregoing warranties and
remedies except in writing signed by a duly authorized officer of
Manufacturer. Warranties or remedies that differ from the foregoing
shall not otherwise be binding on Manufacturer. The Buyer’s
acceptance of delivery of the Goods constitutes acceptance of the
foregoing warranties and remedies, and all conditions and limitations
thereof.

4

1200H0652 REV. 0