Zoeller 810 User manual

1
© Copyright 2010 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
intheownershipofaZoellersubmersiblewastewaterproduct.
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 ORFATALPERSONALINJURYORMAJOR
PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUALAND ON THE PUMP.
THISMANUALIS INTENDED TOASSISTIN THEINSTALLATION
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 hazards thatCAN cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause personal injury
or property damage.
INDICATESSPECIALINSTRUCTIONSWHICHARE
VERY IMPORTANTAND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMINGANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
REFER TO WARRANTY ON PAGE 2.
Congratulations on the purchase of a Zoeller submersible
progressingcavitygrinderpump.Foroversixtyyearsthename
Zoellerhasrepresentedthestandardforsubmersibledewatering
and sewage pumps. The same high quality workmanship and
easy maintenance design has been incorporated into this line
of heavy-duty submersible progressing cavity grinder pumps.
ThisZoellerpumpwillprovideyearsoftrouble-freeservicewhen
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
0610
Supersedes
0809
NOTICE TO INSTALLER: Instructions must remain with installation.
Product information presented
here reflects 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

2
© Copyright 2010 Zoeller Co. All rights reserved.
than in raw sewage 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.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky
40211, Attention: Customer Service Department to obtain any needed
repair or replacement of part(s) or additional information pertaining to
our warranty.
MANUFACTUREREXPRESSLYDISCLAIMSLIABILITYFORSPECIAL,
CONSEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH
OF EXPRESSED OR IMPLIED WARRANTY; AND ANY IMPLIED
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF
MERCHANTABILITYSHALLBELIMITEDTOTHEDURATIONOFTHE
EXPRESSED WARRANTY.
Somestatesdonotallowlimitationsonthedurationofanimpliedwarranty,
so the above limitation may not apply to you. Some states do not allow
theexclusionor limitation ofincidentalor consequential damages,so the
above limitation or exclusion may not apply to you.
Thiswarrantygivesyouspecificlegalrights and you may alsohaveother
rights which vary from state to state.
Limited Warranty
Manufacturer warrants, to the purchaser and subsequent owner during
thewarrantyperiod, every newproductto be freefrom 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,
whichevercomes first. Parts that fail withinthe warranty period, one year
from date of purchase by the end user, or 18 months from the date of
originalmanufactureoftheproduct,whichevercomesfirst,thatinspections
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,
accidentoractofGod;thathasnotbeeninstalled,operatedormaintained
inaccordance 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 feminine sanitary products, etc. in all applications other
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 retrofit kits are
available.
3. The810and815canbeinstalledinaPrepackagedJobReadySystem
or may be used in a Field Assembled basin package. Page 5 shows
acouple of the Prepackaged Systems. FieldAssembled Systemsare
discussed on page 3.
4. Zoeller 810 and 815 Grinder Pumps can be retrofitted 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 qualified 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
float control switches. It is the responsibility of the installing party to
see that float 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 fittings 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
float 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 flapper 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 fingers. Use a wrench when checking
or removing star cutter.
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 certified pres-
sure relief valve must be installed in the system to prevent excessive
pressure buildup.

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© Copyright 2010 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 flat disk. Cutting action
takes place with the rotation of the star cutter at 1725 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 retrofitted 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 qualified licensed electrician.
4. A properly sized disconnect switch, supplied by others, shall be
installed on the service side of the pump and control panel.
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
PUMP PERFORMANCE CURVE
MODEL 810/815

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© Copyright 2010 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 qualified licensed electrician.
FIGURE 3A. Models 810
and 815 Wiring Diagram
002397
10" MAX.
5" MIN.
FIGURE 2. Pump Control Switch Installation
Use the diagram above to secure the float 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:Failuretokeepwithinpropertetherlimits
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
FLOAT TREE
MIN. OFF
16"
FLOAT
PUMP CONTROL
Electrical Data
Amps KVA
Code
Winding
Resistance
Line-to-Line
Model BHP RPM Voltage Phase Hertz Full Load Shut Off Locked
Rotor
E810 1 1725 230 1 60 6.0 6.0 24.5 G 2.3 / 2.0*
E815 2 1725 230 1 60 10.5 10.5 44.0 B 1.80 / 1.60*
*Line to line reading from the electrical load will only reflect the run winding resistance. Start winding resistance can only be measured after
removing the cover.
FIGURE 3B. Models 810
and 815 Wiring Diagram
(932 Replacement Grinder System)
018929
RUN
O.L.
MOTOR
(3)
BLUE RED
GREEN
START
(1) (2)
YELLOW
BLUE RED
CAPACITOR
(WHITE) (BLACK)
(BROWN)
RED
BLACK
WHITE

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© Copyright 2010 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
SK2540 SK2569
FIGURE 4B - PACKAGED SYSTEM WITH
SQUARE GUIDE RAIL SYSTEM
SK2533
4
22 3/8
14 1/16 DIA.
4 3/8
6 7/8
8 3/8
6 5/8
FIGURE 5. FIGURE 5A.
SK2810

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© Copyright 2010 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. Remove the unitfrom packing. Prepackaged outdoorsystems are preassembledat
theZoeller Company andrequire a minimumof fieldassembly work. Float switches
areset and tetheredfor proper operation from theFactory. The alarm switch 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 float switch bulb or the unit will not operate
properly. Verify that where the float switches are set will work for your application.
Verifying that the float 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 backfill all around and deep enough to provide
either 12” of compacted backfill or 6” when a concrete pad is required. Ensure the
removable cover extends above the finished grade line and the grade slopes away
from the unit. Backfill 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 sufficiently locate the basin outside of the loading area of the
adjacent structures.
6. The location of the inlet fitting is determined by the depth of the inlet pipe. The
inlet fitting must be used with 4” pipe. It is best to install the inlet on the side of the
basin opposite the float 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. Thebottom of the excavation cannow be back filled andcompacted. Set basinin
hole and connect the 4” inlet pipe to the inlet hub.
8. The discharge piping is connected to the 1¼” threaded fitting 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. Connect pullrod to Pump assembly. Connect lift cableto top of pump. Lower the
pump into basin ensuring the discharge pipe bracket slides into the disconnect
fitting.
11. Pouring a concrete anchor around system can now be completed. Basin should
be filled with water when pouring concrete to minimize movement of the system.
Backfillaroundbasinwithspecifiedmedia. Careshouldbeusedtoavoiddamaging
componentsorleavingvoidswhenbackfilling. RefertoBasininstallationreference
guide on more specific 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 wiring diagram in box.
Use the included sealant when closing Junction box.
14. Ifused,acontrolpanelisinstalledwithinsightofthesystem. Connectfloatswitches
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 field 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.
Maximumoperating temperatureofpumpliquidforgrinderpumpsmustnotexceed130°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 specific 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:
• Drainpumphousingbylayingpumphorizontalwithdischargedown.Thenstandpump
on legs.
• Storepumpinside whenever possible orcoverwith some typeofprotectivecovering.
• 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 verified proceed with the following checks:
• Pump power cables and control floats properly installed and voltage verified.
• Conduit connections to panel are properly sealed.
• Afterinstallingthepumpintothecontainmentarea,withadequatesubmergence,open
the discharge valve fully. Start the unit using manual controls. If flow 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 qualified electrician take voltage and current measurements with the pump
running.Record thesereadingsinthespaceprovidedin the “Owner’sInformation”
section on page 1 of this manual for future reference.
ADJUSTMENT PROCEDURE
Pumps: No adjustments are required.
Floats: Referto the system drawing or to the panel wiring schematic for the desired
location of each float 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
enteringtheenclosure.Priortorestartingsystem,thepanelshouldbeinspected
forpresence ofmoisture and any loose connections.
Valves: Consultthevalve/actuatorsupplierforinformationconcerningthesesystems
components.
Operation

7
© Copyright 2010 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 microfinish. Surfaces
must be flat 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 field 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 qualified 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 tosoften the thread lock sealer on the bolt forease 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 finish. Do not attempt grinding
in the field. Send parts to a qualified 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 flat 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
correctshims.Installwasherandtorquehexheadboltto71-75in.-lbs.
apply Loctite 262 thread-lock sealant or equal to bolt threads prior to
insertion. Check running clearance with pump in vertical posi
tion to
remove end play. Clearance must be between 0.007" and 0.012" to
obtain efficient 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 fill 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
aharnesswithsafetyropeextendingtothesurfacesothattheycan
be pulled out in case of asphyxiation. Sewage water gives off methane
and hydrogen sulfide gases, both of which can be highly poisonous.
Installation and checking of electrical circuits and hardware should be
performed by a qualified 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
qualified 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 month:
• Check for proper and unobstructed float operation.
• Listen for proper check valve operation.

8
© Copyright 2010 Zoeller Co. All rights reserved.
Service Checklist
Electrical precautions. Before servicing a grinder pump, always shut off the main power circuit. Make sure you are wearing
insulatedprotective sole shoes and not standing inwater.Under flooded conditions, contact your local electric company ora qualified 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 flashing 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, float 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” float. 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 float 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]
Manufacturers of..
www.zoeller.com