Zoeller QWIK JON ULTIMA 202 User manual

QWIK JON®ULTIMA 202 SYSTEM
INSTALLATION INSTRUCTIONS
PREINSTALLATION CHECKLIST
NOTICE TO INSTALLER: Instructions must remain with installation.
© Copyright 2016 Zoeller Co. All rights reserved.
DATE INSTALLED:
MODEL NUMBER:
REFER TO WARRANTY ON PAGE 2.
SEE BELOW FOR LIST OF WARNINGS
Patent No. 7,203,976
Other Patents Pending
50/60 Hz
Product information presented
of publication. Consult factory
regarding discrepancies or
inconsistencies. visit our web site:
- 1 -
ZT0155_Ec
0318
1216
Supersedes
P/N 082550
1. To reduce the risk of electrical shock, a properly grounded receptacle or
control box must be installed in accordance with the governing codes. Never
remove ground pin from plug.
2. Make certain that the ground fault interrupter protected receptacle or control
box is within the reach of the pump’s power supply cord. DO NOT USE AN
EXTENSION CORD. Extension cords that are too long or too light do not
deliver voltage to the pump motor, and they could present a safety
hazard if the insulation were to become damaged or the connection end were
to fall into a damp or wet area.
3. Make sure the pump's electrical supply circuit is equipped with fuses or circuit
breakers of proper capacity. A separate branch circuit is recommended, sized
according to the governing electrical codes for the current shown on the pump
name plate.
4. Testing for ground. As a safety measure, each electrical outlet should be
checked for ground using an Underwriters Laboratory Listed circuit analyzer
whichwillindicateif thepower,neutralandgroundwiresarecorrectlyconnected
to your outlet. If they are not, call a licensed electrician.
5. FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP FROM ITS
POWER SOURCE BEFORE HANDLING. If pump is wired direct, de-energize
the circuit at the control box. DO NOT, UNDER ANY CIRCUMSTANCES,
REMOVE THE GROUND PIN. Wear insulated protective shoes and do not
stand in water. Certain plug types may include a 3-prong ground plug to help
protect against electrical shock. A properly grounded 3-prong receptacle or
control box must be installed in accordance with governing codes.
6. Installation and servicing of the pump's electrical circuits and hardware should
only be performed by a licensed electrician.
7. Installation and maintenance of this appliance is not intended for persons
(including children) with reduced physical, sensory or mental capabilities, or
lack of experience or knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for their
safety.
8. Risk of electrical shock. Do not remove power supply cord and strain relief
or connect conduit directly to the pump. If the supply cable is damaged, it
must be replaced by an authorized Zoeller Representative.
9. Pump contains oil which becomes pressurized and hot when operating. Allow
2-1/2 hours after disconnecting before attempting service.
pmuP.01 is not intended for potable water due to possible contamination by oil
contained in the pump.
11. Risk of electrical shock. These pumps have not been investigated for use
in swimming pools and marine areas.
1. Inspect all materials. Occasionally, products are damaged during shipment. If the unit is damaged, contact your dealer before using. DO NOT remove the
test plugs from the pump.
2. Carefully read all the literature provided to familiarize yourself with details regarding installation and use. These materials should be retained for
future reference.
SAFETY INSTRUCTIONS
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR
PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL AND ON THE PUMP.
THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND
OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE PUMP.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR
TO PERFORMING ANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
This is a SAFETY ALERT SYMBOL.
Symbol on the pump or in the manual, look for one of the
following signal words and be alert to the potential for
personal injury or property damage.
Warns of hazards that CAN cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause personal injury or
property damage.
CAUTION
Warns of electrical shock hazards that can cause serious
personal injury, death or major property damage.
Read operator's manual.
Identifies any terminal which is intended for connection to
an external conductor for protection against electrical
shock in case of a fault, or the terminal of a protective
earth (ground) electrode.
zoellerpumps.com

© Copyright 2016 Zoeller Co. All rights reserved.
- 2 -
1. The QWIK JON® ULTIMA is with a specially designed grinder pump
and is capable of pumping fecal matter, toilet paper and also sanitary
articles which might accidentally be dropped into the toilet. It is not the
manufacturer's suggestion to such foreign objects into the sewer
main as they might clog the sanitary sewer.
2. Check to be sure your power source is adequate to handle the amperage
requirements of the motor as indicated on the pump or unit I.D. tag.
4. Maximum operating temperature must not exceed 40 °C (104 °F).
5. Do not use cleaning products containing bleach in the toilet tank, toilet or
attached as they will degrade the pump seals.
SEE BELOW FOR LIST OF CAUTIONS
3. All plumbing (discharge and carbon filter vent) must be installed to meet
local codes. Unit must be vented. Do not use an automatic plumbing
vent
6. This product is designed for use with one toilet only.
1. Repair and service should be performed by an Authorized Service Station
only. (Consult Factory.)
4. All connecting to the system must be on the same level.
SEE BELOW FOR LIST OF NOTES
NOTES
3. Pumps with the “UL” mark and/or the “US” mark are tested to UL Standard
UL778. CSA pumps are to CSA Standard C22.2 No.
108. Qwik Jon®Ultima units only. It is not designed for use in any other
application.
2. NOTE: Recommended for installations up to (20') total dynamic head.
Consult Factory if installation is above (15') vertical height in DN25
(1") pipe. Mini-Grinder Pump is designed for use in Qwik Jon®Ultima
units only. It is not designed for use in any other application.
6 m
5 m
LIMITED WARRANTY
Manufacturer warrants, to the purchaser and subsequent owner during
the warranty period, every new product to be free from defects in material
and workmanship under normal use and service, when properly used
and maintained, for a period of one year from date of purchase by the
end user, or 18 months from date of original manufacture of the product,
whichever comes first. Parts that fail within the warranty period, one
year from date of purchase by the end user, or 18 months from the
date of original manufacture of the product, whichever comes first, that
inspections determine to be defective in material or workmanship, will be
repaired, replaced or remanufactured at Manufacturer's option, provided
however, that by so doing we will not be obligated to replace an entire
assembly, the entire mechanism or the complete unit. No allowance
will be made for shipping charges, damages, labor or other charges
that may occur due to product failure, repair or replacement.
This warranty does not apply to and there shall be no warranty for
any material or product that has been disassembled without prior
approval of Manufacturer, subjected to misuse, misapplication, neglect,
alteration, accident or uncontrolled weather event; that has not been
installed, operated or maintained in accordance with Manufacturer's
installation instructions; that has been exposed to outside substances
including but not limited to the following: sand, gravel, cement, mud,
tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents,etc.),
or other abrasive or corrosive substances, wash towels or any other
abusive entity, etc. in all pumping applications. The warranty set out
in the paragraph above is in lieu of all other warranties expressed or
implied; and we do not authorize any representative or other person
to assume for us any other liability in connection with our products.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR
SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR
BREACH OF EXPRESSED OR IMPLIED WARRANT Y; AND
ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR
PURPOSE AND OF MERCHANTABILITY SHALL BE LIMITED TO
THE DURATION OF THE EXPRESSED WARRANTY.
Some jurisdictions do not allow limitations on the duration of an implied
warranty, so the above limitation may not apply to you. Some jurisdictions
do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights and you may also have
other rights which vary from jurisdiction to jurisdiction.
of part(s) or additional information pertaining to our warranty.
Contact authorized distributors to obtain any needed repair or replacement
HELPFUL HINTS FOR EASY INSTALLATION DO’S AND DON'T’S, continued
DO’S AND DON'T’S FOR INSTALLING A UNIT
1. DO read all installation material with the unit.
2. DO inspect unit for any visible damage caused by shipping.
Contact dealer if unit appears to be damaged.
3. DO clean all visible debris from the unit.
4. DO always disconnect pump from power source before handling.
DO always connect to a separately protected and properly grounded
ground fault protected circuit. DO NOT ever cut, splice or damage
power cord. DO NOT carry or lift pump by its power cord. DO NOT
use an extension cord.
5. DO install a ball or gate valve and a union in the discharge line
downstream of the check valve.
6. DO test pump immediately after installation to be sure that the system
is working properly.
7. DO review all applicable local and national codes and verify that the
installation conforms to each of them.
8. We DO NOT recommend this product be connected to utilities other than
those found in a normal bathroom application. Washing machines and
dishwashers are examples of equipment that we DO NOT recommend.
9. DO inspect and test system for proper operations at least every 3 months.
1. Read all instructions before beginning installation.
2. Be sure the floor is level within 3 mm (1/8").
3. Install vent pipe seal with flange side of seal on outside of lid.
4. Use soapy water to lubricate all seals to aid installation.
5. Install rubber coupling/union in vent line to aid disassembly.
6. Do not over torque toilet mounting screws.
7. Do not use an automatic plumbing vent device.
8. Obtain model number and date code, and record information in the
space provided on the front of this manual. Refer to this information
when calling the factory.
7. Conductor color coding: Type 1 - Line (Brown), Neutral (Blue), Ground
(Yellow / Green). Type 2 - Line (Black), Neutral (White), Ground (Green).
8. Electrical control box or electrical box are waterproof required.

SERVICE PARTS
© Copyright 2016 Zoeller Co. All rights reserved.
- 3 -
EA0092
Item
Description
1
2
9
3
4
5
6
7
8
Seal
Check valve
Nut with straight pipe adapter
Discharge fittings
Carbon filter vent
11
10
12
Qwik Jon®Ultima Sewage Removal System
Replacement pump with discharge pipe
Tank
Tank cover
Rubber coupling with hose clamps
Extension kit for behind the wall install (optional)
Piggyback switch
TYPICAL PIPING CONFIGURATIONS
Installation may not
be exactly as shown.
Refer to Step 1 on Page
5 for piping details.
2.4 m (8')
CEILING*
2.1 m (7')
CEILING*
20.3 cm (8")
MIN.
SUBFLOOR 19 mm (3/4")
THICK MINIMUM.
*Ceiling heights shown for reference only.
NOTE: All installations must
comply with all applicable
governing codes.
EA0067
51 mm x 203 mm
(2" x 8")
FLOOR JOISTS
**Option: hose with clamp.
PVC elbow**
11
10
12
2
6
7
8
9
3
5
4
1
This drawing may not be exactly the same as product.

© Copyright 2016 Zoeller Co. All rights reserved.
- 4 -
CONDITION POSSIBLE CAUSE REMEDY
A. PUMP WILL NOT ATART OR RUN.
Low voltage, blown fuse, open circuit. Have a qualified electrician check fuse and circuit.
Impeller bound. Contact a Zoeller Service Station.
Motor or wiring shorted.
Debris on float switch. Remove debris.
B. PUMP STARTS TOO SOON. Float “ON” point is adjusted too low. Raise the float stops, make sure the float is between the
C. WATER LEVEL EXCESSIVE BEFORE PUMP TURNS Float “ON” point adjusted too high. Lower the upper float stop.
D. PUMP WILL NOT SHUT OFF OR RUNS TOO LONG
BEFORE WATER IS PUMPED.
Debris under float. Remove debris from around float.
Faulty float switch. Contact a Zoeller Service Station.
Float “Off” point adjusted too low. Raise the lower float stop.
Pump is air locked. Make sure vent hole in discharge pipe is clear.
Water level too low. Raise the lower float stop.
Waste material has accumulated blocking
flow of material to pump intake.
Hold flush handle down on toilet for 15 seconds. If unit will
not clear, unplug and wait 30 minutes. Plug unit back in
and repeat. If unit still will not turn off, it will need to be
opened and the debris relocated.
E. PUMP OPERATES BUT
DELIVERS LITTLE OR NO WATER.
Debris around intake. Clean area around intake.
Blockage in discharge pipe. Remove pipe and flush out debris.
Low or incorrect voltage. Have a qualified electrician check house wiring.
Damaged Impeller. Contact a Zoeller Service Station.
Incorrect float adjustment. Contact Product Support Department.
Pump is air locked. Make sure vent hole in discharge pipe is clear.
Vertical lift too high. Change discharge piping or contact Product Support
Department.
ON.
two stops.
TROUBLESHOOTING
DIMENSIONS
EA0061
Install carbon filter vent, please replace
the carbon filter periodically, no need to
install vent pipe.
237
480
235
517
89
364
178
326
110
45 Unit : mm
(18-7/8")
(9-1/4")
(14-3/8")
(20-3/8")
(3-1/2")
(1-3/4")
(12-7/8")
(9-3/8")
(4-3/8")
(7")
If the above checklist does not solve the problem, consult the Zoeller Product Support Department by [email protected] Do not attempt to service or otherwise
disassemble pump.
Care of finish: soap and water is all that is recommended for cleaning the outside of the tank. Other cleaning products may cause discoloration and scratching.

Sewage: Access to a sewage line is required. The Qwik Jon®Ultima requires
a DN25 (1") (or DN20 [3/4"] your codes permit) sewage discharge line to
connect to an existing sewage line. A ball or gate valve should
© Copyright 2016 Zoeller Co. All rights reserved.
- 5 -
QWIK JON
®
ULTIMA QWIK REFERENCE GUIDE
STEP 1 LOCATION SELECTION
Plan your new installation carefully.
Floor: The should be structurally sound and level within 3 mm (1/8"). If the
is not level, use hydraulic cement or similar material to level the floor.
floor floor
Water: A water supply will be needed to operate the toilet. Usually a DN15 (1/2")
line with a shut-off valve is
Electrical:Areceptacle of the appropriate voltage will be needed to supply electrical
power to the pump.
Vent: Access to a vent pipe is required. The use of a mechanical vent system is
NOT recommended as the toilet will not
NOTE: If a built-in installation is to be used, locate the pump unit in an area that
will allow access to the pump and switch.
OUTLET
WATER
SUPPLY
DISCHARGE
PIPE
VENT
PIPE
LEVEL FLOOR
BALL OR GATE VALVE
SOLD SEPARATELY
SK2588
STEP 2 LEVELING OF PUMP UNIT
Do not use wooden shims to level the pump unit!
Ensure that nails, screws or other sharp objects do not puncture the pumpunit!
Level the pump unit to within 3 mm (1/8") using hydraulic cement or similar material.
STEP 3 ROUGH-IN
1) Position the pump unit a minimum of 3 mm (1/8") from the wall
with the inlet facing forward. Attach the bellows to the inlet using
the worm drive clamp provided.
2) Place the toilet in front of pump unit aligning the discharge of the
toilet with the inlet of the pump unit. Make sure that the bellows
will bridge the gap adequately for installation. The toilet
tank should be a minimum of 13 mm (1/2") from the wall.
3) Lightly mark the locations of the pump unit, toilet andcloset
bolt locations on the Lightly mark the wall with theheight
of the pump unit and the bottom and sides of the toilet tank to
ensure against interference from pipe runs later.
4) Remove the toilet from the pump unit and set it aside.
EA0063
(STAND-ALONE INSTALLATION) (BEHIND THE WALL INSTALLATION)
1) Installing the grinder unit behind a wall will require an
extension kit (P/N 10-2123) sold separately.
2) Place the toilet assembly a minimum of 13 mm ( 1/2" ) from
the wall and mark the closet bolt locations on the floor.
3) Measure the appropriate length of 3-1/2" Schedule
PVC
40
pipe provided with the extension kit and cut it to
length. See sketch below.
4) Set toilet aside.
Toilet assembly is top heavy. Take special
precautions to ensure that toilet does not tip over and break.
EA0063
carbon filter vent:
The use
of a mechanical vent system is NOT recommended as the toilet will not
Please replace the carbon filter periodically.
Optional
(OPTIONAL CARBON
FILTER VENT)
discharge line.
be installed in the
if
EA0062

© Copyright 2016 Zoeller Co. All rights reserved.
- 6 -
PIPINGSTEP 4
2) While
1)
the discharge pipe, position and mark the location of
the pump unit discharge
3) Cut and DN40 (1-1/2") vent pipe as required to ensure that
the pipe does not interfere with other components. Make the
connection to the pump unit with the provided street elbow.
A 2" x 1" 90° discharge has been provided. However, it
may be easier to pipe straight up depending on the installation.
Proper venting is required. Do not use a mechanical
type vent.
4) Temporarily set the toilet in place to check that there is no piping
interference. Remove the toilet and set it aside.
5) Clean, prime and solvent weld the discharge piping and pump unit
discharge
When applying solvent weld to discharge ensure that
none gets into the check valve assembly. Pay close attention to the proper
alignment of the discharge previously marked.
6) Clean and solvent weld vent piping as required for proper venting.
Cut and the pipe and as required for (1")
DN25
diameter discharge pipe (may be reduced to [3/4"]DN20 diameter
if codes permit).
7)
Note: Adding other bathroom - The Qwik Jon®Ultima is designed
to accept additional bathroom utilizing the two side inlets.
To keep ventilation effectively, please replace the carbon filter
periodically.
Available for connecting DN25 (1") pipe. Simply reverse the pipe adaptor
Available for connecting DN25 (1") pipe.
Only need to reverse the pipe adaptor.
dry-fit fittings
fixtures
fixtures
Optional carbon filter vent:
and cut out the molded-in plug at the provided indentation.
dry-fitting
dry-fit
fitting.
fitting
vent
EA0064
Indentation
Check valve
Check valve
Cut cleanly and remove burrs and rough edges to avoid
clogging.

© Copyright 2016 Zoeller Co. All rights reserved.
- 7 -
1) Install the closet bolts at the points marked earlier.
2) Place the toilet assembly over the closet bolts. Install the anchoring
hardware and tighten in an alternating pattern. Check for level and shim
as required. Be careful when tightening bolts or nuts against china to
avoid cracking the china.
3) Install rubber bellows onto the toilet discharge and grinder tank hub
and secure with the worm clamps provided for installation. See sketch
in Step 3. For built-in installation, install the rubber couplings to both
the grinder tank and the toilet discharge and secure to extension pipe
with worm clamps provided. See sketch in Step 3.
4) Install the water supply line from the existing water shut-off valve to the
toilet water supply connection.
5) Open the water supply valve and check for leaks. The toilet tank should
to the proper level. Adjust if required.
6) Plug the pump's power cord into the outlet. If a plug is not included,
please refer to hardwiring instructions and diagram in STEP 7.
7) Flush the toilet and watch for proper operation. Listen for the pump to
start. The pump unit requires proper venting in order for toilet to
Check for leaks.
8) Repeat cycles to assure proper operation.
STEP 5 TOILET INSTALLATION (TOILET SUPPLIED BY OTHERS)
STEP 6
Carbon filter vent
(1) Open the cover.
(2) Replace the carbon filter.
To keep ventilation effectively, please replace the carbon filter periodically.
EA0056
REPLACE THE CARBON FILTER
FLOOR LEVEL TO WITHIN 3 mm (1/8")
PUMP UNIT
AUX. INLET
WATER
SUPPLY
OUTLET
DISCHARGE
PIPE
CARBON FILTER VENT
EA0065
(PLEASE REPLACE THE
CARBON FILTER
PERIODICALLY.)

© Copyright 2016 Zoeller Co. All rights reserved.
- 8 -
STEP 7 HARD-WIRING THE FLOAT SWITCH CONNECTION
Green
GNL
White
White
Black
Black
Yellow
/Green
G N L N
GNL
Blue
Blue
Brown
Brown
Type 1 Type 2
These are the original installation instructions.
FOR UNITS WITHOUT PLUGS INTENDED FOR PERMANENT CONNECTION ONLY.
G L