Zoeller Qwik Jon Ultima 204 User manual

QWIK JON®ULTIMA 204 SYSTEMS
INSTALLATION INSTRUCTIONS
PREINSTALLATION CHECKLIST
1. To help reduce the risk of electrical shock, a properly
grounded receptacle or control box of grounding type must
be installed and protected by a ground fault circuit interrupter
(GFCI) in accordance with the National Electrical Code and
applicable local codes. Never remove ground pin from plug.
If pump is wired direct, a GFCI must be installed in the control
box. (SEE WARNING BELOW)
2. Make certain that the ground fault interrupter protected
receptacle or control box is within 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 sufcient voltage
to the pump motor. But more important, 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.Aseparate
branch circuit, sized according to the National Electrical Code
for the current shown on the pump name plate is recommended.
(See Note 3.)
4. TESTING FOR GROUND.As a safety measure, each electrical
outlet should be checked for ground using an Underwriters
Laboratory Listed circuit analyzer which will indicate if the
power, neutral and ground wires are correctly connected to your
outlet. If they are not, call a qualied 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.
Grounded pumps are supplied with a 3-prong grounded plug
to help protect you against the possibility of electrical shock.
DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE
GROUND PIN. To reduce the risk of electrical shock, a properly
grounded receptacle or control box of grounding type must be
installed and protected by a ground fault circuit interrupter (GFCI)
in accordance with National Electrical Code and applicable
local codes.
6. Installation and checking of electrical circuits and hardware
should only be performed by a qualied licensed electrician.
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.
NOTICE TO INSTALLER: Instructions must remain with installation. SECTION: 6.10.065
FM2460
0512
Supersedes
0210
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 specic details regarding installation and use before
attempting the installation. These materials should be retained for future reference.
1. 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.
2. All plumbing (discharge and vent lines) must be installed
to meet local codes. Unit must be vented. Do not use an
automatic plumbing vent device.
3. Maximum operating temperature for model 204 must not
exceed 130°F (54°C).
4. Do not use cleaning products containing bleach in the attached
xtures as they will degrade the pump seals.
1. Repair and service should be performed by an Authorized
Service Station only. (Consult Factory.)
2. NOTE: Recommended for installations up to 20' total dynamic
head. Consult Factory if installation is above 15' vertical
height in 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.
3. Mini-grinder pump is rated for 115V, 60 Hz, 7 Amps, .5 HP.
4. NOTE: Pumps with the “UL” mark and pumps with the
“US” mark are tested to UL Standard UL778. CSA Certied
pumps are certied to CSA Standard C22.2 No. 108. Qwik
Jon®Ultima units only. It is not designed for use in any other
application.
5. All xtures connecting to the system must be on the same
oor level.
MODEL NO. ____________________
DATE CODE: __________________
DATE INSTALLED: _____________
SEE BELOW FOR LIST OF NOTES
NOTES
REFER TO WARRANTY ON PAGE 2.
SEE BELOW FOR LIST OF WARNINGS
SEE BELOW FOR LIST OF CAUTIONS
Patent Pending
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 2012 Zoeller Co. All rights reserved.
Manufacturerwarrants,to the purchaser and subsequent ownerduring
thewarrantyperiod, every new product to befreefromdefectsinmaterial
and workmanship under normal use and service, when properly used
and maintained, for a period of one year from date of purchase by the
enduser,or18monthsfrom date of original manufacture oftheproduct,
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
inspectionsdeterminetobe defective in material or workmanship, will be
repaired,replaced or remanufactured atManufacturer'soption,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
approvalofManufacturer, subjected tomisuse,misapplication,neglect,
alteration,accidentoract of God; that has not been installed, operatedor
maintainedin 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 feminine sanitary products,
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.
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.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR
SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR
BREACH OF EXPRESSED OR IMPLIED WARRANTY; AND
ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR
PURPOSE AND OF MERCHANTABILITY SHALL BE LIMITED TO
THE DURATION OF THE EXPRESSED WARRANTY.
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
Helpful Hints For Easy Installation
1. Read all instructions before beginning installation.
2. Be sure the oor is level within 1/8".
3. Use soapy water to lubricate all seals to aid
installation.
4. Install rubber coupling/union in vent line to aid
disassembly.
5. Do not use an automatic plumbing vent device.
6. 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
Factory.
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.

3
© Copyright 2012 Zoeller Co. All rights reserved.
Typical Piping Congurations
NOTE: All installations must comply with all applicable Electrical
and Plumbing Codes, including, but not limited, to National Electrical
Code; Local; Regional and/or State Plumbing Codes, etc.
1
3
4
6
5
2
Service Parts
QWIK JON ULTIMA 204
204-A
Standard
204-A
Premium
8/07
thru
Current
3/12
thru
Current
Item Description Part No.
1 Qwik Jon®Ultima Model 204 System 204-1000 204-1006
2N202 replacement pump with discharge pipe 017374 152165
3Tank cover with discharge tting 018533 018533
4 Tank 018534 018534
5 Seal 017350 017350
6 Float switch assembly 018532 018532
SK2671
SK2587
Installation may not
be exactly as shown.

4
© Copyright 2012 Zoeller Co. All rights reserved.
CONDITION POSSIBLE CAUSE REMEDY
A. PUMP WILL NOT START OR
RUN.
Low voltage, blown fuse, open
circuit.
Have a qualied electrician check fuse
and circuit.
Impeller bound. Contact a Zoeller Service Station.
Motor or wiring shorted.
Debris on oat switch. Remove debris
B. PUMP STARTS TOO SOON. Float “ON” point is adjusted too
low.
Raise the oat stops, make sure the
oat is between the two stops.
C. WATER LEVEL EXCESSIVE
BEFORE PUMP TURNS ON. Float “ON” point adjusted to high. Lower the upper oat stop.
D. PUMP WILL NOT SHUT OFF
OR RUNS TOO LONG BEFORE
WATER IS PUMPED.
Pump not plugged into piggyback
oat switch receptacle.
Ensure pump is not plugged directly
into the outlet. Plug pump into
piggyback oat switch receptacle.
Debris under oat. Remove debris from around oat.
Faulty oat switch. Contact a Zoeller Service Station.
Float “Off” point adjusted too low. Raise the lower oat stop.
Pump is air locked. Make sure vent hole in discharge
pipe is clear.
Water level too low. Raise the lower oat stop.
E. PUMP OPERATES BUT
DELIVERS LITTLE OR NO
WATER.
Debris around intake. Clean area around intake.
Blockage in discharge pipe. Remove pipe and ush out debris.
Low or incorrect voltage. Have a qualied electrician check
house wiring.
Damaged Impeller. Contact a Zoeller Service Station.
Incorrect oat adjustment. Contact Technical Service
Department.
Pump is air locked. Make sure vent hole in discharge
pipe is clear.
Vertical lift too high. Change discharge piping or contact
Technical Service Department.
Before servicing a pump, always shut off
the main power breaker and then unplug the pump -
making 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 prior to pump
removal.
Submersible pumps contain oil which become
pressured and hot under operating conditions - allow 2½
hours after disconnecting before attempting service.
If the above checklist does not solve the problem, consult
Zoeller Technical Service Department 1-(800) 928-PUMP
- 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.

5
© Copyright 2012 Zoeller Co. All rights reserved.
Qwik Jon®Ultima Qwik Reference Guide
STEP 1 Location Selection
Plan your new installation carefully.
Floor: The oor should be structurally sound
and level within 1/8". If the oor is not level,
use hydraulic cement or similar material to
level the oor.
Water:Awater supply will be needed to operate
the shower and lav.
Electrical: A 115 volt GFCI receptacle will
be needed to supply electrical power to the
pump.
Sewage: Access to a sewage line is required.
The Qwik Jon® Ultima requires a 1" (or 3/4" if
your codes permit) sewage discharge line to
connect to an existing sewage line. A ball or
gate valve should be installed in the discharge
line.
Vent: Access to a vent pipe is required. The
use of a mechanical vent system is NOT
recommended.
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.
GFCI
OUTLET
DISCHARGE
PIPE
VENT
PIPE
LEVEL FLOOR
BALL OR GATE VALVE
SOLD SEPARATELY.
SK2672
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 pump unit!
Level the pump unit to within 1/8" using hydraulic cement or
similar material.
SK2673

6
© Copyright 2012 Zoeller Co. All rights reserved.
STEP 3 Piping
1) Adding bathroom xtures - The Qwik Jon®Ultima
is designed to accept bathroom xtures utilizing the
two side inlets. These inlets can be attached via the
2" MPT (outside diameter) or the 1½" slip (inside
diameter). These inlets must have the inner portion
drilled out using a 1¾" hole saw(see Figure 3.2).
This is to ensure there is no leakage problems from
inlets not in use. When utilizing side inlets, install a
check valve on the incoming line.
2) Cut and dry-t the pipe and ttings as required for
1" diameter discharge pipe (may be reduced to 3/4"
diameter if codes permit).
3) While dry-tting the discharge pipe, position and mark
the location of the pump unit discharge tting.
4) Cut and dry-t 1-1/2" vent pipe as required to ensure
that the vent pipe does not interfere with other
components. Make the connection to the pump unit
with the provided street elbow. A2" x 1" 90° discharge
tting 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.
5) Clean, prime and solvent weld the inlet and discharge
piping and pump unit discharge tting.
When applying solvent weld to discharge
tting, ensure that none gets into the check valve assembly
(see Figure 5.3). Pay close attention to the proper alignment
of the discharge tting previously marked above.
6) Clean and solvent weld vent piping as required for
proper venting.
SK2673 SKxxxx
DRILL POINT
1-1/2" SLIP INSIDE
2" MPT OUTSIDE
SK2586
Figure 3.1 Figure 3.2 Figure 3.3
Discharge Vent
Do not put glue in this area.

7
© Copyright 2012 Zoeller Co. All rights reserved.
STEP 3 NOTES

8
© Copyright 2012 Zoeller Co. All rights reserved.
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
®
®visit our web site:
www.zoeller.com