536686 1 Zoeller Qwik Jon Ultima 203 System Install Manual User

User Manual: Pump 536686 1 Zoeller Qwik Jon Ultima 203 System Install Manual

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NOTICE TO INSTALLER: Instructions must remain with installation.

SECTION: 6.10.064
FM2408
1212
Supersedes
0310

Your Peace of Mind is Our Top Priority ®
®

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
(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624

Patent No. 7,203,976
Other Patents Pending

visit our web site:
www.zoeller.com

QWIK JON ULTIMA 203 SYSTEMS
®

INSTALLATION INSTRUCTIONS
PREINSTALLATION CHECKLIST

MODEL NO. ____________
DATE CODE: ___________
DATE INSTALLED: ______

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 specific details regarding installation and use before attempting the installation. These
materials should be retained for future reference.

1. Make sure there is a properly grounded receptacle available. All pumps
are furnished with provisions for proper grounding to protect you against the
possibility of electrical shock.
(SEE WARNING BELOW)
2. Make certain that the receptacle 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.
But, more important, they could present a safety hazard if the insulation were
to become damaged or the connection end were to fall into the sump.
3. Make sure the pump electrical supply circuit is equipped with fuses
or circuit breakers of proper capacity. A separate branch circuit is
recommended, sized according to local electrical code for the current shown
on the pump nameplate.
4. Testing for ground. As a safety measure, each electrical outlet should be
checked for ground using a 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 Added Safety. Use of a residual current device with an operating current
not higher than 30 mA is recommended.
6. FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP FROM
ITS POWER SOURCE BEFORE HANDLING. 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 local electrical code and all applicable
local codes and ordinances.
7. “Risk of electrical shock” Do not remove power supply cord and strain
relief or connect conduit directly to the pump.
8. Installation and servicing of electrical circuits and hardware should be
performed by a qualified licensed electrician.

SEE BELOW FOR LIST OF CAUTIONS
1. The Qwik Jon ® Ultima is fitted with a specially-designed grinder pump
and is capable of pumping fecal matter, toilet paper and sanitary articles
which may be accidentally dropped into the toilet. It is not recommended
to flush such foreign objects as they might clog the sanitary sewer.
2. 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.
3. 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.
4. Maximum operating temperature must not exceed 130°F.
5. Do not use cleaning products containing bleach in the toilet tank, toilet or
attached fixtures as they will degrade the pump seals.

NOTES

SEE BELOW FOR LIST OF NOTES
1. Repair and service should be performed by an Authorized Service Station
only (consult factory).
2. 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. Pumps with the “UL” mark and/or the “US” mark are tested to UL Standard
UL778. CSA Certified pumps are certified to CSA Standard C22.2 No.
108. Qwik Jon ® Ultima units only. It is not designed for use in any other
application.
4. All fixtures connecting to the system must be on the same floor level.

9. Pump installation and servicing should be performed by a qualified person.
10. Risk of electric shock - These pumps have not been investigated for use in
swimming pool and marine areas.
11. If the supply cable is damaged, it must be replaced by the manufacturer or
its technical service or similarly qualified persons in order to avoid a hazard.
12. The appliance is not intended for use by persons (including children) with
reduced physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety.
13. Pump is not intended for potable water due to possible contamination by oil
contained in the pump.

Refer to Warranty on page 2.

P/N 018509

SEE BELOW FOR LIST OF WARNINGS

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 one year from date of purchase by the end user, or
18 months from date of original manufacture of the product, whichever comes
first. 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 first, 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
or feminine sanitary products, or any other abusive entity, 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 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.

DO’S AND DON'T’S, CONTINUED

HELPFUL HINTS FOR EASY INSTALLATION
1.
2.
3.
4.
5.
6.
7.
8.

Read all instructions before beginning installation.
Be sure the floor is level within 1/8".
Install vent pipe seals with flange side of seal on outside of lid.
Use soapy water to lubricate all seals to aid installation.
Install rubber coupling/union in vent line to aid disassembly.
Do not over-torque toilet mounting screws.
Do not use an automatic plumbing vent device.
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 the factory.

DO’S AND 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.

8’ CEILING *

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 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.

TYPICAL PIPING CONFIGURATIONS
NOTE: All installations must
comply with all applicable
local codes.

7’ CEILING *

Installation may not
be exactly as shown.

SUBFLOOR 3/4"
THICK MINIMUM
2” x 8”
FLOOR JOISTS

CHECK VALVE
P/N 30-0181

8"
MIN

SK2932

* Ceiling heights shown for reference only.

SERVICE PARTS
3

203-A

QWIK JON ULTIMA 203
®

Item

(PREMIUM)

9/06
thru
Current

Description

203-A

5/12
thru
Current

Part No.

Qwik Jon Ultima Model 203 Sewage Removal System

203-0005

203-1006

203 replacement pump with discharge pipe

017374

152165

Tank cover with discharge fittings

017373

Tank

018513

Seal

017350

Float switch assembly

018501

Flange extension kit

018510

Closet seal

017347

2
1

SK2613

TROUBLE SHOOTING
Condition

Possible Cause
Low voltage, blown fuse, open circuit.

A. PUMP WILL NOT START OR RUN.

Impeller bound.
Motor or wiring shorted.

Remedy
Have a qualified electrician check fuse and circuit.
Contact a Zoeller Service Station.

Debris on float switch.

Remove debris.

B. PUMP STARTS TOO SOON.

Float “ON” point is adjusted too low.

Raise the float stops, make sure the float is between the two stops.

Float “ON” point adjusted too high.

Lower the upper float stop.

Pump not plugged into piggyback float switch receptacle.

Ensure pump is not plugged directly into the outlet. Plug pump
into piggyback float switch receptacle.

Debris under float.

Remove debris from around float.

Faulty float switch.

Contact a Zoeller Service Station.

Float “Off” point adjusted too low.

Raise the lower float stop.

Pump is air locked.

Make sure vent hole in discharge pipe is clear.

Water level too low.

Raise the lower float stop.

Waste material has accumulated, blocking flow of
material to pump intake.

Hold flush handle down on the toilet for 15 seconds. If unit will
not clear, unplug and wait 30 minutes. Plug unit back in and
repeat. If unit still will not turn off, it will need to be opened and
the debris relocated.

Debris around intake.

Clean area around intake.

Blockage in discharge pipe.

Remove pipe and flush out debris.

Low or incorrect voltage.

Have a qualified electrician check house wiring.

Damaged Impeller.

Contact a Zoeller Service Station.

Incorrect float adjustment.

Contact Product Support Dept.

Pump is air locked.

Make sure vent hole in discharge pipe is clear.

Vertical lift too high.

Change discharge piping or contact Product Support Dept.

WATER LEVEL EXCESSIVE BEFORE PUMP
TURNS ON.

D. PUMP WILL NOT SHUT OFF OR RUNS TOO LONG
BEFORE WATER IS PUMPED.

E. PUMP OPERATES BUT DELIVERS LITTLE OR NO
WATER.

If the above checklist does not solve the problem, consult the Zoeller Product Support Department (502) 778-2731. 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.

QWIK JON ® ULTIMA QWIK REFERENCE GUIDE
STEP 1

LOCATION SELECTION

Plan your new installation carefully.
Floor: The floor should be structurally sound and level within 1/8". If the floor is not level, use hydraulic
cement or similar material to level the floor.

VENT
PIPE

DISCHARGE
PIPE

Water: A water supply will be needed to operate the shower and lav.

BALL OR GATE VALVE
SOLD SEPARATELY.

Electrical: A 115 volt GFCI receptacle will be needed to supply electrical power to the pump.

GFCI
OUTLET

Sewage: Access to a sewage line is required. The Qwik Jon ® Ultima requires a 1" (or 3/4" if 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.,
as the toilet will not flush.

WATER
SUPPLY

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.

LEVEL FLOOR

SK2588

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 within 1/8" using hydraulic cement or similar material.

SK2614

STEP 3
1)

ROUGH-IN

(STAND-ALONE INSTALLATION)

Position the pump unit a minimum of 1/8" from the wall with the
inlet facing forward. Attach the bellows to the inlet using the
worm drive clamp provided.
Place the toilet in front of pump unit aligning the discharge of the
toilet with the inlet of the pump unit. Make sure that the bellows
will bridge the gap adequately for final installation. The toilet
tank should be a minimum of 1/2" from the wall.

Lightly mark the locations of the pump unit, toilet and closet
bolt locations on the floor. Lightly mark the wall with the height
of the pump unit and the bottom and sides of the toilet tank to
ensure against interference from pipe runs later.

(BEHIND THE WALL INSTALLATION)
1)

Installing the grinder unit behind a wall will require an
extension kit (P/N 10-2123) sold separately.

Place the toilet assembly a minimum of 1/2" from the wall
and mark the closet bolt locations on the floor.

Measure the appropriate length of 3½" Schedule 40 PVC
pipe provided with the extension kit and cut it to length.
See sketch at right.

Set toilet aside.

Toilet assembly is top heavy. Take special
precautions to ensure that toilet does not tip over and break.

Remove the toilet from the pump unit and set it aside.
1/8"

STEP 3-2

STEP 4-4

STEP 3-1

STEP 4-1

STEP 3-3, 3-4

STEP 4-3

SK2615

SK2616
STEP 4-2

STEP 4

PIPING

1) Adding bathroom fixtures - The Qwik Jon ® Ultima is designed to accept
bathroom fixtures 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 44 mm (1¾") hole saw(see
Figure 3.2). This is to ensure there are no leakage problems from inlets not in
use. When utilizing side inlets, install a check valve on the incoming line.
2) Cut and dry-fit the pipe and fittings as required for 1" diameter discharge
pipe (may be reduced to ¾" diameter if codes permit).
3) While dry-fitting the discharge pipe, position and mark the location of
the pump unit discharge fitting.
Discharge

4) Cut and dry-fit 1½" 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. A 2" x 1" 90° discharge fitting 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 fitting.
When applying solvent weld to
discharge fitting, ensure that none gets into the check valve assembly (see
Figure 3.3). Pay close attention to the proper alignment of the discharge fitting
previously marked above.
6) Clean and solvent weld vent piping as required for proper venting.

Vent
Do not put glue in this area.
2" MPT OUTSIDE

1-1/2" SLIP INSIDE
DRILL POINT

Figure 3.1

STEP 5

Figure 3.2

SK2673

Figure 3.3

SK2586

SK2591

TOILET INSTALLATION (TOILET SUPPLIED BY OTHERS)

Install the closet bolts at the points marked earlier.

Place the toilet assembly over the closet bolts. Install the anchoring
hardware and tighten in an alternating pattern. Check for level and shim
as required. Be careful when tightening bolts or nuts against china to
avoid cracking the china.

Install rubber bellows onto the toilet discharge and grinder tank hub
and secure with the worm clamps provided for installation. See sketch
in Step 3. For built-in installation, install the rubber couplings to both
the grinder tank and the toilet discharge and secure to extension pipe
with worm clamps provided. See sketch in Step 4.

Install the water supply line from the existing water shut-off valve to the
toilet water supply connection.

Open the water supply valve and check for leaks. The toilet tank should
fill to the proper level. Adjust if required.

Plug the pump's power cord into the outlet.

Flush the toilet and watch for proper operation. Listen for the pump to
start. The pump unit requires proper venting in order for toilet to flush.
Check for leaks.

Repeat flush cycles to assure proper operation.

DISCHARGE
PIPE

VENT PIPE
(PER ALL CODES.
DO NOT USE
MECHANICAL VENT.)

GFCI
OUTLET

WATER
SUPPLY

AUX. INLET
PUMP UNIT
FLOOR LEVEL TO WITHIN 1/8"

NOTE: May not be pictured exactly as shown.

SK2595

FEET

METERS

PUMP PERFORMANCE CURVE
MODEL 202

TOTAL DYNAMIC HEAD

35
10
30
8

25
20
15
10

0
GALLONS
LITERS 0

5
20

10
40

15
60

20
80

25
100

120

40
140

45
160

50
180

FLOW PER MINUTE

TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE

MODEL

202

Feet
Meters
5
1.5
10
3.0
15
4.6
20
6.1
25
7.6
Shut-off Head:

Gal.
Liters
45
170
40
151
35
132
27
102
16
61
30 ft. (9.1m)

018512

MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624

visit our web site:
www.zoeller.com

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