Dover Hydro systems MiniDos 0.4% User manual

Model 0.4%
Model 1%
Model 2.5%
Model 5%
Model 10%
Model 20%
Fluid Flow Range:
0.03 gpm to 12 gpm*
7 lph to 2,700 lph*
Injection Range
Dosage:
0.025% to 20%
1:4000 to 1:5
Operating Pressure:
6 to 140 psi*
0.5 to 9.6 bar*
*Specifications vary by model.
Operating Manual

3
A
B
C
A
A
2 in.
51 mm.
Part # 013815 Rev. L
B
C
A
10% 20%
0.4%
2.5%
5%
Quick Start-up

4
Installed directly in the fluid supply line, the injector operates without electricity, using fluid (water) pressure
as the power source. The fluid drives the injector, which pulls the required percentage of concentrate
directly from the chemical solution container. Inside the Hydro patented mixing chamber, the concentrate
is mixed with the fluid, and the fluid pressure forces the mixed solution downstream. The amount of
concentrate will be directly proportional to the volume of fluid entering the injector, regardless of variations
in flow or pressure.
Fluid flow drives
motor piston.
Chemical does not
come in contact
with the motor.
Chemical is mixed
in the patented
mixing chamber.
Blended solution
Intake from
chemical container
Operating Principle
Accurate and Reliable

5
This document does not form a contractual engagement on the part of Hydro Systems Company and is for
information only. Hydro reserves the right to alter product specifications or appearance without prior notice.
For Your Records
The serial number of your Hydro injector is located
on the injector body. Please record this number in the
space below and reference it when calling your distributor
or Hydro for information, parts and service.
Serial #..............................................................................
Date Purchased ................................................................
Please read this manual carefully before putting the Hydro injector into operation.
This booklet has the information you will need for the use and care of your new Hydro injector. If you have any further
questions about your injector, the warranty, routine maintenance or proper usage, please contact your nearest distributor
or Hydro Systems customer service.
These models are designed to inject liquid concentrate or soluble powder that are recommended and approved for
injection into fluid systems.
lt is the responsibility of the operator to determine the correct dosage settings of the unit using the chemical
manufacturers’ recommendation for dispensing their product, and to assure that proper dosage is being maintained.
Maintenance and Warranty
Hydro offers a three year limited warranty from the original date of purchase for manufacturing or materials defects only.
With proper use and care, your injector should provide you long-term performance.
Contents
Operating Principle .............................................................................................................................................4
Package Contents ..............................................................................................................................................6
Specifications .....................................................................................................................................................6
Safety Precautions .............................................................................................................................................7
Warranty Compliance .........................................................................................................................................7
General Tips .......................................................................................................................................................7
Operations ..........................................................................................................................................................8
Installation & Start-up .........................................................................................................................................9
Suggested Installation Diagram .........................................................................................................................9
Remote Injecting ...............................................................................................................................................10
Maintenance......................................................................................................................................................10
Routine Maintenance Instructions 0.4% ..........................................................................................................11
Routine Maintenance Instructions 1% .............................................................................................................12
Routine Maintenance Instructions 2.5% & 5% ................................................................................................13
Routine Maintenance Instructions 10% ...........................................................................................................14
Routine Maintenance Instructions 20% ...........................................................................................................15
Troubleshooting ................................................................................................................................................16

6
54
51
55
44
44
44
95
17
51
25
27 44
• Hydro Injector (not shown) • Mounting Bracket
• Dosage Piston • Mounting Nuts and Bolts
• O-ring • Filter
• Manual (not shown) • Suction Tube
• Lower Shaft Assembly
Housing Proprietary Engineered
Composite Material
Avg. Dosing Accuracy +/- 5% of ratio
Repeatability +/- 3% of ratio
Pressure Loss 0.2 - 1.2 bar max
Maximum Temp. 100ºF (38ºC)
Minimum Temp. 34ºF (1ºC)
Maximum vertical suction
of concentrate
13 Feet (3.6 Meter)
Maximum horizontal
suction of concentrate
49 Feet (15 Meter)
Self-Priming Yes
Seal Material Available:
*Contact your Hydro
representative for specific
chemical information
Aflas
Viton
EPDM
Model NPT BSP
0.4% 112608 112609
0.4% Heavy Duty 112638 112639
1% 112600 112601
1& Heavy Duty 112630 112631
2.5% 112602 112603
2.5% Heavy Duty 112632 112633
5% 112604 112605
5% Heavy Duty 112634 112635
10% 112606 112607
10% Heavy Duty 112636 112637
20% 112620 112621
20% Remote
Injection 112622 112623
MiniDos 7 gpm (65 max. psi)
Model 20% 4% - 20% (1:25 - 1:5)
Flow Rate: ................. 0.07 - 7 gpm (16 - 1,500 lph)
Operating Pressure: .. 6 - 65 psi (0.5 - 4.5 bar)
Pipe Coupling: ..........3/4" NPT/BSP
MiniDos 10 gpm (65 max. psi)
Model 10% 2% - 10% (1:50 - 1:10)
Flow Rate: ................. 0.07 - 10 gpm (16 - 2,200 lph)
Operating Pressure:... 6 - 65 psi (0.5 - 4.5 bar)
Pipe Coupling: ........... 3/4" NPT/BSP
MiniDos 12 gpm (140 max. psi)
Model 0.4% 0.025% - 0.4% (1:4000 - 1:250)
Model 1% 0.20% - 1% (1:500 - 1:100)
Model 2.5% 0.50% - 2.5% (1:200 - 1:40)
Model 5% 1% - 5% (1:100 - 1:20)
Flow Rate: ................. 0.03 - 12 gpm (7 - 2,700 lph)
Operating Pressure:... 6 - 140 psi (0.5 - 9.6 bar)
Pipe Coupling: ........... 3/4" NPT/BSP
Package Contents
Specifications
The injector is packaged with the following items:

7
Remove Red Caps Prior to Installation
Your injector is 100% factory tested before delivery
and may contain a small amount of water. The three
red plastic caps are fitted after testing to ensure
cleanliness of the injector.
Before Applying Aggressive Chemicals
Please consult your distributor, chemical manufacturer
or contact Hydro’s customer service to confirm
compatibility with your injector. Always wear
proper safety protection as recommended by
chemical supplier.
Label all Fluid Lines, Valves and Connections
If the solution that is being injected is not suitable
for drinking, all fluid lines should be labeled:
Warning - not for human consumption!
Monitor Outlet Flow
It is the user’s responsibility to monitor the output
of chemical injected.
A Filter is Recommended and Required
Install a filter of 140 mesh (104 micron) or finer
depending on your fluid quality to prolong the working
life of the injector and for the warranty to be valid.
A filter is imperative since most fluid contains
impurities or particles, especially if the fluid source
comes from a well, pond or lake.
For A Long Service Life
Start with clean fluid by using an inline filter to reduce
impurities. Keep the solution container covered and
clean. Keep the suction tube filter 2" (5 cm) from
the bottom of the container. Perform maintenance
procedures as recommended (see Maintenance
page 10).
Soluble Powder Use
Ensure the chemical is completely dissolved before
starting the injector. If necessary, dissolve the chemical
in hot water and allow to cool before using. Failure to
thoroughly dissolve the chemical will cause premature
wear to the dosage piston and the inner cylinder.
!
Please read this instruction manual thoroughly. Following the procedures, will increase the life of your injector.
Warning: Please read precautions thoroughly before operation. Must meet all
applicable local codes and regulations.
Avoid a Potentially Hazardous Chemical Accident
Select a safe location. Chemical container should be
kept away from children and/or high usage areas
and the location must also not be susceptible to
freezing temperatures.
Avoid Solution Contamination
Use only clean FILTERED fluid. Do not allow
contaminants to enter the solution container. They
can be pumped into the fluid line and may cause the
spread of disease. Dirt, debris and other contaminants
in the solution container may cause excessive wear
to the unit.
Fluid Temperature
Min: 34°F (1°C), Max: 100°F (38°C)
Maximum Fluid Pressure
0.4%, 1%, 2.5%, 5% - 140 psi (9,6 bar)
10% & 20% models have maximum operating
pressure of 65 psi (4,5 bar). Operating pressure and
flow are reduced while using remote injection kit.
Install a pressure regulator and/or pressure relief valve
to ensure operating pressure does not exceed the
maximum specification.
Before Removing An Injector From The System
Release fluid pressure. While the system is in
operation, turn off the incoming fluid valve. Leave the
out going valve open. This will relieve the pressure
at the injector and all parts of the system after the
injector. Injector is now safe to remove.
Keep From Extreme Temperature
Protect the injector from freezing temperatures or
excessive heat.
Rinse Injector After Each Use
Additive allowed to remain in injector can dry out,
foul or damage the lower end at the next start-up
(see Maintenance page 10).
Injector Not in Use for an Extended Period
If the injector has not been stored properly deposits
may have dried onto the motor (see Maintenance
page 10). Before operation, soak entire unit into room
temperature water approx. 72°F (22°C) for an eight
hour period.
Safety Precautions/Warranty Compliance
General Tips

8
Clicking Sound is Normal
Fluid flowing through the injector will automatically cause the injector
to “click” and inject a set amount of solution into the fluid line. The
higher the flow rate the more frequent the “clicking”. The injector
is designed to inject solution proportionally (at the same set ratio)
regardless of fluid flow.
Service Fluid Flow
Fluid flow and pressure must be within the established specifications
(see Specification on page 6) for your model.
Change Feed (Injection) Rate
The feed rate on the injector is adjustable EVEN WHILE OPERATING
AND UNDER PRESSURE. To change feed rate see Fig 1 (a, b or
c) and Fig 2 (a, b or c) based on your injection rate. Do not remove
#79 when injector is under pressure.
MiniDos 0.4%, 1%, 2.5% and 5%, see Fig 1a and 2a
Rotate Ratio Adjuster (#61) (Fig 1a) up or down using the Setting
Indicator Mark (Fig 2a) to select the desired feed rate.
MiniDos 10%, see Fig 1b and 2b
1. Remove Interlock Pin (#65) (Fig 1b.).
2. Rotate Ratio Adjuster (#61) up or down to the desired setting.
Use the top of the Ratio Adjuster Sleeve to line up with the desired
feed rate setting (Fig 2b).
3. Re-insert Upper Interlock Pin (#65). Clip must be parallel with
settings to be able to re-insert.
MiniDos 20%, see Fig 1c and 2c
1. Remove Ratio Locking Pin (#79) (Fig 1c.).
2. Rotate Outer Cylinder (#7) up or down to the desired setting.
Use the top of the Outer Cylinder to line up with the desired feed
rate setting (Fig 2c).
Bypass Operation
Injecting solution into the fluid line can be TEMPORARILY
stopped with the On/Off feature (Fig. 3). Moving the On/Off
Lever to the OFF position allows service fluid to pass through
the injector without injecting chemical. No "clicking" will be
heard.
With the On/Off lever set to the ON position the injector will
operate as normal and “clicking” will be heard when fluid is
flowing. It is recommended to use the three-valve bypass (see
Fig. 5), for continued bypassing or servicing of the injector.
Fig. 3
Fig. 4
Typical wall
mounting
Run Position
(clicking) Off Position
(not clicking)
004014(2x)
195008
Fig. 1b
Fig. 1a
Fig. 2a
A
#61
B
C
A
B
C
A
B
C
A
B
C
A
MiniDos 0.4%, 1%, 2.5% and 5% MiniDos 10%
#79
MiniDos 20%
Fig. 1c
Fig. 2b Fig. 2c
#61
#65
#7
NOTE: Do not adjust feed rate below lowest setting line.
Measure outlet fluid to assure desired feed rate is being delivered.
#79
#79
Operations

9
Fluid Filter (Required)
Install a filter of 140 mesh (104 micron) or finer depending
on your fluid quality to prolong the working life of the injector
and for the warranty to be valid. Hydro recommends a
Twist II Clean®filter that can be ordered with your injector.
Mounting Injector
Securely fasten your injector to a solid object such as a wall
or in a cold fluid line. Note arrow on injector indicates fluid flow.
Backflow Preventor (Recommended)
Install one that meets local code requirements.
Pressure Safety Release Device (Recommended)
Prevents pressure from exceeding specifications of the unit.
Bypass Valve Set-up (Recommended)
Allows the injector to be taken off-line for maintenance
or storage when not in use.
Fluid-Hammer Arrester (Recommended)
Prevents fluid-hammer damage to the injector when operating
quick closing solenoid, pneumatic or hand-operated ball valves
on the fluid system.
Anti-Siphon Valve (Optional)
To prevent solution from being siphoned out (from the solution
container) into the feed lines when the upstream valve is shut off.
The anti-siphon valve must be installed on the downstream outlet.
Additional Siphoning Prevention
Place solution container on a level below the injector suction
tube fitting. Using the inlet side as a shut-off valve could cause
full strength solution to siphon into the feed line.
Solution Container
Use any size container. A lid or cover is recommended. To
connect your solution container, gently push the end of the
suction tube onto the bottom of the suction tube fitting assembly.
Place the filter into the solution container at least 2" (5cm) from
the bottom and fill with at least 2" (5cm) of chemical solution.
Never Use Petroleum Based Lubricants
The injector is shipped with a thin coat of silicone around the
seals for ease-of-assembly. Petroleum based lubricants such
as Vaseline©, baby oil, WD40©, or motor oil on the O-rings or
any part of the injector should never be used as this can cause
particles to adhere and clog or damage the injector.
Check System for Leaks and Start-Up Procedures
Open the bypass valve (A), close inlet valve (B) and outlet
valve (C) to prevent fluid flow into the injector. SLOWLY
turn on the main fluid line. Run fluid flows between 5 -12 gpm
(11-45 l/m) through the plumbing system. Turn on all of the
valves located downstream from your injector to release trapped
air. SLOWLY turn on the inlet valve (B). Open the outlet valve (C)
and close valve (A). As fluid travels through the injector, you will
hear a “clicking” sound. Check for leaks and correct if necessary.
INLET VALVE OUTLET
VALVE
BACK FLOW
PREVENTOR BYPASS
VALVE
DIRECTION OF FLOW
INLET FILTER
140 MESH / 104 MICRON
(MINIMUM REQUIRED)
FLOW CONTROL
VALVE @ OUTLET
50 MM
2 IN
COVERED CONTAINER
SOLUTION FILTER
SUCTION TUBE
ANTI-
S
IPH
O
N
VALVE
(OPTIONAL)
WATER HAMMER
ARRESTER
PRESSURE
REGULATOR
(RECOMMENDED)
(RECOMMENDED)
(RECOMMENDED)
(REQUIRED)
(RECOMMENDED)
PRESSURE
GAUGE
(OPTIONAL)
(OPTIONAL)
FILL VALVE
(OPTIONAL)
6" minimum
PRESSURE SAFETY
DEVICE
(RECOMMENDED)
(RECOMMENDED)
(OPTIONAL)
Fig. 5
!
(A)
(B) (C)
Installation & Start-up
Suggested Installation Diagram
Refer to Fig. 4 and Fig. 5

10
Rinse Injector After Each Use
Additive allowed to remain in injector can dry, foul or
damage the lower end at the next start-up. Place suction
tube into a 1 qt. (0.95 liters) or more container of fresh
filtered water. Flow fresh water through the injector by
operating until container is empty. This procedure is not
needed for continuous operation.
Clean Solution Container
Keep covered to prevent dirt, flies, feathers and other
flying debris from entering the container. Rinse container
thoroughly and often. Do not mix chemicals together that
might react and cause a precipitate. Use FILTERED fluid
when filling container.
Clean Suction Tube Filter Screen
Inspect each time new solution is added. Clean filter
screen (#27) and suction tube (#25) as necessary by
rinsing in fresh water. Replace if necessary. Keep filter
screen off bottom of solution container to prevent dirt
and precipitate from clogging filter.
Clean Inlet Filter
Clean or replace inlet filter as required to increase the life
of the unit as well as reduce pressure loss.
Bypass Injector
When not in use place the injector in bypass mode by
using the three valve bypass (preferred) or turn the
On/Off lever on the top of the injector to the off position.
Storage
For extended storage, rinse injector (see “Rinse Injector
After Each Use”) and place underwater in a container.
Apply monthly, <0.1 oz. (29 ml) of chlorine bleach to
avoid algae growth. KEEP FROM FREEZING.
Remote Injector Kit (not included)
Is recommended for the following:
Injectors In a Series:
When injecting multiple chemical injections, using two or more
injectors. Each injector adds chemical to the fluid(water) system,
while bypassing the next injector and eliminating the potential
damage to that injector (see Fig. 6). To prevent mineral buildup
within the body of the unit. Use when injecting chemicals that
cause minerals to precipitate from fluid.
NOTE: When mixing more than one chemical, always refer
to your chemical manufacturer information guide for proper
application. Contact your local distributor or Hydro Systems
customer service for information or to order.
Fig. 6
Remote
Injector Kit
shown in
a series.
Perform these maintenance
procedures to extend the life of your unit.
Every
3 - 6 Months
Every
6 - 12 months
Replace as
necessary
1. Clean seal area (#13).
2. Check #17 O-ring,
#51 Shaft Assembly,
clean and/or replace
as necessary.
1. Replace #17 O-ring and
#51 Shaft Assembly.
2. Clean and/or replace
#13 Check Poppet, #11
Suction Tube Fitting.
1. #37 Cylinder
2. #17 O-ring
3. #51 Shaft
MiniDos (0.4%)
Refer to pages
18 & 19
Reference numbers refer to Page 17 - 24
Kit Part Numbers
011762
Every
3 - 6 Months
Every
6 - 12 months
Replace as
necessary
1. Clean seal areas (#
17, 14 & 13).
2. Check #17 O-ring,
# 68 Cylinder, clean
and/or replace
as necessary.
1. Replace #17 O-ring and
#44 Dosage Piston.
2. Clean and/or replace
#13 Check Poppet, #11
Suction Tube Fitting.
1. #68 Cylinder
2. #14, #17 O-ring
3. #51 Shaft
4. #44 Dosage Piston
MiniDos (1%)
Refer to page 20
Every
3 - 6 Months
Every
6 - 12 months
Replace as
necessary
1. Clean seal areas
(# 17, 14 & 13).
2. Check #17 O-ring,
#37 Cylinder, clean
and/or replace
as necessary.
1. Replace #17 O-ring and
#44 Dosage Piston.
2. Clean and/or replace
#13 Check Poppet,
#11 Suction Tube Fitting.
1. #37 Cylinder
2. #14, #17 O-ring
3. #52 Shaft
4. #44 Dosage
Piston.
Every
3 - 6 Months
Every
6 - 12 months
Replace as
necessary
1. Clean seal areas (#
17, 14 & 13).
2. Check #17 O-ring,
#37 Cylinder, clean
and/or replace
as necessary.
1. Replace #17 O-ring
and #44 Dosage Piston.
2. Clean and/or replace
#13 Check Poppet,
#11 Suction Tube Fitting.
1. #37 Cylinder
2. #14, #17 O-ring
3. #52 Shaft
4. #44 Dosage Piston
Every
3 - 6 Months
Every
6 - 12 months
Replace as
necessary
1. Clean seal areas
(# 17, 14).
2. Check #17 O-ring,
#7 Cylinder, clean
and/or replace
as necessary.
1. Replace #17 O-ring and
#44 Dosage Piston.
2. Clean and/or replace
#60.
1. #7 Cylinder
2. #14, #17 O-ring.
3. #44 Dosage Piston
MiniDos (2.5%)
& (5%) Refer to
pages 21 & 22
MiniDos (10%)
Refer to page 23
MiniDos (20%)
Refer to page 24
Remote Injecting
Maintenance

11
Step 1.
Unscrew #7 OUTER
CYLINDER from body.
Step 3.
Remove #16 Gasket.
Step 2.
1/4 turn to remove #51
SHAFT ASSEMBLY
Step 5.
Remove #17 O-ring.
Step 8.
Replace #51
SHAFT ASSEMBLY.
Step 9.
Screw #7 OUTER
CYLINDER onto body.
Step 7.
Replace #82 SHAFT SEAL
SPACER and #16 Gasket.
Step 6.
Replace #17 O-ring.
↓
Step 4.
Remove #82 SHAFT
SEAL SPACER.
Routine Maintenance Instructions 0.4%

12
Step 1.
Unscrew #7 OUTER
CYLINDER from body.
Step 3.
Remove #52 UPPER
SHAFT.
Step 2.
1/4 turn to unlock and remove
#51 LOWER SHAFT and replace.
Step 5.
Remove #17 O-ring and replace.
Step 8.
Reinstall lower shaft with new
dosage piston and turn 1/4
turn to lock.
Step 9.
Screw #7 OUTER
CYLINDER onto body.
Step 7.
Re-install #82 SEAL SPACER
and #16 GASKET.
Step 6.
After replacing #82 SEAL
SPACER and #18 GASKET,
replace #52 UPPER SHAFT.
Turn 1/4 turn to lock in place.
↓
↓
Step 4.
Remove and clean #16 GASKET
and # 82 SEAL SPACER.
Routine Maintenance Instructions 1%

13
Step 1.
Unscrew #7 OUTER
CYLINDER from body.
Step 3.
Replace #44 DOSAGE PISTON
thin lips up. Clean & inspect #14
O-ring replace if necessary.
Step 2.
Rotate #51 or #52 SHAFT
90° and remove.
Step 5.
Replace #17 O-ring.
Step 8.
Reinstall lower shaft with new
dosage piston by turning 90°
to lock in place.
Step 9.
Screw #7 OUTER
CYLINDER onto body.
Step 7.
Re-install #16 GASKET
and #82 SEAL SPACER
Step 6.
Re-install #52 UPPER SHAFT
and #17 O-ring.
↓
Step 4.
Remove & Clean seal areas
#16 & #82.
2.5% 5% 2.5% 5%
Routine Maintenance Instructions 2.5 & 5%

14
Step 1.
Unscrew #7 OUTER
CYLINDER from body.
Step 3.
Remove #83 SHAFT
SEAL SPACER.
Step 2.
1/4 turn and remove #52
SHAFT, #16 GASKET and
#15 RETAINER.
Step 5.
Replace #83 SHAFT
SEAL SPACER.
Step 8.
Re-install #52 SHAFT with
#16 GASKET, #15 RETAINER.
Step 9.
Screw #7 OUTER
CYLINDER onto body.
Step 7.
Replace #44 DOSAGE
PISTON thin lips up (towards
the top of the shaft).
Step 6.
Squeeze ears on shaft
and remove #44
DOSAGE PISTON.
↓
Step 4.
Remove #17 O-ring and replace.
Routine Maintenance Instructions 10%

15
Step 1.
Unscrew #61 OUTER
CYLINDER from body.
Step 3.
Remove #73 DOSAGE
PISTON GUIDE, clean
and inspect #14 O-ring.
Step 2.
Unscrew to unlock and remove
#93 CAPSCREW.
Step 5.
Unscrew and remove #72
ADAPTER as well as #68 O-ring,
#15 SEAL RETAINER. Clean and
replace if damaged or worn.
Step 8.
Replace #73 DOSAGE
PISTON GUIDE and #44
DOSAGE PISTON.
Step 9.
Screw #61 OUTER
CYLINDER onto body.
Step 7.
Reset #68 O-ring and screw
#72 ADAPTER onto body.
Step 6.
Remove and replace #17
O-ring. Re-install #83 SHAFT
SEAL SPACER and #15
SEAL RETAINER.
↓
Step 4.
Remove #44 DOSAGE PISTON.
↓
Routine Maintenance Instructions 20%

16
Problem Cause Solution
No Clicking
Sound
Fluid not flowing through unit
Are the red plugs at the inlet, outlet and suction tube fitting openings removed?
Is the unit installed backward? The arrow on the unit must point in the direction
of the fluid flow.
Has the new injector been stored for an extended period. If so, submerge the injector
in room temperature water for 24 hours so that the working parts can reabsorb fluid
and swell back to the proper size.
If still not clicking, do not open the upper body. Call Hydro Customer Service.
Fluid flowing through unit
Fluid rate is below or exceeds rated service flow of injector. (See Specifications page 6).
If below increase flow rate, if above, reduce flow rate.
Operating pressure exceeds maximum limit. Install a pressure reducer valve.
(See Specifications for maximum flow rate page 6).
On/Off Lever in off position. Place the On/Off lever switch to the ON position.
By-pass valve not closed. Check and set valve to the OFF position.
Problem Cause Solution
No Clicking
Sound
Main Piston Assembly #9 worn. Replace # 9 Main Piston Assembly. Clean fluid filter.
Cover #1 or main body #40 worn
or scored. Replace and install or clean fluid filter.
On/Off Lever in off position. Place the On/Off lever switch to the ON position.
By-Pass Valve not closed. Set Valve to the closed position.
Dirty or plugged inlet filter. Ensure mesh size is correct for proper filtration. Clean filter.
#17 Worn or not seated properly. Re-seat #17 or replace.
Clicking Sound
No Suction
of Solution
Suction tube #25 (#60 - 20%) or
suction tube fitting #11 cracked, loose,
leaking or clogged suction
tube filter.
Check for proper fit, replace and/or clean as necessary.
Dosage piston #44 worn or installed
incorrectly, inner cylinder #37 (#68 -
1% & #7 - 20%) worn.
Replace. Ensure during maintenance replacement that #44 dosage piston
was installed correctly flared-end up.
O-ring retainer #82 (#15 - 10% & 20%)
installed incorrectly Install correctly.
O-ring seat #14 or dosage piston #44
damaged or worn. Replace, on 0.4% models replace #51 Shaft Assembly.
Check valve #13 (#60 - 20%) leaking. Clean & replace as necessary.
Clicking Sound.
Under
Injecting
#44 Dosage Piston worn. Replace, on 0.4% models replace #51 Shaft Assembly.
#37 (#7 - 20%) Inner Cylinder worn. Replace.
Unit operates at high-flow and not
at low flow. Replace #17 O-ring.
Main Piston Assembly #9 worn. Replace # 9 Main Piston Assembly. Clean fluid filter.
Cover #1 or main body #40 worn
or scored. Replace and install or clean fluid filter.
Fluid
Re-filling
Solution Tank
Check valve #13 leaking. Check seat area on suction tube fitting #11. Check valve and seal must fit
loose in the suction tube fitting. Clean seal and inside fitting for debris.
Washer seal on #13 is swollen
or chemical attack. Replace with new check valve assembly.
Hose Kit #60 (20%) leaking. Replace.
Troubleshooting
Injector in Operation or After Scheduled Maintenance
New Install - Always Pressure Up Slowly (Follow start up on page 9)

17
Injector Repair Parts ....................................................................................................................................... 18
0.4%: ............................................................................................................................................................. 19
1%: ................................................................................................................................................................ 20
2.5%: ............................................................................................................................................................. 21
5%: ................................................................................................................................................................ 22
10%: .............................................................................................................................................................. 23
20%: .............................................................................................................................................................. 24
Accessories:................................................................................................................................................... 25
Kits & Spare Parts List

18
86
87
34
1
85
21
9
40
20
Reference # Description
1 Upper Body
9 Motor Piston
20 O-ring
21 Bypass Shaft
34 Cotter Ring
40
NPT Lower Body
BSP Lower Body
20% NPT
20% BSP
20% NPT Remote Inject
20% BSP Remote Inject
85 Upper Shaft Pin
86 Mixing Chamber Gasket
87 On/Off Handle
Injector Repair Parts

19
Lower End
Assembly
54
55
Kit C
011110V
37
12
17
51
13
91 11
51
011112V
Kit E
10
37
12
10
17
16
12 82
60
61
27
Kit G
011113V
92
17
37
79
91 11
10
51
16
7
13
25
11
Kit D
011111
13 10
91
Kit H
011662S
9
Kit A
011732
011109V
Kit M
501534 MiniDos 0.4% Wear Kit Parts
17
51
13
27
25
12
7
37
79
17
82
16
61
60
51
11
91
10
92
0.4%
Ref. # Description of Part
7 MiniDos Outer Cylinder
10 MiniDos 0.4% Spring
11 Suction Tube Fitting, 1/8"
12 O-ring
13 Check Poppet w/Washer
16 Gasket
17 O-ring
25 Suction Tube 1/8" ×3'
27 Filter For Suction Tube 1/8"
37 MiniDos 0.4% Inner Cylinder
51 MiniDos 0.4% Shaft Assy
60 O-ring
61 MiniDos 0.4% Ratio Adjuster
79 Interlock Pin
82 Shaft Seal Spacer
91 Seal, Check Valve
92 Hose Nut 1/8"
Injector Repair Parts
Note: Viton seal materials are standard.
Other seal materials are available.

20
25
27
12
82
16
52
51
61
7
26
37
68
79
17
60
63
13
10
80
11
71
12
51
17
37
51
27
011068V
Kit G
17 63 71
12
68
13
80
10
11
26
52
16
7
61
60
82
79
25
52
11
13
10
80
51
17
68
63 12
16
10
011046V
Kit D
13
11
12
80
68
51
17
63
Kit H
011662S
9
011071V
Kit A
011073V
Kit E
011072V
Kit C
Kit M
011732
54
55
1%
Lower End
Assembly
Manual Description of Part
7 Cylinder, Outer
10 Spring
11 Suction Tube Fitting
12 O-ring
13 Check Poppet w/Washer
16 Gasket
17 O-ring
25 Suction Tube, ¼" X 5'
26 Anti Lock Gasket
27 Filter For Suction Tube, ¼" Id
37 Inner Cylinder
51 Lower Shaft Assembly
52 Shaft, Upper
60 O-ring
61 Ratio Adjuster
63 O-ring, Inner Cylinder
68 Inner Cylinder For #37
71 Nut, Suction Tube Fitting
79 Interlock Pin
80 Twistlock
82 Shaft Seal Spacer
Note: Viton seal materials are standard.
Other seal materials are available.