Main is full and atleast has to drop the first quarter
It will transfer a very small amount when engine is started with same caveats above
You can see it transfer over if you start engine and quickly go to the filler cap
While transferring . It will stop if incline or decline is too great or road is too bumpy
It doesn't need to be low or have the low light on to transfer. If yours is not transferring then there is a problem somewhere.
Does the green light come on and stay on when you hit the button. Also is the sub tank warning in the dash off because if it is on then there is a fault and won't transfer.
It is a slow transfer so you won't see it quickly on the gauges and it's quiet so you will only hear from underneath or near the filler for the main. It dumps back into the main filler neck.
If the warning is on then try disconnecting the battery for a few minutes.
I will assume yours is the same or very similar to my ZD30, the pump activates for several seconds every time you start the vehicle (this is why if you don't top up the sub when you do your fuel calcs you have a built in error), BTW in 19 years I have never noticed the transfer light come on when I'm starting the vehicle. You can manually transfer fuel anytime you like, if the tank is to full the transfer just won't happen until the level drops to an acceptable level, again in 19 years of owning mine I've never come across the exact level a transfer will happen at but I can tell you on mine it is before 1/4 is reached.
Best way to check if transfer is working is to get under and listen or put your hand on the transfer pump and get someone to start the vehicle, I'm deaf so I need to put my hand on it to feel it start and stop.
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