Zoeller 810 User manual

1
© Copyright 2014 Zoeller Co. All rights reserved.
Model Number: ______________ Date Code: _______________
Simplex  Duplex
Packaged System FieldAssembled System
Job Name: ____________________________________________
Distributor: ____________________________________________
Date of Purchase: _________ Zoeller S/O No.: ______________
Contractor: ____________________________________________
Date of Installation: ____________________________________
System Readings During Start-up: Voltage _____Amps ______
OWNER’S MANUAL
MODELS 810 & 815 SUBMERSIBLE GRINDER UNITS
in the ownership of a Zoeller submersible wastewater product.
Pleasereadandreviewthismanualbeforeinstallingtheproduct.
Followthestepsinthismanualforaproperstart-up.Manyitems
contained within, when followed correctly, will not only ensure
a long and problem-free life for the pump, but also save time
andmoneyduringinstallation.ReferenceFM2435andFM2436
for replacement parts on 810 and 815 Series Progressing
Cavity Grinder Pumps respectively. Should further assistance
be necessary please call our Technical Service Department at
1-800-928-PUMP (7867).
Owner’s Information
Safety Instructions
TOAVOIDSERIOUS OR FATALPERSONAL INJURYOR MAJOR
PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUALAND ON THE PUMP.
THISMANUAL IS INTENDEDTOASSISTIN THE INSTALLATION
AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH
THE PUMP. This is a SAFETYALERT SYMBOL.
When you see this 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.
WarnsofhazardsthatWILLcauseseriouspersonal
injury, death or major property damage.
Warnsof hazardsthat CAN causeserious personal
injury, death or major property damage.
Warns of hazards that CAN cause personal injury
or property damage.
INDICATESSPECIALINSTRUCTIONSWHICHARE
VERYIMPORTANTAND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMINGANY WORK ON THIS PUMP.
MAINTAINALL SAFETY DECALS.
CAUTION
REFER TO WARRANTY ON PAGE 2.
Congratulations on the purchase of a Zoeller submersible
progressingcavitygrinderpump. Since 1939 the nameZoeller
has represented the standard for submersible dewatering and
sewagepumps.Thesamehighquality workmanship andeasy
maintenance design has been incorporated into this line of
heavy-dutysubmersibleprogressingcavitygrinderpumps.This
Zoeller pump will provide years of trouble-free service when
installed according to the manufacturer’s recommendations.
This manual incorporates the installation, operation,
maintenance,andserviceinstructionsintoonedocumenttoaid
Table of Contents
Safety Instructions.......................................................................1
Limited Warranty, Checklist andApplication..........................2-3
General Information.....................................................................3
Pump Wiring Instructions............................................................4
Typical Outdoor Prepackaged System.......................................5
Installation and Operation Instructions......................................6
Maintenance..................................................................................7
Service Checklist..........................................................................8
SECTION: 6.10.025
FM2458
0214
Supersedes
0112
NOTICE TO INSTALLER: Instructions must remain with installation.
Product information presented
here reects conditions at time
of publication. Consult factory
regarding discrepancies or
inconsistencies. MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
[phone] • 1 (800) 928-PUMP • FAX [phone]
visit our web site:
www.zoeller.com
®
Your Peace of Mind is Our Top Priority
®

2
© Copyright 2014 Zoeller Co. All rights reserved.
or other abrasive or corrosive substances, wash towels or feminine sanitary
products,etc.inallpumpingapplications. Thewarrantysetoutintheparagraph
above is in lieu of all other warranties expressed or implied; and we do not
authorizeanyrepresentativeorotherpersontoassumeforusanyotherliability
in connection with our products.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211,
Attention: Customer Support Department to obtain any needed repair or
replacement of part(s) or additional information pertaining to our warranty.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL,
CONSEQUENTIALOR INCIDENTAL DAMAGES OR BREACH OF
EXPRESSED OR IMPLIED WARRANTY; AND ANYIMPLIED WARRANTY
OFFITNESSFORAPARTICULARPURPOSEANDOFMERCHANTABILITY
SHALLBELIMITEDTOTHEDURATIONOFTHEEXPRESSEDWARRANTY.
Some states do not allow limitations on the duration of an implied warranty,
so the above limitation may not apply to you. Some states 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 specic legal rights and you may also have other rights
which vary from state to state.
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
workmanshipundernormaluseandservice,whenproperlyusedandmaintained,
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 rst. 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 rst, 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.
Thiswarrantydoesnotapply toandthereshall benowarranty foranymaterial
orproduct that hasbeendisassembledwithoutprior approval ofManufacturer,
subjectedtomisuse,misapplication,neglect,alteration,accidentoruncontrollable
actofnature;thathasnotbeeninstalled,operatedormaintainedinaccordance
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.),
1. Zoeller Progressing Cavity Grinder Pumps are designed for grinding
and pumping sanitary sewage from submersible lift stations. The
pump is intended to grind and pump reasonable quantities of items
normally found in sanitary sewage applications.
2. Zoeller 810 and 815 Progressing Cavity Grinder Pumps can be
installedinnewapplicationsorasadirectreplacementforanygrinder
application of like size and capacity. Some rail system retrot kits are
available.
3. The810and815canbeinstalledinaPrepackagedJobReadySystem
or may be used in a Field Assembled basin package. Page 5 shows
acouple of the Prepackaged Systems. FieldAssembled Systems are
discussed on page 3.
4. Zoeller 810 and 815 Grinder Pumps can be retrotted to existing
positive displacement pump installations.
Applications
Preinstallation Checklist
1. Inspect your progressing cavity grinder pump. If the unit has been
damaged in shipment, contact your dealer before installing. Do Not
remove the test plug in the cover nor the motor housing.
2. Carefullyreadallliteraturetofamiliarizeyourselfwithdetailsregarding
installation and use. Retain materials for future reference.
1. Makesurepumpconnectioncontainsagroundterminal.Thepower
cord on all Zoeller Progressing Cavity Grinder Pumps contains a green
conductor for grounding to help protect you against the possibility of
electric shock.
2. Make certain the electrical service is within reach of the power
supply cord.
3. Make sure any panels and branch circuits are equipped with
proper size fuses and circuit breakers.An independent power circuit is
recommended, sized according to the National Electrical Code, for the
current shown on the grinder pump nameplate.
4. For your protection, always disconnect the power source to the
grinder pump before handling. All grinder pumps must be properly
grounded and wired in accordance with the “National Electrical Codes”
and all local codes and ordinances.
5. Installation of electrical hardware and checking of control panels
and circuits should be performed by a qualied licensed electrician.
6. Risk of electrical shock - These pumps have not been investigated for
use in swimming pool areas.
7. According to the state of California (Prop 65), this product contains
chemicals known to the state of California to cause cancer and birth
defects or other reproductive harm.
1. Make sure the power source is capable of handling the
electrical requirements of the grinder pump, as indicated on the
nameplate.
2. A disconnect switch should be installed ahead of the pump.
3. The progressing cavity grinder pumps are operated by variable level
oat control switches. It is the responsibility of the installing party to
see that oat control switches will not hang up on the grinder pump
or other pit peculiarities and are secured so that the grinder pump will
shut off. It is recommended to use rigid pipe and ttings and the pit be
at least 24" in diameter for simplex systems and 36" in diameter for
duplex systems or larger.
4. Grinderinstallationsshouldbecheckedyearlyfordebrisand/orbuildup
which may interfere with the “ON” or “OFF” positions of variable level
oat control switches. Repair and service, other than cutter assembly
maintenance, should be performed by Zoeller Engineered Products
authorized service stations only.
5. Maximum operating temperature must not exceed 130°F,
(54°C).
6. Donotoperateanunsubmergedprogressingcavitypump.Drypump
operation may damage the hydraulic stator due to lack of lubrication.
Do not run dry.
7. To ensure proper pump operation, a swing or apper style check
valve must be installed in the pump discharge line. A faulty or
non-functionalcheckvalvewhencombinedwithapressuresewer
may prevent the pump from starting.
Do not attempt to turn star cutter located on
bottom of the unit with ngers. Use a wrench when checking
or removing star cutter.
CAUTION
SEE BELOW FOR
LIST OF CAUTIONS
SEE BELOW FOR
LIST OF WARNINGS
Progressing cavity grinder pumps are designed
for pressure sewer applications. A UL listed and CSA certied pres-
sure relief valve must be installed in the system to prevent excessive
pressure buildup.

3
© Copyright 2014 Zoeller Co. All rights reserved.
Recommended Limits ofApplication for Progressing Cavity Grinder Pumps
Simplex Station Duplex Station
Model HP Homes GPD Homes GPD
810 1 1 400 2 800
815 2 1 400 2 800
These recommended application limits are for pump stations pumping to a gravity main. Low-pressure collection systems should be designed with
a pump located at each house. For applications where a lift station would handle more than 2 homes, consider the 840 or 71 Series grinder pump.
For applications where a lift station would handle more than 60 homes, a solids handling type pump should be considered.
General Information
FIGURE 1.
018330
PROGRESSING CAVITY
GRINDER PUMP DESCRIPTION
1. Pumps are constructed of class 30 cast iron protected with powder
coated epoxy for long life when pumping sewage in submersible
applications. The cutter assembly is comprised of stainless steel
components hardened to a value of 55-60 on the Rockwell C scale;
a star shaped cutter and a precision ground at disk. Cutting action
takes place with the rotation of the star cutter at 1750 RPM against
the stationary cutter plate (see page 7).
2. The cutter mechanism on the model 810 & 815 is single directional.
3. Pump motors are single phase. Single phase motors require a run
capacitor, which is mounted in the the upper cap of the pump (ref.
page 4). The units have an internal thermal overload.
4. The 810 & 815 progressing cavity grinder pumps are single seal.
5. The pressure relief valve provides motor protection under inadvertent
shut-off head condition.
6. Aprogressingcavitygrinderpumpisanintermittentdutypumpdesigned
for pumping sanitary sewage. It is not a dewatering or trash pump.
FIELD ASSEMBLED INSTALLATION
1. Installationandpipinginstructionsareincludedwiththecontrolpanel,
rail system and basin instructions. If pump is being retrotted to an
existing rail system, accessory parts may be required. Consult the
factory and advise make and model of rail system being used.
2. Refer to the appropriate Indoor/Outdoor prepackaged instructions
for more information on system installation.
3. All electrical connections including pump to control box and power
supply to control panels must comply with the “National Electrical
Code” and applicable local codes. Conduit and panel enclosure
openingsmusthaveagas-tightseal.Installationofelectricalpanelsand
connections should be made by a qualied licensed electrician.
4. A properly sized disconnect switch, supplied by others, shall be
installed on the service side of the pump and control panel.
PUMP PERFORMANCE CURVE
MODEL 810/815

4
© Copyright 2014 Zoeller Co. All rights reserved.
Pump Wiring Instructions
FORYOURPROTECTION,ALWAYSDISCONNECTTHEPUMPFROMITSPOWERSOURCEBEFOREHANDLING.
AllelectricalconnectionsmustbewiredandgroundedinaccordancewiththeNationalElectricalCodeandallapplicable
local codes and ordinances.
“Risk of electrical shock” Do not remove the power supply cord and strain relief or connect conduit directly to pump.
Installation and checking of electrical circuits and hardware should be performed by a qualied licensed electrician.
FIGURE 3A. Models E810
and E815 Wiring Diagram
002397
RUN
O.L.
MOTOR
(3)
BLUE RED
WHITE
BLACK
GREEN
L1 L2
START
(1) (2)
YELLOW
BLUE RED
CAPACITOR
(WHITE) (BLACK)
(BROWN)
10" MAX.
5" MIN.
FIGURE 2. Pump Control Switch Installation
Use the diagram above to secure the oat switch properly and obtain the proper tether to customize the on-off cycle to each application. Note the
minimum off level shown above. On Prepackaged Systems, the tether length is set at 5”.
Note: Failure to keep within proper tether
limits may prevent reliable switch operation.
Note: Cable must be mounted in horizontal
position.
Determining Pumping Range
in Inches (1 inch - 2.5 cm)
Use only as a guide. Due to weight
of cable, pumping range above
horizontal is not equal to pumping
range below horizontal. Ranges are
based on testing in nonturbulent
conditions. Range may vary due to
watertemperatureandcordshape.As
tether length increases, so does the
variance of the pumping range.
Tether Length (inches) 5 10
Pumping Range (GPM) 9 13.5
min. max.
SK305D
SK2651
ALARM FLOAT
PUMP CONTROL
FLOAT TREE
FLOAT
16"
MIN. OFF
Electrical Data
Amps KVA
Code
Winding
Resistance
Line-to-Line
Model BHP RPM Voltage Phase Hertz Full Load Shut Off Locked
Rotor
E810 1 1750 230 1 60 7.0 7.0 24.5 G 2.3 / 2.0*
E815 2 1750 230 1 60 10.5 10.5 44.0 B 1.80 / 1.60*
RE810 1 1750 230 1 60 7.0 7.0 24.5 G **
RE815 2 1750 230 1 60 10.5 10.5 44.0 B **
* Line to line reading from the electrical load will only reect the run winding resistance. Start winding resistance can only be measured after
removing the cover.
** Start & run winding resistance can only be measured after removing the cover and checking at the through wall terminals.
FIGURE 3B. Models RE810
and RE815 Wiring Diagram
(932 Replacement Grinder System)
152554
RUN
O.L.
MOTOR
(3)
BLUE RED
GREEN
START
(1) (2)
YELLOW
BLUE RED
CAPACITOR
(WHITE) (BLACK)
WHITE
BLACK
RED
R
2
64
5
RELAY
YELLOW
BLUE
ORANGE
(BROWN)

5
© Copyright 2014 Zoeller Co. All rights reserved.
All installations must comply with all applicable electrical and plumbing codes, including but not limited to the National Electrical Code, local,
regional and/or state plumbing codes, etc.
Typical Outdoor Grinder Pumping System Installations
FIGURE 4A - PACKAGED SYSTEM WITH
FLEXIBLE HOSE DISCONNECT
24"
MINIMUM ANTI FLOATATION RING
1 1/4" BRASS CHECK VALVE
SHUT-OFF BALL VALVE
ALARM FLOAT
PUMP CONTROL FLOAT
12" MIN. OFF LEVEL
FIBERGLASS BASIN
1/8" 302 STAINLESS
STEEL LIFTING CABLE
1 1/4" FLEXIBLE
DISCONNECT FITTING
1 1/4" BULK HEAD
DISCHARGE FITTING
24
SOLID FIBERGLASS
COVER
GROMMET SEAL
2" ELECTRICAL PVC PIPE
4" INLET W-SEAL
(FIELD INSTALLED)
24"
MINIMUM
60"
DISCHARGE HOSE
HIGH WATER ALARM
(NOT INCLUDED)
WATERTIGHT "QWIK BOX"
(NOT INCLUDED)
FLOAT TREE
48"
72"
1 1/4"SCH 80 PVC PIPE
BRASS ANTI-SIPHON VALVE
1 1/4" MALE THREAD X SLIP FITTING
1 1/4" MALE THREAD X
SLIP FITTING
SK2540 SK2569
FIGURE 4B - PACKAGED SYSTEM WITH
SQUARE GUIDE RAIL SYSTEM
SK2533
6 5/8
8 3/8
5 1/4
4 3/8 10 1/2 DIA.
22 3/8
4
FIGURE 5 FIGURE 5A
SK2810

6
© Copyright 2014 Zoeller Co. All rights reserved.
1. Review the drawing in Fig. 4 on page 5 and the actual system to become familiar
with the components in the packaged grinder pump system. Review where the unit
willbeinstalled. Determinewherethepowerfeed,inletpipe,anddischargepipewill
be located.
2. Removethe unit frompacking. Prepackagedoutdoor systems arepreassembled at
the Zoeller Company and require a minimum of eld assembly work. Float switches
areset and tetheredfor proper operationfrom the Factory. The alarmswitch should
be located 2” above the pump “on” level.
3. Float switches are tied in place for shipping purposes on all model prepackaged
systems. Cut the cable tie around each oat switch bulb or the unit will not operate
properly. Verify that where the oat switches are set will work for your application.
Verifying that the oat switches are set properly and will not hang up inside
the basin is the responsibility of the installing contractor.
4. Dig a hole for the basin. The hole should be at least 24” larger in diameter than
the basin diameter to provide 12” of backll all around and deep enough to provide
either 12” of compacted backll or 6” when a concrete pad is required. Ensure the
removable cover extends above the nished grade line and the grade slopes away
from the unit. Backll and subbase should be 1/8” –3/4” pea gravel or 1/8” –1/2”
crushed stone. (Reference basin installation instructions included with unit)
5. Note: Care must be taken when excavating in order to avoid underground
utilities and disturbance of existing structure foundations. The hole should
be located at least ten feet from adjacent structures. Additional distance may
be required to sufciently locate the basin outside of the loading area of the
adjacent structures.
6. The location of the inlet tting is determined by the depth of the inlet pipe. The
inlet tting must be used with 4” pipe. It is best to install the inlet on the side of the
basin opposite the oat switches. To install, use a 5” hole saw to drill into the side
of the basin at the correct elevation. Center the hub inner diameter with the hole
in the basin. Attach the hub to the side of the basin using the sealant and hardware
provided.
7. The bottom of the excavation can now be back lled and compacted. Set basin in
hole and connect the 4” inlet pipe to the inlet hub.
8. The discharge piping is connected to the 1¼” threaded tting located in the basin
sidewall.
9. On basin depths of 72” and greater, the system’s disconnect assembly is shipped
looseandmustbescrewedintothedischargepiping.Applypipedope to threaded
connection.
10. Connectpull rodto Pump assembly. Connectlift cable to top of pump. Lower the
pump into basin ensuring the discharge pipe bracket slides into the disconnect
tting.
11. Pouring a concrete anchor around system can now be completed. Basin should
be lled with water when pouring concrete to minimize movement of the system.
Back ll around basin with specied media. Care should be used to avoid damaging
components or leaving voids when back lling. Refer to Basin installation reference
guide on more specic requirements.
12. Note: The progressing cavity grinder basin is a sewage holding tank. Vent
connectionshouldbeinstalledinaccordancewithallnational,stateandlocal
plumbing codes.
13. Dig a trench for the electrical conduit. Trench should be located at least 18” deep
and follow all applicable NEC codes. Connect electrical wiring to Junction box
accordingto wiring instructions included in this manual and wiringdiagram inbox.
Use the included sealant when closing Junction box.
14. If used, a control panel is installed within sight of the system. Connect oat switches
and pump cords according to the “Pump Wiring Instructions” found in this manual
and located inside the panel enclosure.
15. Removeanydebrisfromthebasin. Usingcleanwater,checkthesystemforproper
operation.
16. Sealandsecurethelidusingtheproperboltsandsealantwhenusingalidwithout
a formed gasket.
17. Add water to the basin and test the system for leaks and proper pump operation.
18. Record system start up data for future reference.
Outdoor Prepackaged System Installation Instructions
This set of instructions is for factory prepackaged outdoor progressing cavity grinder systems only. If this is a eld assembled outdoor system you can
use these instructions as a guideline.
GENERAL
Zoeller pumps are lubricated and tested at the factory prior to shipment and require
minimum pre-start-up maintenance.
Maximumoperatingtemperature ofpumpliquidforgrinderpumpsmustnotexceed130°F
(54°C).
These units are not designed to handle liquids other than sanitary sewage. If pump is
used to dewater areas with contaminated liquids with heavy or abrasive materials, the
warranty will be voided.
NAMEPLATE DATA
The nameplate, located on the top of the pump, indicates specic information about
the construction of the pump. The model number and date code information should be
recorded on the front page in the “Owner’s Information” section of this manual.
SHORT TERM STORAGE
When not in use, the pump should be stored and the following is advised:
• Drain pump housing by laying pump horizontal with discharge down. Then stand pump
on legs.
• Store pump inside whenever possible or cover with some type of protective covering.
• Tape or seal in plastic bag the terminal ends of wire leads.
• Spray coat unpainted surfaces with rust inhibiting oil.
• The impeller should be rotated every six months in order to keep the seal lubricated
and not develop a permanent set.
If panel is to be stored, the following is advised:
• Store the panel inside whenever possible and leave in the shipping box.
• All openings shall be sealed.
• Store in an upright position.
• Do not stack anything on top of panel.
START-UP PROCEDURE
Before placing the equipment into operation the following should be checked:
• Clean pit.
• Electrical boxes dry and securely installed.
• Floats positioned properly.
• Discharge valves open.
• Adequate water level in basin for pump submersion.
Once the above has been veried proceed with the following checks:
• Pump power cables and control oats properly installed and voltage veried.
• Conduit connections to panel are properly sealed.
• After installing the pump into the containment area, with adequate submergence, open
the discharge valve fully. Start the unit using manual controls. If ow is appreciably
less than rated performance, pump may be air locked. To expel trapped air, jog the
unit several times, using the manual controls.
• Have a qualied electrician take voltage and current measurements with the pump
running.Recordthese readingsinthespaceprovidedin the“Owner’sInformation”
section on page 1 of this manual for future reference.
ADJUSTMENT PROCEDURE
Pumps: No adjustments are required.
Floats: Refer to the system drawing or to the panel wiring schematic for the desired
location of each oat switch setting.
Valves: Dischargevalvesshouldbeplacedinthefullyopenposition.Systemsshould
notbeoperatedforextendedperiodsoftimewiththedischargevalvespartially
closed due to damaging the valve.
SHUTDOWN PROCEDURES
If a system is shutdown for more than six months, the following is recommended:
Pumps: If pit is to remain dry, then the pump can remain in the pit. Do not run dry. If
the pit is to remain wet, the pump should be removed and stored as noted
above.
Panels: The panel should have all openings sealed to prevent moisture and dust from
enteringthe enclosure.Priortorestartingsystem,thepanelshouldbeinspected
forpresence ofmoisture andany looseconnections.
Valves: Consult the valve/actuator supplier for information concerning these systems
components.
Operation

7
© Copyright 2014 Zoeller Co. All rights reserved.
Cutter Maintenance
To remove star cutter: Heat the center bolt
to 350°F to loosen Loctite® thread sealant.
Grind the Star Cutter and Disc seen here to a 32 micronish. Surfaces
must be at to within 0.001" T.I.R. Gap must be between 0.007" and
0.012" on these parts.
1. All power circuits must be disconnected and locked out before
any attempts are made at servicing. The star cutter and disc can
be removed and sharpened by grinding the cutting faces. Both star
cutter and disc must be removed from the pump. Removal of these
parts can be accomplished in the eld by removing pump from the
sump and positioning horizontally to access the intake of the pump. If
seals or other repairs are required, the pump must be totally removed
and serviced in a shop by a qualied pump technician or authorized
service center.
2. Thoroughly clean the star cutter and disc assembly. Tilt pump back to
the vertical position to make certain the end play has been removed.
Check and record the clearance between the star cutter and disc with
a feeler gage. The correct running clearance is between 0.007" and
0.012".
3. With pump in horizontal position, heat the hex head bolt in the center
of the star cutter with a propane torch. The bolt must be heated to
350° F to soften the thread lock sealer on the bolt for ease of removal.
Remove the bolt by turning in a counterclockwise rotation. It will be
necessary to use a wood block to prevent the star cutter from turning
while removing the bolt. Pull star cutter from the shaft and remove
the spacer shims located behind the star cutter.
4. Remove the six cap screws holding the disc and remove disc from
the pump.
5. The disc and star cutter can be replaced with new service parts or
resurfacedbygrinding.Resurfacingisaccomplishedbysurfacegrinding
both disc and star cutter to a 32 micro nish. Do not attempt grinding
in the eld. Send parts to a qualied machine shop or return to the
factory for repair. The disc, star cutter and shims are a matched set.
Keep parts together. Measure disc before and after resurfacing with
micrometer and record measurements.
6. After resurfacing, the disc and star cutter must be at within 0.001". If
thedischasbeensurfaceground,itwillbenecessarytoremoveshims
to compensate for the material removed from the disc. As a starting
point, remove shims of the same thickness as the amount machined
from the cutter disc (step 6 above). Final running clearance must be
between 0.007" and 0.012". Be sure pump is in vertical position and
all end play has been removed before measuring.
7. Clean bottom of pump where disc is located and replace disc and
retainer screws. Torque to 63-67 in-lbs. Replace star cutter with the
correct shims. Install washer and torque hex head bolt to 71-75 in.-lbs.
apply Loctite 262 thread-lock sealant or equal to bolt threads prior to
insertion. Check running clearance with pump in vertical position to
remove end play. Clearance must be between 0.007" and 0.012" to
obtain efcient grinding when pump is put back in service.
8. Check the oil in the motor housing before reinstalling. Contact the
factory if the oil has a milky appearance or burnt smell. The level
should be even with the ll plug when pump is in the upright position.
Add oil if required. Use insulating oil supplied by the factory.
FIGURE 7.
General Maintenance
Repair and service should be performed by a Zoeller
Pump Company Authorized Service Station only.
SAFETY PROCEDURES
Foryourprotection,alwaysdisconnectpumpand
panel from its power source before handling.
Never enter the basin until it has been properly
ventedandtested.Anypersonenteringabasinshouldbewearing
a harness with safety rope extending to the surface so that they can
be pulled out in case of asphyxiation. Sewage water gives off methane
and hydrogen sulde gases, both of which can be highly poisonous.
Installation and checking of electrical circuits and hardware should be
performed by a qualied electrician.
Pump is never to be lifted by power cord.
Unit must be cleaned and disinfected, inside the
pumping chamber and all exterior surfaces, prior to servicing.
GENERAL SYSTEM INSPECTION
Before the system is placed into operation, it should be inspected by a
qualied technician. Wiring and grounding must be in accordance
with the National Electrical Code and all applicable local codes
and ordinances.
LUBRICATION PROCEDURES
No lubrication is required.
If pumps are to be stored for more than six months, refer to short term
storage procedure in the Operation section.
PREVENTIVE MAINTENANCE
Preventive maintenance is recommended to ensure a long service life
from the product. Provided is a suggested maintenance schedule.
Every year:
• Inspect basin, report any sighting of grease accumulation.
• Check for proper and unobstructed oat operation.
• Listen for proper check valve operation.
Every 8 years or 2,000 hours of operation:
• Remove pump, inspect and service using a Zoeller rebuild kit.
• Flush and clean basin.

8
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Service Checklist
Electrical precautions. Before servicing a grinder pump, always shut off the main power circuit. Make sure you are wearing
insulated protective sole shoes and not standing in water. Under ooded conditions, contact your local electric company or a qualied licensed
electrician for disconnecting electrical service to the pump prior to removal.
Grinder pumps contain oil which becomes pressurized and hot under operating conditions.Allow 2½ hours after shut down
before servicing pump.
Condition
A. Pump will not start or run.
B. Motor overheats and trips on overload.
C. Pump will not shut off.
D. Pump operates but delivers little or no water.
E. Pump starts and stops too often.
F. Large red ashing light comes on at control box.
G. Grease and solids accumulate in pit around pump.
Common Causes
Blownpanelorcircuitbreakerfuse,lowvoltage,thermaloverloadopen,defectivecapacitor
circuit, cutter or impeller clogged, oat switch held down or defective, incorrect wiring in
control panel, water in cap assembly, check valve not installed or malfunctioning.
Incorrect voltage, impeller or cutter blocked, negative head (discharge lower than intake
of pump). Defective “off” oat. Pump runs continuously at low water level. Low oil level in
motor shell. Pump running at shut-off head, check valve not installed or malfunctioning.
Debris under oat assembly, defective switch, incoming sewage exceeds capacity of
pump.
Intakeclogged withgreaseorsludge,low orincorrectvoltage,cloggeddischarge
line, operating near shut-off head.
Check valve stuck open or defective. Sump pit too small to handle incoming sewage.
Level control out of adjustment. Thermal overload tripping.
High water in pit. Check pump for clogging, or overload trip.
Break up solids and run pump with water running into the pit. Allow level to lower to the
pump intake. Continue until solids are cleared from the pit.
Do not drain kitchen grease down the sink.
MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
[phone] • 1 (800) 928-PUMP • FAX [phone]
Your Peace of Mind is Our Top Priority
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®visit our web site:
www.zoeller.com