ZOELLER 803, 805, 807 Grinder Pumps Instruction Manual

Trusted. Tested. Tough.®
FM2903 0424
Supersedes 0621

 803, 805, 807 Grinder Pumps

Notice to installing contractor: Instructions must remain with installation.
Product information presented here reflects conditions at time of publication. Consult factory regarding discrepancies or inconsistencies.

INSTALLATION & SERVICE INSTRUCTIONS
803/805/807 GRINDER PUMPS

PB: Piggyback
i.e. M803 = 1/2 HP, 115 V, Auto, 60 Hz

PREINSTALLATION CHECKLIST – ALL INSTALLATIONS

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 the literature provided to familiarize yourself with specific details regarding installation and use. These materials should be retained for future reference.
3. Zoeller does not recommend using grinder pumps in any part of a septic system.

WARNING
SEE BELOW FOR LIST OF WARNINGS

1. To reduce the risk of electrical shock, a properly grounded receptacle or control box must be installed in accordance with the governing codes. Never remove ground pin from plug.
2. Make certain that the ground fault interrupter protected receptacle or control box is within the reach of the pump’s power supply cord. DO NOT USE AN EXTENSION CORD. Extension cords that are too long or too light do not deliver sufficient voltage to the pump motor, and they could present a safety hazard if the insulation were to become damaged or the connection end were to fall into a damp or wet area.
3. Make sure the pump’s electrical supply circuit is equipped with fuses or circuit breakers of proper capacity. A separate branch circuit is recommended, sized according to the governing electrical codes for the current shown on the pump name plate.
4. Testing for ground. As a safety measure, each electrical outlet should be checked for ground using an Underwriters Laboratory Listed circuit analyzer which will indicate if the power, neutral and ground wires are correctly connected to your outlet. If they are not, call a qualified 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. Wear insulated protective shoes and do not stand in water.
6. Installation and servicing of the pump’s electrical circuits and hardware should only be performed by a qualified, licensed electrician.
7. Installation and maintenance of this appliance is not intended for persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience or knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
8. Risk of electrical shock. Do not remove power supply cord and strain relief or connect conduit directly to the pump. If the supply cable is damaged, it must be replaced by an authorized Zoeller Representative.
9. Pump contains oil which becomes pressurized and hot when operating. Allow 2-1/2 hours after disconnecting before attempting service.
10. Pump is not intended for potable water due to possible contamination by oil contained in the pump.
11. Risk of electric shock. These pumps have not been investigated for use in marine areas.
12. Do not attempt to turn cutter located on bottom of the unit with fingers. Use allen wrench when checking or removing cutter.

CAUTION
SEE BELOW FOR LIST OF CAUTIONS

1. Zoeller Grinder Pumps are designed for grinding and pumping sewage from homes. The pump is intended to grind and pump all normal sewage including reasonable quantities of disposable diapers, sanitary napkins, paper towels, rubber materials, cleaning wipes, plastics, cigarette butts and other items normally found in sewage.
2. Check to be sure your power source is capable of handling the voltage requirements of the motor, as indicated on the pump name plate.
3. The installation of variable level float switches is the responsibility of the installing party, and care should be taken that the tethered float switch will not hang up on the pump apparatus or pit peculiarities and is secured so that the pump will shut off. It is recommended to use rigid pipe and fittings and the pit be 18” (45 cm) or larger in diameter.
4. Vent hole. It is necessary that all submersible sump, effluent, and sewage pumps capable of handling various sizes of solid waste be of the bottom intake design to reduce clogging and seal failures. If a check valve is incorporated in the installation, a 3/16” (5 mm) vent hole must be drilled in the discharge pipe below the check valve and pit cover to purge the unit of trapped air. Vent hole should be checked periodically for clogging. The vent hole on a High Head application may cause too much turbulence. If you choose not to drill a vent hole, be sure the pump case and impeller is covered with liquid before connecting the pipe to the check valve. NOTE: THE HOLE MUST BE BELOW THE BASIN COVER AND CLEANED PERIODICALLY. Water stream will be visible when pump is operating.
5. Pump should be checked frequently for debris and/or build up which may interfere with the float “on” or “off” position. Repair and service should be performed by an Authorized Zoeller Service Station only.
6. Maximum operating temperature for standard model pumps must not exceed 130 °F (54 °C).
7. Do not operate a pump in an application where the Total Dynamic Head is less than the minimum Total Dynamic Head listed on the Pump Performance Curves.
8. For health reasons, do not unplug, turn off, or disable pump and use pump tank system as a way to fill up a sink or laundry tray, etc.
9. Pumps must be installed in accordance with the National Electrical Code and all applicable local codes and ordinances. Pumps are not to be installed in locations classified as hazardous in accordance with National Electric Code, ANSI, NFPA 70.

NOTE: 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.

LIMITED WARRANTY

Manufacturer warrants, to the purchaser and subsequent owner during the warranty period, every new product to be free from defects in material and workmanship under normal use and service, when properly used and maintained, for a period of three years from date of manufacture. 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 uncontrollable 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, 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 USA, 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 specific legal rights and you may also have other rights which vary from state to state.
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.
DO’S & DON’T’S FOR INSTALLING 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 remove all debris from the basin. Be sure that the pump will have a hard, level surface beneath it. DO NOT install on sand, gravel or dirt.

4. DO be sure that the area is large enough to allow proper clearance for the level control switch(es) to operate properly.

5. DO Always Disconnect Pump From Power Source Before Handling.
   DO always connect to a separately protected and properly grounded circuit.
   DO NOT ever cut, splice, or damage power cord (Only splice in a watertight junction box).
   DO NOT carry or lift pump by its power cord.
   DO NOT use an extension cord.

6. DO install a check valve and a union in the discharge line.
   DO NOT use a discharge pipe smaller than the pump discharge.

7. DO NOT utilize this unit for pumping gasoline or other hazardous liquids.

8. DO test pump immediately after installation to be sure the system is working properly.

9. DO review all applicable governing codes and verify that the installation  conforms to each of them.

10. DO consult manufacturer for clarifications or questions.

11. DO consider a two-pump system with an alarm where an installation may become overloaded or primary pump failure would result in property damages.

12. DO consider a D.C. Backup System where a sump or dewatering pump is necessary for the prevention of property damages from flooding due to A.C. power disruptions, mechanical or electrical problems or system overloading.

13. DO inspect and test system for proper operations at least every 3 months.

SERVICE CHECKLIST

WARNING
ELECTRICAL PRECAUTIONS- 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 flooded conditions, contact your local electric company or a qualified licensed electrician for disconnecting electrical service prior to pump removal.
WARNING
Submersible pumps contain oils which becomes pressurized and hot under operating conditions. Allow 2-1/2 hours after disconnecting before attempting service.

or incorrect wiring, open switch, impeller or seal bound mechanically, defective capacitor or relay when used, motor or wiring shorted. Float assembly held down. Switch defective, damaged, or out of adjustment.
B.| Motor overheats and trips overload or blows fuse.| Incorrect voltage, negative head (discharge open lower than normal) impeller or seal bound mechanically, defective capacitor or relay, motor shorted.
C.| Pump starts and stops too often.| Floattight on rod, check valve stuck or none installed in long distance line, overload open, level switch(s) defective, sump pit too small.
D.| Pump will not shut off.| Debris under float assembly, float or float rod bound by pit sides or other, switch defective, damaged or out of adjustment.
E.| Pump operates but delivers little or no water.| Check strainer housing, discharge pipe, or if check valve is used vent hole must be clear. Discharge head exceeds pump capacity. Low or incorrect voltage. Incorrect motor rotation. Capacitor defective. Incoming water containing air or causing air to enter pumping chamber.
F.| Drop in head andlor capacity after a period of use.| Increased pipe friction, clogged line or check valve. Abrasive material and adverse chemicals could possibly deteriorate impeller and pump housing. Check line.

If the above checklist does not reveal the problem, consult the Product Support Department. Do not attempt to service or otherwise disassemble pump.
Service must be peformed by a Zoeller Authorized Service Station. Go to www.zoellerpumps.com to find the Authorized Service Station in your area.

RECOMMENDED INSTALLATION FOR ALL APPLICATIONS

1. Electrical wiring and protection must be in accordance with National Electrical Code and any other applicable state and local electrical requirements.
2. Install proper Zoeller unicheck (combination union and check valve), preferably just above the basin (indoor installations) to allow easy removal of the pump for cleaning or repair. If high head or below cover installation is required use 30-0164 on 1-1/2″ (DN40) pipe, 30-0152 on 2″ (DN50) pipe and 30-0160 on 3″ (DN80) pipe.
3. All installations require a basin cover to prevent debris from falling into the basin and to prevent accidental injury.
4. When a Unicheck is installed, drill a 3/16″ (5 mm) dia. hole in the discharge pipe even with the top of the pump. NOTE: THE HOLE MUST ALSO BE BELOW THE BASIN COVER AND CLEANED PERIODICALLY. (High Head unit see #3 under “Caution” on front page). Water stream will be visible from this hole during pump run periods.
5. Securely tape or clamp power cord to discharge pipe, clear of the float mechanism(s).
6. Use full-size discharge pipe.
7. Basin must be in accordance with applicable codes and specifications.
8. Pump must be level and float mechanism(s) clear of sides of basin before starting pump.
9. Basin must be clean and free of debris after installation.
10. Gate Valve or Ball Valve to be supplied by installer and installed according to any and all codes.
11. For nonautomatic pumps, locate float switches as shown in sketches. The best place for the “off” point is above the motor housing and positioned 180° from the inlet. Never put “off” point below discharge on pump
12. Gas tight seals required to contain gases and odors.
13. Vent gases and odors to the atmosphere through vent pipe.

INSTALLATION SKETCHES

All installations must comply with all applicable electrical and plumbing codes.
TYPICAL FLOAT HANGER ON STEEL COVER PITS On some installations it may be desirable to install an independent hanger for the level control switches to avoid possible hang ups on the pumps, piping, valves, etc. Float hangers are available from Zoeller Company on Catalog Sheet FM0526 or can be fabricated from standard pipe and fittings.

PERFORMANCE DATA

TOTAL DYNAMIC HEAD/FLOW PER MINUTE SEWAGE

SINGLE PHASE WIRING INSTRUCTIONS

WARNING
FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP FROM ITS POWER SOURCE BEFORE HANDLING. Single phase 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 changed to the proper type, wired and grounded in accordance with the National Electrical Code and all applicable local codes and ordinances.
WARNING
“Risk of electrical shock” Do not remove power supply cord and strain relief or connect conduit directly to the pump.
WARNING
Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.
WARNING
Units supplied without a plug (single and three phase) and single phase nonautomatic units with a 20 amp plug must have a motor control and liquid level control provided at time of installation. The control device should have suitable voltage, ampere, frequency, grounding and horsepower rating for the pump to which it is connected.

REPAIRS

1. All power circuits must be disconnected and locked out before any attempts are made at servicing. The cutter rotor and disc can be removed and sharpened by grinding the cutting faces. Both rotor 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 cutter rotor 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 rotor and disc with a feeler gage. The correct running clearance is between 0.003″ (0.076 mm) and 0.008” (0.203 mm).

3. With pump in horizontal position, heat the hex head bolt in the center of the rotor with a propane torch. The bolt must be heated to 350° F (177° C) to soften the thread lock sealer on the bolt for ease of removal. Remove the bolt by turning in a  ounterclockwise rotation.
   It will be necessary to use a wood block to prevent the rotor from turning while removing the bolt. Pull rotor from the shaft and remove the spacer shims located behind the rotor.

4. Remove the screws holding the disc and remove disc from the pump.

5. The disc and the rotor cutter can be replaced with new service parts or resurfaced by grinding. Resurfacing is accomplished bysurface grinding both disc and rotor to a 32 micro finish. Do not attempt grinding in the field. Send parts to a qualified machine
   shop for repair. The disc, rotor 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 rotor must be flat within 0.001” (0.025 mm). If the disc has been surface ground, it will be necessary to remove shims to compensate for the material removed from the disc plus any amount over 0.008” (0.203 mm) measured in the field (step 2, above) before the rotor and disc were disassembled from the pump. The shim thicknesses and disc should be measured with a micrometer and the amount removed from the disc plus any clearance over 0.008” (0.203 mm) must match the shim thickness being removed.

7. Clean bottom of pump where disc is located and replace disc and retainer screws. Replace rotor with the correct shims. Install washer and torque to 30 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 0.003″ (0.076 mm) and 0.008” (0.203 mm) to obtain efficient grinding when the pump is put back in service.

8. Check the oil in the motor housing on 803/805/807 pumps before reinstalling. 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.

© Copyright 2024 Zoeller® Co. All rights reserved.
These are the original installation instructions.

Documents / Resources

| ZOELLER 803, 805, 807 Grinder Pumps [pdf] Instruction Manual
803, 805, 807, 803 805 807 Grinder Pumps, 803 Grinder Pumps, 805 Grinder Pumps, 807 Grinder Pumps, Grinder Pumps, Grinder, Pumps
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References

• Zoeller Pump Company | Wastewater Pumps and Systems
• Zoeller Pump Company | Wastewater Pumps and Systems

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