MAINTENANCE MANUAL D8R 0.2 - 2% - Irrigation...

MAINTENANCE MANUALMAINTENANCE MANUALD8R D8R

0.2 0.2 -- 2%2%

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STANDARD INSTALLATIONSTANDARD INSTALLATION

200 Mesh/ 80 micron

filter

Union ball check/

check valve or water hammer arrestor

Inlet Outlet

Concentrate

Optional accessories:

•Pressure regulator

•Solenoid valves

•Water meter

•Flow restrictor

Optional accessories

MAIN MENUMAIN MENU• CHAPTER 1 Removing the dispenser from the installation• CHAPTER 2 Disassembling the dispenser • CHAPTER 3 Reassembling the dispenser • CHAPTER 4 Piston Maintenance• CHAPTER 5 Maintenance of air bleed assembly• CHAPTER 6 Maintenance of vacuum breaker • CHAPTER 7 Troubleshooting guide

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SPECIFICATIONSSPECIFICATIONS• Injection Range:

1:500 (0.2%) to 1:50 (2%)1:500 (0.2%) to 1:50 (2%)• Water Flow Range:

2.2 to 40 GPM2.2 to 40 GPM• Operating Water Pressure:

2 to 110 PSI2 to 110 PSI• Maximum Water Temperature:

104°F 104°F –– 40°C40°C

Note: Normal safety precautions should be practiced when Note: Normal safety precautions should be practiced when working with chemicals and equipment.working with chemicals and equipment.

5© COPYRIGHT, DOSATRON INTERNATIONAL SA, 2002

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CHAPTER 1CHAPTER 1REMOVING THE DISPENSER FROM INSTALLATIONREMOVING THE DISPENSER FROM INSTALLATION

DISASSEMBLING OF THE DISPENSER FROM THE DISASSEMBLING OF THE DISPENSER FROM THE INSTALLATIONINSTALLATION

After turning off the water and relieving the pressure on the unit, unscrew the dispenser inlet/outlet couplings and allow it to drain.

Unscrew the suction tube nut and remove the hose.

CHAPTER 2CHAPTER 2DISASSEMBLING THE DISPENSERDISASSEMBLING THE DISPENSER

DISASSEMBLING THE DISPENSERDISASSEMBLING THE DISPENSER

Unscrew the retaining nut.

CautionCaution: Stem may be full of undiluted chemical. Be aware of

hazardous materials and take the necessary precautions for

protection.

WATCH OUT FOR SPLASHING !WATCH OUT FOR SPLASHING !

Pull the injection stem assembly out of the dosing sleeve, and let the solution

drain out of it.

Remove the check valve barb.

With the injection stem assembly in your hands, unscrew the check valve

Gently push the check valve out of the dosing stem with a pencil or similar object.

Do not scratch the inside of the dosing stem.

Remove the seal, retainer, cone and spring from the check valve guide.

Note: the white retainer ring may be difficult to remove if the unit is old or has chemical residue.

DISASSEMBLING THE Y OF DISPENSERDISASSEMBLING THE Y OF DISPENSER

Unscrew the bell housing and remove it.

Carefully remove the piston assembly straight up without bending or damaging

the plunger.

Remove the bell housing seal. Remove the screen from the body, put the dispenser body on a table, hold it firmly and at the same time lift the screen with

your fingers.

DISASSEMBLING THE DISPENSERDISASSEMBLING THE DISPENSERDisassembly of the diffuser assembly is only necessary if a leak develops in the nut area.

Remove the screw from the threaded diffuser nut

Unscrew the diffuser nut.

Push the diffuser towards the interior of the dispenser. Bump it with your palm if necessary.

Remove the diffuser assembly from the internal part of the

dispenser.

Disassembly of the diffuser assembly is only necessary if a leak develops in the nut area.

When the disassembly of the Dosatron unit is complete, soak it in lukewarm soapy water. A soft bristled brush may be used to break residue.

Change seal kit every 12 months. Seal kit part No. 8ED005 includes:

8J008 Plunger seal8J026 Injection stem O-ringMDI032 Check valve springPDI051 Check valve coneJDI013 Check valve seal20J002 Check valve O-ring

CLEANING & MAINTENANCE PROCEDURECLEANING & MAINTENANCE PROCEDURE

CHAPTER 3CHAPTER 3REASSEMBLING THE DISPENSERREASSEMBLING THE DISPENSER

REASSEMBLING THE DISPENSERREASSEMBLING THE DISPENSER

Place the screen inside the body. Then, reseat or replace the bell housing O-ring. Replace the O-ring if leaking or if shows signs of wear.

Make sure that the groove on the inner part of the diffuser is aligned with the key inside the outer part

of the diffuser.

Replace the diffuser O-ring if the diffuser

is leaking.

Install the diffuser assembly into the body. Be sure to align the notch in the diffuser with the tooth that is molded in the body.

Put in place the retaining nut and the screw. Note: The small metal screw is self tapping. It may not land in the exact same position on the body as it first had. Just tighten the screw down and it will bite the blue plastic.

Replace the check valve O-

Replace the check valve cone and the spring. Insert them in the check valve guide. Then, put the check valve retainer

to hold the cone and the spring in place.

Caution: Small, spring loaded parts are easily lost!Caution: Small, spring loaded parts are easily lost!

Insert the check valve seal with the raised part facing inward. Assemble the check valve assembly by firmly pushing the guide and the barbed fitting together.

Replace the injection stem O-ring.

Insert the check valve assembly inside the injection

sleeve Thread the check valve nut

The injection stem assembly is now ready.

Replace the plunger seal. Make sure not to damage the seal or the plunger.

Carefully, without damaging the plunger, insert the piston assembly inside the

dispenser’s body.

Screw the bell housing onto the body of the dispenser.

Insert the injection assembly. Make sure the tabs in the retainer nut align

with the holes in the diffuser nut.

Tight the retaining nut. The scale should be straight in the front of the unit and you should be able to see at the maximum one or two threads between

the blue body and the retaining nut.

The dispenser is ready to be reinstalled.

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CHAPTER 4 CHAPTER 4 MAINTENANCE OF PISTONMAINTENANCE OF PISTON

PISTON MAINTENANCEPISTON MAINTENANCEDisassembly of pistonDisassembly of piston

Unscrew and remove the plunger assembly.

PISTON MAINTENANCEPISTON MAINTENANCE

Piston “Fit” TestPiston “Fit” Test

Insert the piston into the upside down bell housing half way down. Then let go of the piston. The piston should be snug in the upper housing and should not fall in. If it does, the piston

shell needs to be replaced. Also inspect the inside of the bell housing and look for deep vertical scratches or excessive wear. If this is the case, the bell housing needs to be

replaced.Note: It is best to remove the plunger prior to Note: It is best to remove the plunger prior to doing this test so it will not interfere.doing this test so it will not interfere.

PISTON MAINTENANCEPISTON MAINTENANCEPiston “Fit” TestPiston “Fit” Test

Note: It is best to remove the plunger prior to Note: It is best to remove the plunger prior to doing this test so it will not interfere.doing this test so it will not interfere.

Insert the lower part of the piston half way down the body. Then let go of the piston. The piston should be snug in the body and should not fall in. If it does, the piston shell needs to

be replaced. Also inspect the inside of the body and look for deep vertical scratches or excessive wear. If this is the case, the body needs to be replaced.

Remove the four upper valves by removing the screw and washer on the top of each valve.

Remove the four screws and washers that support the bearings.

Remove the two screws that hold down the vertical rod guide.

Remove the vertical rod guide.

Remove the two screws that hold in place the actuator assemblyPull up and remove the vertical rod.

With the help of a flat screw driver or needle nose pliers push out the end of the toggle spring.

Lift carefully the white plastic arm and remove the metal pin,

pulling it through the toggle spring.

Gently lift the actuator assembly and remove the two bearings.

Pull out the actuator assembly from the piston shell. Be careful not to loose the short metal pin

that goes through the white plastic leg and slides inside the

piston shell guide.

PISTON MAINTENANCEPISTON MAINTENANCEAssembly of pistonAssembly of piston

Change the seals of the two lower piston valves. Insert the shortest metal pin through the hole of the white plastic leg.

Insert the actuator assembly inside the new piston shell. Be sure the pin gets

into the piston shell guide.

Place the arm of the actuator assembly in the toggle spring. Insert the longer metal pin inside the actuator assembly’s arm. Make sure to grab the straight end of the

toggle spring and pull it under (winding it) and let it rest inside the shell.

Push down on the pin to lodge it in its groove.

Grab the straight end of the toggle spring with needle nose pliers and place it inside the groove located in

the actuator assembly’s arm.

Place the two screws on either side of the arm and tighten them down. No washers needed.

Carefully lift the actuator assembly and insert the two bearings. Before pushing both at the same time down into their seat. Make sure that the short metal pin inside the piston shell guide is in place if not, realign it.

Make sure that the metal pin of the pinion is in the same side as

the vertical rod. Carefully insert the vertical rod.

Make sure that first tooth of the vertical rod is inside the first tooth of the pinion.

Hold together the pinion and the vertical rod and put the rod retainer on top of the

vertical rod.

Install the two screws of the rod retainer in place. Make sure that the tooth of the

pinion and the tooth of the rod are in place.

Install the four screws and washers that hold the bearings down.

Change the seals of the four piston upper valves if necessary. Insert the four upper piston valves. Thread the screws all the way in to hold the valves in place. Make sure the metal washers are in place. It is normal to feel a slight play when

moving the valves.

Change the plunger seal. Screw the plunger assembly all the way up at the bottom of the

piston.

PISTON MAINTENANCEPISTON MAINTENANCEReset PistonReset Piston

To reset the piston, remove the piston from the dispenser. Holding the piston push down on the vertical rod all the way down, it may click. Push the vertical rod all the

way up, it should click. Push the vertical rod all the way down once more and it should click. Insert the piston inside the dispenser.

To insert the piston inside the dispenser follow instructions on pages 29 and 30

CHAPTER 5CHAPTER 5MAINTENANCE OF AIR BLEEDMAINTENANCE OF AIR BLEED

Maintenance air bleed assemblyMaintenance air bleed assembly

Remove the 10 retaining bypass assembly screws and the air bleedassembly.

Note: The air bleed assembly with 8 screws has no serviceable paNote: The air bleed assembly with 8 screws has no serviceable parts. rts. Please contact us for further assistance.Please contact us for further assistance.

Remove the spring and the bypass switch.

Replace the O-ring of the bypass assembly.

Put the spring in place, smaller

diameter down.

Replaced the two bypass seals in each side of the bypass switch.

Put in place the bypass switch in the bypass assembly. Make sure all the holes including the one in the bypass switch are in the same

direction. Insert the small metal tube in the middle of the bypass switch.

Put in place the screw with the metal washer that goes in the middle of the bypass switch, push the screw all the way in

with the help of the screwdriver.

Holding in place the bypass switch put the bypass assembly on top of the bell housing trying to catch the holes for the screws. Pushing down on the bypass

assembly, tighten the screw holding the switch.

Tighten the rest of the screws starting with the one opposite to the

switch.

Make sure the on and off switch is not loose when you move it.

Place the switch on the “ON” position.

CHAPTER 6CHAPTER 6MAINTENANCE OF THE VACUUM BREAKERMAINTENANCE OF THE VACUUM BREAKER

In installations prone to siphoning, Watch out!

You may need to use the integrated vacuum breaker. To do so, remove the black nut under the body, remove the metal disc and replace it with the metal washer found in the accessories accompanying the new unit. Screw the black nut on.

DISASSEMBLING THE DISPENSERDISASSEMBLING THE DISPENSERDisassembly of the vacuum breaker is only necessary if a leak develops.

To clean up the vacuum breaker, unscrew the retainer nut.

Remove the vacuum breaker washer.

DISASSEMBLING THE DISPENSERDISASSEMBLING THE DISPENSERDisassembly of the vacuum breaker is only necessary if a leak develops.

Remove the seal. Remove the ball. Clean all the parts.

Replace the seal if there is a leak.

Insert the ball.

Screw the retaining nut.Put the washer in place.

CHAPTER 7 CHAPTER 7 TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTINGTROUBLESHOOTING

Do piston “fit” test (pages 36-37). Replace piston shell, body and/or bell housing as necessary. Make sure your installation has a 200 mesh filter before the Dosatron. Flush unit by injecting clear water often is wear us due to chemical.

Worn piston shells, bell housing and/or body

Clean the in line water filter. Clean the inside screen (see pages 15 and 20).

In-line water filter or inside screen is clogged

1. Reduce the flow rate and restart the unit slowly.2. Open bell housing, check O-rings around the four piston valves to see if they are missing or dislodged. 3. Reset the piston (see page 60 for instructions) screw bell housing back on.

Excessive water flow

PISTONPiston is not clicking

Reset piston (see page 60 for instructions) and install water hammer arrestor in the appropriate location.

Water hammer

Do piston “fit” test (pages 36-37). replace piston shells, body and bell housing as necessary. Make sure your installation has a 200 mesh filter before the Dosatron. Flush unit by injecting clear water often is wear us due to chemical.

Scratched/scored piston shells, bell housing and/or body

Reset piston. See page 60 for instructions or flip bypass to ON position.

Piston locked up/not clicking or bypass in OFF position

The arrow on the unit should point in the same direction as the water flow.

The unit is installed in the wrong direction

REMEDYCAUSESYMPTOM

Replace toggle spring. Call for instructions.Broken toggle springPISTONPiston is not clicking Replace actuator assembly. Call for instructions.Broken actuator “barrel” spring

Clean or replace check valve parts and reassemble check valve correctly.

Check valve dirty, worn, assembled incorrectly or missing

DOSING Water flowing back into solution container.

Check suction tube connection. Inspect suction tube for pin holes or cracks.Check tightness of connection nuts.Cut ½” of top of the hose and reattach it correctly.

Air leak in the suction tube

No suction of solution

Clean or replace plunger seal.If plunger seal is missing, check incoming water pressure; refer to unit manual for specifications.

Plunger seal is damaged, swollen or missing

Clean or replace check valve parts. In particular the seal and the cone.

Check valve worn, improperly assembled, dirty or damaged

Clean suction tube and strainer or replace hose assembly.Raise strainer 2” off the bottom of stock tank solution.

Suction tube or strainer clogged

Reset piston (see page 60 for instructions) or flip bypass to ON position.

Piston locked up/not clicking or bypass in OFF position

REMEDYCAUSESYMPTOM

Do piston “fit” test (pages 36-37). If necessary replace piston shells, bell housing and/or body. Make sure your installation has a 200 mesh filter before the Dosatron.

Worn or scratched piston shells, bell housing and/or body

Check suction tube connection. Inspect suction tube for pin holes or cracks. Check tightness of connection nuts. Cut ½” off top of the hose and reattach it correctly.

Suction of air

Under-Injection

Listen to the unit clicking, count the individual clicks, should not exceed 36 clicks in 15 seconds otherwise is excessive flow. If excessive flow reduce the flow rate and restart the unit slowly.

Excessive water flow

Replace plunger seal.Worn plunger seal

Replace injection stem.Worn or cracked injection stem

Clean or replace check valve parts. In particular the seal and the cone.

Check valve worn, improperly assembled, dirty or damaged

REMEDYCAUSESYMPTOM

Position correctly or replace the diffuser seal.Check tightness of the nut.

Diffuser seal is damaged or positioned incorrectly

Position correctly or replace the diffuser if damaged.

Diffuser is installed incorrectly

Position correctly, clean the seal seat, or replace the bell housing seal.

Bell housing seal is damaged, positioned incorrectly or missing

Leaks between the body and the bell housing

Check and replaced the body if necessary.Body may be cracked

LEAKSLeaks in the vicinity of the black nut under the body

REMEDYCAUSESYMPTOM

Thank you for using Dosatron liquid dispensers.

Please contact us at (800) 523-8499 for further assistance or visit our website at

www.dosatronUSA.com

2090 Sunnydale Blvd., Clearwater, Florida 33765

MAINTENANCE MANUAL D8R 0.2 - 2% - Irrigation...

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