Zoeller SHARK 800 Series User manual

1
© Copyright 2020 Zoeller®Co. All rights reserved.
Congratulations on the purchase of the Zoeller submersible
grinder pump. Since 1939, the name Zoeller®has represented the
standard for submersible dewatering and sewage pumps. The same
high quality workmanship and easy maintenance design has been
incorporated into this line of heavy-duty submersible grinder pumps.
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, and service instructions into one document to aid
in the ownership of a Zoeller®submersible wastewater product.
ModelNumber:_____________DateCode:_______________
Automatic  Nonautomatic
Packaged System Field Assembled 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 818, 819 & 820 SUBMERSIBLE GRINDER UNITS
Please read and review this manual before installing the product.
Follow the steps in this manual for a proper start-up. Many items
contained within, when followed correctly, will not only ensure a
long and problem-free life for the pump, but also save time and
money during installation. For replacement parts lists, please
reference FM2993 for 818 series, FM2995 for 819 series, and
FM1531 for 820 series. Should further assistance be necessary
please call our Product Support Department at 1-800-928-PUMP
(7867).
Owner’s Information
Table of Contents
Safety Instructions...............................................................1
Limited Warranty .................................................................2
Preinstallation Checklist ......................................................3
General Information ............................................................4
Pump Wiring Instructions ...................................................5
Typical Indoor Prepackaged System..................................6
Indoor Prepackaged Installation Instructions....................7
Typical Outdoor Prepackaged System...............................8
Outdoor Prepackaged Installation Instructions.................9
Operation............................................................................10
Cutter Maintenance ...........................................................11
Service Checklist................................................................12
Safety Instructions
TOAVOIDSERIOUSORFATALPERSONAL INJURYOR 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.
This is a SAFETY ALERT 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.
Warns of hazards that WILL cause serious personal
injury, death or major 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.
INDICATES SPECIAL INSTRUCTIONS WHICH ARE
VERY IMPORTANT AND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARN-
INGS PRIOR TO PERFORMING ANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
PUMPS WITH THE “UL” MARK AND PUMPS WITH THE
“US” MARK ARE TESTED TO UL STANDARD UL778. CSA
CERTIFIED PUMPS ARE CERTIFIED TO CSA STANDARD
C22.2 NO. 108.
CAUTION
REFER TO WARRANTY ON PAGE 2.
FM2167
0420
Supersedes
0219
P/N 019555
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
TEL: [phone] • 1 (800) 928-PUMP • FAX: [phone]
Visit our website:
zoellerpumps.com
Register your
Zoeller Pump Company
Product on our website:
http://reg.zoellerpumps.com/

2
© Copyright 2020 Zoeller®Co. All rights reserved.
LIMITED WARRANTY
1. Zoeller Grinder Pumps are designed for grinding and pumping sewage from
single family residential and commercial duty sewage pump stations. The
pump is intended to grind and pump reasonable quantities of items normally
found in residential sewage.
2. Zoeller Grinder Pumps can be installed in new applications or as a direct
replacement for any grinder application of like size and capacity.
3. RefertotheZoellermodels810and815whenretrottingexistingpositive
displacement pump installations.
Applications
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,
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.
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,
foraperiodofthree years from thedateofpurchase.Proofofpurchaseis required.
Partsthatfailwithinthewarrantyperiod,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 act of
nature; 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femininesanitaryproducts,etc.
in all applications other than 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.
*ZoellerCompanydoesnotrecommendasimplexstationonanythingovertwohomesinordertomaintaincontinuousserviceduringunusualconditions.
Recommended Limits of Application 800 Series Grinder Pumps
Theserecommendedapplicationlimitsareforpumpstationspumpingtoagravitymain.Low-pressurepipesystemsshouldbedesignedwithapumplocatedat
each house. For applications where a lift station would handle between 15 and 60 homes, consider the 71 Series grinder pump. For applications where a lift station
would handle more than 60 homes, a solids handling type pump should be considered.
Simplex Station Duplex Station
Model HP Homes GPD Homes GPD
810 Progressing Cavity Grinder 1.0 1 400 2 800
815 Progressing Cavity Grinder 2.0 1 400 2 800
818 1.0 1 400 2 800
819 1.5 1 400 2 800
820 2.0 1 400 2 800
840 w/o Reversing Control 2.0 2* 800 10 4,000
840 w/ Reversing Control 2.0 2* 800 15 6,000
841 2.0 2* 800 10 4,000
842 2.0 2* 800 10 4,000
In instances where property damages are incurred as a result of an alleged product failure,
the property owner must retain possession of the product for investigation purpose.

3
© Copyright 2020 Zoeller®Co. All rights reserved.
Preinstallation Checklist
1. Inspect your 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. Carefully read all literature to familiarize yourself with details regarding
installation and use. Retain materials for future reference.
1. Make sure pump connection contains a ground terminal. The power cord on
all Zoeller Grinder Pumps contains a green conductor for grounding to help
protect you against the possibility of electric shock.
2. Make certain the receptacle 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. Automatic pumps have three prong plug caps and must be connected to a
three prong grounded receptacle with ground fault circuit interrupter (GFCI).
5. 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.
6. Installation of electrical hardware and checking of control panels and circuits
shouldbeperformedbyaqualiedlicensedelectrician.
7. Riskofelectricalshock-Thesepumpshavenotbeeninvestigatedforusein
swimming pool areas.
8. Prop65WarningforCaliforniaresidents:
:CancerandReproductiveHarm-
www.P65Warning.ca.gov.
SEE BELOW FOR LIST OF WARNINGS
CAUTION
SEE BELOW FOR LIST OF CAUTIONS
Do not attempt to turn cutter located on bottom
of the unit with ngers. Useawrenchwhencheckingorremov-
ing cutter.
1. Makesurethepower source iscapableofhandlingthe electricalrequirements
of the grinder pump, as indicated on the nameplate.
2. A disconnect switch should be installed ahead of the pump.
3. If Grinder pumps are operated by control panels with variable level oat
controlswitches,itistheresponsibilityoftheinstallingparty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24"indiameterforsimplexsystemsand
36"indiameterforduplexsystemsorlarger.
4. Grinderinstallationsshouldbechecked yearly for debrisand/orbuildupwhich
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. Pump and oat switch electrical connections must be permanently installed,
operational and protected from submergence.
7. Junction box conduit must be installed with watertight connection. Zoeller
junction boxes include a UL Listed potting kit for sealing conduit. Failure to
properly install this sealant material could void warranty.
Electrical Data
Amps KVA
Code
Winding
Resistance
Line-to-Line
Model HP Mode RPM Voltage Phase Hertz Full Load In Air Shut Off Locked
Rotor
WM818 1 Auto 3450 115 1 60 13.6 8.0 10.2 46 F 0.67 / 3.4
N818 1 Non 3450 115 1 60 13.6 8.0 10.2 46 F 0.67 / 3.4
WH818 1Auto 3450 200-208 1 60 7.7 3.7 8.7 27.7 F 2.0 / 1.4
I818 1 Non 3450 200-208 1 60 7.7 3.7 8.7 27.7 F 2.0 / 1.4
WD818 1 Auto 3450 230 1 60 6.5 2.8 4.5 30 P 1.2 / 2.0
E818 1 Non 3450 230 1 60 6.5 2.8 4.5 30 P 1.2 / 2.0
F818 1 Non 3450 230 3 60 6.9 5.3 5.8 44.4 S 2.15
J818 1 Non 3450 200 3 60 7.5 5.7 6.2 47.4 S 1.7
G818 1 Non 3450 460 3 60 3.7 2.5 3.0 21.6 S 8.2
BA818 1 Non 3450 575 3 60 2.7 2.1 2.3 17.5 S 13.6
WH819 1.5 Auto 3450 200-208 1 60 12.0 8.8 8.7 61.6 K0.87 / 2.0
I819 1.5 Non 3450 200-208 1 60 12.0 8.8 8.7 61.6 K0.87 / 2.0
WD819 1.5 Auto 3450 230 1 60 10.8 7.6 8.3 57 K1.2 / 2.0
E819 1.5 Non 3450 230 1 60 10.8 7.6 8.3 57 K1.2 / 2.0
F819 1.5 Non 3450 230 3 60 8.2 5.3 6.5 44.4 N 2.15
J819 1.5 Non 3450 200 3 60 9.2 5.7 7.1 47.4 M 1.7
G819 1.5 Non 3450 460 3 60 4.2 2.5 3.3 21.6 N 8.2
BA819 1.5 Non 3450 575 3 60 3.2 2.1 2.6 17.5 N 13.6
WH820 2Auto 3450 200-208 1 60 15.5 8.8 11.0 61.6 G 0.87 / 2.0
I820 2 Non 3450 200-208 1 60 15.5 8.8 11.0 61.6 G 0.87 / 2.0
WD820 2 Auto 3450 230 1 60 13.7 7.6 10.2 57 H1.2 / 2.0
E820 2 Non 3450 230 1 60 13.7 7.6 10.2 57 H1.2 / 2.0
F820 2 Non 3450 230 3 60 9.9 5.3 7.3 44.4 K2.15
J820 2 Non 3450 200 3 60 11.0 5.7 8.1 47.4 K1.7
G820 2 Non 3450 460 3 60 5.0 2.5 3.7 21.6 K8.2
BA820 2 Non 3450 575 3 60 3.9 2.1 2.9 17.5 K13.6

4
© Copyright 2020 Zoeller®Co. All rights reserved.
1-1/4" NPT
18-5/8" [473 mm]
5" [127 mm]
6-1/2"
[165 mm]
4" [102 mm]
4" [102 mm]
7-5/8"
[194 mm]
4"
[102 mm]
General Information
GRINDER PUMP DESCRIPTION
1. Pumps are constructed of cast iron with powder coated epoxy
protection for long life when pumping sewage in submersible
applications. The cutter assembly is comprised of 440 C stainless
steelcomponentshardenedtoavalueof55-60ontheRockwellC
scale;acutterandaprecisiongroundatdisk.Cuttingactiontakes
place with the rotation of the cutter in the clockwise (looking down
on the unit) direction only, see Fig. 6 on page 11.
2. Pumpmotorsareavailableinsingleandthreephasedesign.Single
phase motors require a starting relay, starting capacitor and a run
capacitor. These items are located in the switch case on the pump.
3. Thesegrinder pumps have a single seal design and do nothave
sensor wires.
4. Automaticreset thermal overload protection isintegral on single
phasemotors.Forthreephasemodels,overloadprotectionistobe
providedinthecontrolpanel.
FIELD ASSEMBLED INSTALLATION
1. Installationand pipinginstructions areincluded withthe 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
onpages6-9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
openings must have a gas and watertight seal.  Installation of
electrical panels, conduit and connections should be made by a
qualiedlicensedelectrician.AULListedpottingkit,P/N10-2350,
isavailablefromZoellerCompany.
4. Wheninstallingapumpwithacheckvalve,orarailsystemwith
acheckvalve, youmustgive thepumpcase timetoll to help
preventairlockwhenloweringtheunitintotheliquid.Thepump
casehasanairventlocatedbehindthedischarge.Thisairventis
across the pump housing mounting surface and must be cleaned
beforeeachreinstall.Anextraairventhole(3/16")maybedrilled
indischargepipebelowthecheckvalvetohelppreventairlock.
Thisdrilledholemustbecleanedbeforeeachreinstall.Afterthe
pump is installed, run the unit submerged to assure the pump case
islled(Watershouldcomeoutof3/16"diameterhole).
SK1621
FIGURE 1.
154108 154108
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE AND DEWATERING
Shut-off Head:
90
100
80
70
53 ft. (16.2m)
27.4
30.5
24.4
21.3
-
-
-
-
MODEL
60
50
40
30
20
10
5
Feet
-
-
16.5
28
37
42
15.2
18.3
12.2
6.1
9.1
3.0
-
-
62
140
106
159
43
Gal.
1.5
Meters
820
Liters
163
-
-
12
81 ft. (24.7m)
-
-
-
-
45
22
32
39
42
43
43
121
83
148
159
43
Gal.
819
LitersGal.
818
Liters
-
-
-
-
16.7
27
36
107 ft. (32.6m)
7
63
26
102
136
43
46
46
46
46
46
174
163
174
174
174
174
46 174
15 40
35 41
25 33
434.6
7.6
10.7
163
163
163151
125
8322
163
155
43 163
46 174
46 174
46 174
20
30
40
50
60
10 15 20 25 30 35 40 45 50 555
20 40 60 80 100 120 140 160 180 200
0
METERS
FEET
PUMP PERFORMANCE CURVE
MODELS 818/819/820
0
TOTAL DYNAMIC HEAD
FLOW PER MINUTE
U.S. GALLONS
LITERS
70
10
80
90
100
110
4
8
12
16
20
24
28
32
820
819
818

5
© Copyright 2020 Zoeller®Co. All rights reserved.
MIN. "OFF" LEVEL
22" MAX.
5" MIN.
20 AMP SWITCH (WD & WH MODELS)
FORYOURPROTECTION,ALWAYSDISCONNECTTHEPUMPFROMITSPOWERSOURCEBEFOREHANDLING. Single phase
automatic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. The3-prongplugmustbeinsertedintoamating3-pronggroundedreceptacle.Ifthe
installationdoesnothavesuchareceptacle,itmustbewiredandgroundedinaccordancewiththeNationalElectricalCodeandallapplicable
local codes and ordinances.
“Risk of electrical shock” Donotremovethepowersupplycordandstrainrelieforconnectconduitdirectlytopump.
Pump Wiring Instructions
Installationandcheckingofelectricalcircuitsandhardwareshouldbeperformedbyaqualiedlicensedelectrician.
FIGURE 4.
FIGURE 5.
ModelsWD&WHarefullyautomatic.Aoatswitchisincludedandfactorywiredinthepumpcircuittoprovideautomaticoperationoncetheoatswitchis
securedproperlytotheoutletpipe.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”.
Determining Pumping Range
in Inches (1 inch - 2.5 cm)
Tether Length 5 10 15 20 22
Pumping Range 9 13.5 18 22 24
Use only as a guide. Due to weight of
cable, pumpingrangeabovehorizontal
is not equal to pumping range below
horizontal.Rangesarebasedontestingin
nonturbulent conditions.Rangemayvary
duetowatertemperature and cordshape.
Astetherlengthincreases,sodoesthe
varianceofthepumpingrange.
Note: Failure to keep within proper tether limits may
preventreliableswitchoperation.
Note: Cable must be mounted in horizontal position. SK2304
min. max.
SK305D
RUN
O.L.
MOTOR
(3)
BLUE RED
BLACK
GREEN
L1 L2
START
(1) (2)
YELLOW
RED
R
RELAY
(WHITE) (BLACK)
YELLOW
(BROWN)
BLUE
1
5
2
WHITE
CAPACITOR
START
WHITE
BLACK
BLACK
CAPACITOR
RUN
RUN
O.L.
MOTOR
(3)
BLUE RED
FLOAT
BLACK
GREEN
L1 L2
START
(1) (2)
YELLOW
RED
R
RELAY
(WHITE) (BLACK)
YELLOW
CAPACITOR
(BROWN)
BLUE
WHITE
1
5
2
BLACK
WHITE
CAPACITOR
START
RUN
BLACK
WHITE
BLACK
010415
AUTOMATIC
WIRING DIAGRAM
010443
NONAUTOMATIC
WIRING DIAGRAM
1 PH
MOTOR
(3)
BLUE RED
BLACK
GREEN
L1 L2
(1) (2)
YELLOW
L3
WHITE
RED
NONAUTOMATIC
WIRING DIAGRAM
3 PH
006848

6
© Copyright 2020 Zoeller®Co. All rights reserved.
SK1691A
SK1691B
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.
Indoor Prepackaged System
FIGURE 2.
TO ALARM PANEL
24" X 1/4" STEEL
(VENT CONNECTION)
10" X 1/4" STEEL
CORD SEAL
INSPECTION PLATE
3" GROMMET SEAL
SWITCH CORD
ALARM FLOAT
BASIN COVER
LIFTING BOLT
16" X 1/4" STEEL
5/16" 304 STAINLESS STEEL
PUMP PLATE
PUMP POWER CORD
SILENCE
INPUT1
POWER
ON
(FIELD INSTALLED)
ALARM
4" RUBBER INLET
CAST IRON ADAPTERS
OFF
24" NOMINAL
TO ALARM PANEL BALL VALVE
(FIELD INSTALLED)
GALVANIZED PIPE
1-1/4" X 32"
GALVANIZED PIPE
1-1/4" X 12"
GRINDER PUMP
SINGLE PHASE,2HP
1-1/4" GROMMET SEAL
(FIELD INSTALLED)
CAST IRON CHECK VALVE
1-1/4" FEMALE NPT
AUTOMATIC
36"
1-1/4" PVC SLIP X SLIP
HIGH WATER ALARM
(FIELD INSTALLED)
PIPE SEAL

7
© Copyright 2020 Zoeller®Co. All rights reserved.
Indoor Prepackaged System Installation Instructions
Thissetofinstructionsisforfactoryprepackagedindoorsystemsonly.Ifyoursystemisaeldassembled
indoorsystem,usetheseinstructionsasaguideline.Ifyoursystemisanoutdoorsystemthengotothenextsectioninthismanual
thatcoversoutdoorsystems.
1. Indoor grinder pump systems are for installing at grade in an
indoor application only. If you will be installing this system
outsidenexttotheresidencethenyouwillneedanoutdoor
system.DONOTINSTALLTHEINDOORSYSTEMOUTDOORS.
2. ReviewthedrawinginFig.2onpage6andtheactualsystem
to become familiar with the components in the grinder pump
system.Reviewwheretheunitwillbeinstalled.Determine
wherethepowerfeed,inletpipe,dischargepipeandvent
will be located.
3. Removetheunitfromthepacking.Indoorprepackagedsys-
tems are preassembled at the Zoeller Company and require
aminimumofeldassemblywork.Allworkinsidethebasin
canbeperformedviatheinspectionport.Thereshouldbe
noreasontoremovethecoverfromthebasin.Pumpand
oatswitchesarealreadysetinsidethebasin.
4. Removetheinspectionplatefromthecover.Alloatsare
set and tethered for proper operation from the factory. Verify
thatwheretheoatswitchesaresetwillworkforyourap-
plication.Verifyingthattheoatswitchesaresetproperly
and will not hang up inside the basin is the responsibility of
the installing contractor. Float switches are tied in place
forshippingpurposes.Cutthecabletiearoundeachoat
switch bulb or the unit will not operate properly.
5. Dig a hole for the basin. The basin should be located in a
verylow trafc areawithin15’of thepowerdisconnect.
The hole should be at least 8” larger in diameter than the
basinin order toleave4”of backll alltheway around
theperimeter.  Aminimumof 4” ofcompactedsubbase
isalso required. Backllandsubbase should be1/8”to
3/4”peagravelor1/8”to1/2”crushedstone.Alsoreference
the basin installation instructions included with the unit.
6. The 4” inlet hub should be located between the top lip of
thebasin and thealarmoat “on”levelwitha minimum
distanceof10inchesbetweentheoorofthebasinandhub.
Determine the location of the inlet hub based upon your inlet
pipe arrangement. The inlet hub 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4”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. Set the basin in the hole and connect the 4” inlet pipe to the
inlet hub using the rubber insert. If using a cast iron hub,
the 4” inlet pipe will need to be caulked or gasketed to the
hub.Backllaroundthebasinwithspeciedmedia.Care
shouldbetakennottodamagecomponentsorleavevoids
whenbacklling.Finishgradeofoorshouldbepouredin
place around the top 6” of the basin assembly.
8. Connectthedischargepipe,valvesandventaccordingto
all applicable National, State and Local plumbing codes.
9. Mountthealarmpanelonthewallabovethesystem.Connect
thealarmoatswitchandpumppowercord.
10. Clean any debris out of the basin. Fill the basin with water
and check the system for proper operation.
11. Recordsystemstart-updataforfuturereference.
12. Sealandsecurethe inspectionplatetothelidusingtheproper
bolts and sealant. Pouring concrete around the system can
now be completed.

8
© Copyright 2020 Zoeller®Co. All rights reserved.
Typical Outdoor Grinder Pumping System Installation
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.
FIGURE 3.
R
LOUISVILLE, KY
SILENCE
INPUT1
POWER
4" PIPE SEAL
(FIELD INSTALLED)
2" PIPE SEAL
(FIELD INSTALLED)
24" MIN.
FIBERGLASS AFD
1.25-2" Z-RAIL
2" CAST IRON CHECK VALVE
3/4" GUIDE RAILS
2" SCH. 80 BALL VALVE
2" FLEX BOOT FITTING
(LOCATION VARIES
WITH BASIN DEPTH)
FLOAT TREE ASSEMBLY
2HP GRINDER PUMP
2" PVC SCH. 80 PLBG.
1/8" 302 STAINLESS STEEL
LIFTING CABLE
ALARM
ON
OFF
SOLID FIBERGLASS COVER
HIGH WATER ALARM
OR SIMPLEX
CONTROL PANEL
(FIELD INSTALLED)
ALARMFLOATSWITCHMUSTOPERATEOFFLOW
VOLTAGETOBEUSEDWITHQWIKBOX.
SK3110
FOAM TAPE
UL LISTED
EPOXY SEALER
#10-2350 POTTING KIT
APPLIES TO INSIDE AND
OUTSIDE INSTALLATIONS
CONDUIT 1
WIRES OR
PUMP CABLES
1/4" TO 1/2"
(25 mm) (6 mm TO 12 mm)
SK1661
LOCATION VARIES WITH BASIN DEPTH

9
© Copyright 2020 Zoeller®Co. All rights reserved.
Outdoor Prepackaged System Installation Instructions
1. ReviewthedrawinginFig.3onpage8andtheactualsystemto
becomefamiliarwiththecomponentsinthepackagedgrinderpump
system.Reviewwheretheunitwillbeinstalled.Determinewhere
the power feed, inlet pipe, and discharge pipe will be located.
 2. Removetheunitfrompacking.Prepackagedoutdoorsystemsare
preassembled at the Zoeller Company and require a minimum of
eldassemblywork.Floatswitchesaresetandtetheredforproper
operation from the Factory. Systems using an automatic unit, WD
orWHseries,haveanintegral“on/off”oatswitch.SeeFig.4
on page 5 for adjustment instructions. The alarm switch should
belocated3”abovethepump“on”level.Threeoatsystems
used with a control panel are placed at 27”, 24”, and 15” from the
bottomofthebasin.Fouroatsystemsusedwithacontrolpanel
are placed at 33”, 27”, 24”, and 15” from the bottom of the basin.
Iftheinvertlocationisatorbelowtheleveloftheoatswitches,
contact the factory.
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. 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.
5. The location of the inlet hub is determined by the depth of the inlet
pipe. The inlet hub 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 4” 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.
 6. Thebottomofthe excavationcannow be properlybacklled,
compactedandleveled.Setbasininhole.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.) Connect the 4” inlet pipe to the
inlet hub.
7. 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.
 8. PVCor HDPE dischargepiping is connectedto the 2”threaded
ttinglocatedinthebasinsidewall.Supportdischargepipingwith
sufcientbackll.
9. Connectliftcable to topofpump. Lowerthepumpinto basin ensuring
thedischargepipebracketslidesintothedisconnecttting.
10. Note: Thegrinderbasin isa sewageholding tank. Ventconnection
shouldbe installed in accordance with all national,state and local
plumbing codes.
11. Digatrenchforthe electrical conduit. Theconduitshouldbe located
below the frost line. Follow all applicable electrical codes.
 12. Ifusingajunctionbox,connecttheelectricalconduitandwiring
accordingtoinstructionsincludedin this manualandwiringdiagram
inbox.Ifapottingkitisprovidedwiththejunctionbox,followthe
instructionsforsealingtheconduitconnectiontothejunctionbox.
Ifapottingkitisnotprovided,theconduitconnectiontothejunction
boxmustbesealed.
13. Mount the control panel within sight of the system. Connect
oatswitchesand pumpcordsaccording tothe “Pump Wiring
Instructions” found later in this manual and located inside the panel
enclosure.
 14. Removeanydebrisfromthebasin.Usingcleanwater,checkthe
system for proper operation.
15. Seal and secure the lid using the proper bolts and sealant when
using a lid without a formed gasket.
16. Test system for leaks and proper pump operation.
17. Record system start up data for future reference.
Thissetofinstructionsisforfactoryprepackagedoutdoorgrindersystemsonly.Ifthisisaeldassembledoutdoorsystem
youcanusetheseinstructionsasaguideline.Ifthisisanindoorsystemthengobacktopages6-7inthismanualthatcoversindoorsystems.

10
© Copyright 2020 Zoeller®Co. All rights reserved.
Operation
GENERAL
Zoeller pumps are lubricated and tested at the factory prior to shipment
andrequireminimumpre-start-upmaintenance.
Maximumoperatingtemperatureofpumpliquidforgrinderpumpsmust
notexceed130°F(54°C).
These units are designed for intermittent duty sanitary sewage
applications. If pump is used to dewater areas or pump liquids with
heavyorabrasivematerials,thewarrantywillbevoided.
NAMEPLATE DATA
Thenameplate,locatedonthetopof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
Do not install pump until permanent electrical power is available and
system is operational. When not in use, the pump should be stored,
andthefollowingisadvised:
• 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
seals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.
• Pump,oatswitches,electricalcablesandjunctionboxaredryand
properly installed.
• Electricalboxesdry,sealedandsecurelyinstalled.
• Floats positioned properly.
• Dischargevalvesopen.
• 3/16”ventholedrilledinpipebetweencheckvalveandpump.
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andjunctionbox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.Recordthesereadingsinthespaceprovided
in the “Owner’s Information” section on page 1 of this manual for
future reference.
ADJUSTMENT PROCEDURE
Pumps: Noadjustmentsarerequired.
Floats: RefertoFig.4onpage5ortothepanelwiringschematicfor
desiredlocationofeachoatswitchsetting.
Valves: Dischargevalvesshouldbeplacedinthefullyopenposition.
Systemsshouldnotbeoperatedforextendedperiodsoftime
withthedischargevalvespartially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.
Withthepumpinthepit,itshouldbeoperatedforveminutes
onceeverythreemonths.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 entering the enclosure. Prior to restarting system,
the panel should be inspected for presence of moisture and any
loose connections.
Valves: Consultthevalve/actuatorsupplierforinformationconcerning
these systems components.

11
© Copyright 2020 Zoeller®Co. All rights reserved.
Cutter Maintenance
1. All power circuits must be disconnected and locked out before
any attempts are made at servicing. The cutter and disc can be
removedandsharpenedbygrindingthecuttingfaces.Both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
andpositioninghorizontallyto access theintakeofthe pump. Ifseals
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. Removethethreecountersunkscrewsonthering.
3. Thoroughly clean the 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 cutter and disc with
afeelergage.Thecorrectrunningclearanceisbetween0.004"and
0.008".
4. Withpumpinhorizontalposition,heatthehexheadboltinthecenter
ofthe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cutterfromturning
whileremovingthebolt.Pullcutterfromtheshaftandremovethe
spacer shims located behind the cutter.
5. Removethesixcapscrewsholdingthediscandremovediscfrom
the pump.
6. Thediscand cuttercanbe replaced withnew service partsor
resurfaced by grinding. Resurfacing is accomplished by surface
grindingbothdiscand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, cutter and shims are a
matchedset.Keeppartstogether.Measurediscbeforeandafter
resurfacing with micrometer and record measurements.
 7. Afterresurfacing,thediscandcuttermustbeatwithin0.001".If
thedischasbeensurfaceground,itwillbenecessarytoremove
shims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clear-
ancemustbebetween0.004”and0.008”.Besurepumpisinvertical
positionandallendplayhasbeenremovedbeforemeasuring.
8. Clean bottom of pump where disc is located and replace disc and
retainerscrews.Torqueto63-67in-lbs.Replace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0.004"and
0.008"toobtainefcientgrindingwhenpumpisputbackinservice.
 9. Replacesixcapscrews.
10. 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posi-
tion.Addoilifrequired.Useinsulatingoilsuppliedbythefactory.
FIGURE 6.
Toremovecutter:Heatthecenterboltto350°Fto
loosen Loctite®thread sealant.
Grindthe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.

12
© Copyright 2020 Zoeller®Co. All rights reserved.
General Maintenance
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2-1/2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.
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 six months:
• Inspect and test system for proper operation.
• Checkforproperandunobstructedoatoperation.
• Listenforpropercheckvalveoperation.
Every 5 years or 10,000 hours of operation:
• Removepump,inspectandserviceusingaZoellerrebuildkit.
• Flush and clean basin.
RepairandserviceshouldbeperformedbyaZoeller
PumpCompanyAuthorizedServiceStationonly.
SAFETY PROCEDURES
For your protection, always disconnect pump
and panel from its power source before handling.
Neverenterthebasinuntilithasbeenproperly
ventedandtested.Anypersonenteringabasinshouldbewearing
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.
Common Causes
Blownpanelorcircuitbreakerfuse,lowvoltage,thermaloverloadopen,de-
fectivecapacitorcircuit,cutterorimpellerclogged,oatswitchhelddownor
defective,incorrectwiringincontrolpanel,waterincapassembly.
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.
Air lock, debris under oat assembly, defective switch, incoming sewage
exceedscapacityofpump.
Intakecloggedwithgreaseorsludge,pumpairlocked(clearventhole),lowor
incorrectvoltage,cloggeddischarge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.Onsinglephase
pumps,checkthestartcapacitorinthecontrolpanel.See“A”and“D”above.
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.
If the above checklist does not uncover the problem, consult the factory. Do not attempt to service or otherwise disassemble pump. Service must be performed by
Zoeller Authorized Service Stations. Go to www.zoellerpumps.com/servicestations to nd the Authorized Service Station in your area.