D25RE2MaintenanceManual 10-19-05

MAINTENANCE MANUAL
D25RE2
0.2 to 2%
1:500 to 1:50
Press Ctrl + L for full screen
DOSATRON INTERNATIONAL, INC. 800-523-8499

STANDARD INSTALLATION
Inlet Outlet
Optional
accessories Union ball
200 mesh /80 check/check
Optional accessories: micron filter valve or
water
Pressure regulator Concentrate hammer
arrestor
Solenoid valves
Water meter
Flow restrictor
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MAIN MENU
CHAPTER 1 REMOVING THE DISPENSER FROM INSTALLATION

CHAPTER 2 DISASSEMBLING THE DISPENSER
CHAPTER 3 REASSEMBLING THE DISPENSER
CHAPTER 4 PISTON MAINTENANCE
CHAPTER 5 AIR BLEED MAINTENANCE
CHAPTER 6 BY-PASS MAINTENANCE
CHAPTER 7 TROUBLESHOOTING GUIDE
Click on a specific chapter

or
Click for next slide
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SPECIFICATIONS
D25RE2
Injection Range:
1:500 to 1:50 - 0.2 to 2%
Water Flow Range:
0.05 to 11 GPM
Operating Water Pressure:
4.3 to 85 PSI
Maximum Water Temperature:
104F 40C
Note: Normal safety precautions should be practiced when
working with chemicals and equipment.
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CHAPTER 1
REMOVING THE DISPENSER FROM INSTALLATION
D25RE2
0.2 to 2%
1:500 to 1:50
Return to Main Menu

click for next slide
5

REMOVING THE DISPENSER FROM INSTALLATION
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.
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CHAPTER 2
DISASSEMBLING THE DISPENSER
D25RE2
0.2 to 2%
1:500 to 1:50
Return to Main Menu

7

Unscrew and remove the lid.
8
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Place the dispenser upside-down on a

table and remove the 4 dosing assembly
retaining screws.
Use a #2 Phillips screwdriver.
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Pull the injection stem

assembly out of the body, and
let the solution drain out of it.
Caution:
Caution Stem may be full of
undiluted chemical. Be aware of
hazardous materials and take
the necessary precautions for
protection.
WATCH OUT FOR SPLASHING! 10

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Grab the valve support and pull the piston out of the body, at
the same time, push the plunger up.
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Dosing assembly - disassembly
Unscrew and
remove the barbed
fitting.
Unscrew and
remove the conical
nut.
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Remove the
anti-friction ring.
Unscrew and
remove the
adjusting nut
from the
sleeve.
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Remove the injection stem from the top

of the sleeve.
Gently remove the sleeve O-ring.
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Gently push the check valve out of the

injection stem with a pencil or similar
object. Do not scratch the inside of the
injection stem.
Gently remove the injection stem O-ring.
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CLEANING & MAINTENANCE PROCEDURE
When disassembly of the Dosatron unit is complete, soak it in lukewarm soapy
water. A soft bristled brush may be used to break up residue.
J009
Change seal kit every 12 months.
Seal kit part # ED252 includes:
J009 - Plunger seal

PJ121 - Injection stem assembly
J024 - Injection sleeve O-ring
MPDI122 - Check valve assembly
J051 - Check valve seal
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CHAPTER 3
REASSEMBLING THE DISPENSER
D25RE2
0.2 to 2%
1:500 to 1:50
Return to Main Menu

17

Dosing assembly
Replace the O-ring on the dosing stem.
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Dosing assembly
Reinsert the injection stem into the injection sleeve. Make sure that the long groove
in the injection stem aligns with the tooth inside the injection sleeve.
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Dosing assembly
Replace the sleeve O-ring.
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Dosing assembly
Insert the metal

retainer.
Thread the adjusting nut

onto the sleeve until it
reaches the top of the
scale.
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Dosing assembly
Align teeth on the inside of the anti-friction ring with the 2 grooves in
the dosing stem and slide it up to the adjusting nut.
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Dosing assembly
Thread the conical nut onto the dosing

stem. It should be hand tight.
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Dosing assembly
Replace and slide the check valve

assembly into the injection stem.
The cone should point out.
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Dosing assembly
Remove, replace and Thread the barbed fitting onto

position the check valve seal the injection stem. It should be
into the barbed fitting with the hand tight.
groove facing up. 25
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Remove and replace the plunger Insert the piston straight into
seal by sliding the seal over the end the body all the way down.
of the plunger. 26
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Align the metal retaining

plate with the holes in the
body and install 4 screws.
Carefully align the plunger inside Use #2 Phillips screwdriver.
the injection stem assembly. 27
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Reseat or replace the lid O-ring.

Replace the O-ring if leaking. Screw the lid onto the body of the
dispenser. It should be hand tight.
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The dispenser is now

reassembled.
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CHAPTER 4
PISTON MAINTENANCE
D25RE2
0.2 to 2%
1:500 to 1:50
Return to Main Menu

30

PISTON MAINTENANCE
Piston Fit Test
Insert piston into the body half way down, suspend the unit from the valve support ONLY, ONLY
then lift it. The piston should be snug in the body and the body should not fall off, if it does, the
piston shell needs to be replaced. Also inspect the inside of the body and look for deep
vertical scratches, if this is the case, the body needs to be replaced.
Note: Remove plunger seal prior to doing this 31
test so it will not interfere. See page 48. click for next step
PISTON MAINTENANCE
Piston disassembly
Actuate the piston so the piston

valves are in the up position.
Unscrew and remove the valve
support retaining screw.
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PISTON MAINTENANCE
Piston disassembly
Pull the valve support up and slide back to separate it

from the valve.
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PISTON MAINTENANCE
Piston disassembly
On the top of the piston shell, Pull the actuator assembly

unscrew the 4 retaining screws. from under the piston shell.
Use #1 Phillips screwdriver. 34
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PISTON MAINTENANCE
Piston disassembly: actuator assembly
Remove the 2 springs. When changing

a broken spring, it is best to replace
both springs.
35
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PISTON MAINTENANCE
Remove the push rod by

sliding it straight down.
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PISTON MAINTENANCE
Remove the plunger. To do this, lift the plunger from the actuator assembly and
pull it towards the outside of its housing. This separates the actuator assembly
entirely. 37
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PISTON MAINTENANCE
Carefully remove the inlet

valve O-ring, make sure not to
damage the valve.
38
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PISTON MAINTENANCE
Piston reassembly
Replace the inlet valve O-ring.
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PISTON MAINTENANCE
Piston reassembly
Insert the plunger in the housing of the actuator assembly.
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PISTON MAINTENANCE
Piston reassembly
Inspect the condition of the

push rod and ridge (the
actuator assembly and the
push rod should be
replaced if they show signs
of wear or scoring).
The ridge of the push

rod must be aligned
with the corresponding
groove on the actuator Insert the push rod
assembly. with the long end up.
41
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PISTON MAINTENANCE
Piston reassembly
Install the 2 actuator springs with

loop opening downward.
42
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PISTON MAINTENANCE
Piston reassembly
The actuator assembly is now

assembled.
43
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PISTON MAINTENANCE
Piston reassembly
Inspect the exterior piston shell Inspect o-ring and replace if necessary.
flanges. They should not be worn Align the o-ring in the groove on the
or scored. If they are scored, the bottom of the piston shell.
piston shell should be replaced. 44
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PISTON MAINTENANCE
Piston reassembly
Position the actuator assembly in the

piston shell.
Align the push rod and valve with the

corresponding holes in the piston shell. 45
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PISTON MAINTENANCE
Piston reassembly
Push the actuator assembly into the

piston shell and align the screw with
the holes. Install the 4 screws.
Use #2 Phillips screwdriver.
46
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PISTON MAINTENANCE
Piston reassembly
Align the top inlet valve with the

center groove of the valve support
and push forward until the outlet
valves reach their openings in the
piston shell.
47
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PISTON MAINTENANCE
Piston reassembly
Position the valve support retainer Replace the plunger seal by

and install screw. sliding the seal over the end
of the plunger. 48
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PISTON MAINTENANCE
Piston reassembly
The piston is ready to be reinstalled.

49
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PISTON MAINTENANCE
Reset piston
To reset the piston, remove the lid, push the piston all the way down, it may
click, pull the piston all the way up. Holding it in up position, push down on
the vertical rod and it should click. Push the piston back all the way down
and it should click again. Screw the lid back on.
50
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CHAPTER 5
AIR BLEED MAINTENANCE
D25RE2
0.2 to 2%
1:500 to 1:50
Return to Main Menu

51

Air bleed disassembly
Using a small flat blade screwdriver, gently pry loose the rubber cap and
remove it from the top of the air bleed button.
52
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Using a small flat blade Remove the ribbed collar

screwdriver, gently pry by pulling it straight up.
loose the ribbed collar.
53
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Align a 7/8" socket with the Align the two tabs on the air
plastic nut on the underside of bleed with the
corresponding grooves in
the lid and gently twist the air the lid.
bleed turn. 54
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Remove the air bleed button by pushing it through the lid.

55
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Air bleed reassembly
Replace the O-ring.

The only serviceable part on
the air bleed is the O-ring.
56
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Position the air bleed Install the air bleed button

button in the socket. from the inside of the cover.
Turn the socket turn to lock the button in the lid.
57
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Install the ribbed collar so that

the slots align with the tabs on
the air bleed button.
58
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Re-install the rubber cap on the air bleed button. Using a small flat
blade screwdriver, gently put back in place the rubber cap.
59
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CHAPTER 6
BY-PASS MAINTENANCE
D25RE2
0.2 to 2%
1:500 to 1:50
Return to Main Menu

60

BY-PASS MAINTENANCE
By-pass disassembling
Set the by-pass button to ON. Use needle nose pliers or awl to
push pin out.
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BY-PASS MAINTENANCE
Remove the pin from the Remove the "ON-OFF" knob by

"ON-OFF" knob and the firmly snapping it out of the
stainless steel stem of the collar.
by-pass.
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BY-PASS MAINTENANCE
Using a small flat blade screwdriver,

gently pry loose the ribbed collar.
Remove the ribbed collar by lifting it

straight up.
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BY-PASS MAINTENANCE
Align a 7/8" socket with the plastic nut

on the underside of the lid and gently
twist the by-pass turn.
Align the two tabs on the by-pass with

the corresponding grooves in the lid.
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BY-PASS MAINTENANCE
Remove the by-pass by pushing it

through the lid.
The O-ring is the only serviceable

part on the by-pass.
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BY-PASS MAINTENANCE
By-pass reassembling
Slide the stainless steel Install the by-pass from the inside of the lid.
stem into the by-pass. With the socket, turn the by-pass turn to
lock it in the lid.
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BY-PASS MAINTENANCE
Install the ribbed collar so that the slots

align with the tabs on the bypass.
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BY-PASS MAINTENANCE
Carefully position by-pass Lightly tap on the top of the knob

knob in the collar. with a mallet to snap it in place.
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BY-PASS MAINTENANCE
With the lever in the "ON" Install the pin. When completed,
position, align the holes of the the pin should not protrude on
lever and stainless rod of the either side of the lever.
by-pass. 69
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CHAPTER 7
TROUBLESHOOTING GUIDE
D25RE2
0.2 to 2%
1:500 to 1:50
Return to Main Menu

70

SYMPTOM CAUSE REMEDY

PISTON The unit is installed in the wrong The arrow on the unit should point in the same direction
Piston is not clicking direction as the water flow. Water supply and demand valves
should be open.
Piston locked up/not clicking Reset piston. See page 50 for instructions.
Broken actuator spring Replaced both actuator springs.
Excessive water flow 1. Reduce the flow rate and slowly restart the unit.
2. Remove the lid, pull out the piston and check if the O-
rings around the piston valves are missing or dislodged.
3. Reset piston (see page 50 for instructions) screw lid
back on.
Water hammer Reset piston (see page 50 for instructions) and install
water hammer arrestor in the appropriate location.
In line water filter is clogged Clean the water filter.
Worn, scratched/scored piston Do piston fit test (page 31). Replace piston shell and/or
shell and body body. Make sure installation has a 200 mesh filter before
the Dosatron.
DOSING Check valve dirty, worn, Clean or replace the check valve assembly. Pages 24 &
Water flowing back into assembled incorrectly or missing 25.
solution container
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No suction of solution Piston locked up/not clicking Reset piston. See page 50 for instructions.
Air leak in the suction tube Check suction tube connection. Inspect suction
tube for pin holes or cracks. Check tightness of
connection nuts.
Cut inch off the top of the hose and reattach it
correctly.
Suction tube or strainer clogged Clean suction tube and strainer or replace hose
assembly.
Raise strainer 2 inches off the bottom of stock
solution container.
Check valve worn, improperly Clean or replace check valve assembly. Pages
assembled, dirty or damaged 24 & 25.
Plunger seal is damaged, swollen or Clean or replace plunger seal. If plunger seal is
missing missing, check incoming water pressure; refer to
unit manual for specifications.
Worn piston shell and/or body Do piston fit test (page 31). If necessary
replace piston shell and/or body. Make sure your
installation has a 200 mesh filter before the
Dosatron.
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Under-Injection Worn or scratched piston shell Do piston fit test (page 31). If necessary replace
and/or body piston shell and/or body. Make sure the
installation has a 200 mesh filter before the
dispenser.
Suction of air Check suction tube connection. Inspect suction
tube for pin holes or cracks. Check tightness of
connection nuts.
Cut inch off the top of the hose and reattached
it correctly.
Excessive water flow Listen to the unit clicking, count the individual
clicks, should not exceed 46 in 15 seconds
otherwise is excessive flow. If excessive flow
reduce the flow rate and restart the unit slowly.
Worn plunger seal Replace plunger seal.
Worn or cracked injection stem Replace injection stem.

(inside or outside).
Check valve worn, improperly Clean or replace check valve assembly. Pages 24
assembled, dirty or damaged & 25.
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LEAKS Sleeve O-ring damaged, Replace sleeve O-ring.
Leaks near the metal collar under the improperly positioned or
body. missing
Leaks between adjusting nut and the anti- Injection stem O-ring Clean and replace injection stem O-ring.
lock ring. damaged, improperly
positioned or missing
Leaks between body and lid. Lid O-ring damaged, Position O-ring correctly, clean the seating
improperly positioned or surface of the O-ring or replace the lid O-ring.
missing
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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
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MAINTENANCE MANUAL

Press Ctrl + L for full screen

DOSATRON INTERNATIONAL, INC. 800-523-8499

CHAPTER 1 REMOVING THE DISPENSER FROM INSTALLATION

Click on a specific chapter

REMOVING THE DISPENSER FROM INSTALLATION

Return to Main Menu

DOSATRON INTERNATIONAL, INC. 800-523-8499

After turning off the water and

Unscrew the suction tube nut

DISASSEMBLING THE DISPENSER

Return to Main Menu

DOSATRON INTERNATIONAL, INC. 800-523-8499

Unscrew and remove the lid.

Place the dispenser upside-down on a

Pull the injection stem

WATCH OUT FOR SPLASHING! 10

Dosing assembly - disassembly

Remove the injection stem from the top

Gently remove the sleeve O-ring.

Gently push the check valve out of the

Gently remove the injection stem O-ring.

J009 - Plunger seal

REASSEMBLING THE DISPENSER

Return to Main Menu

DOSATRON INTERNATIONAL, INC. 800-523-8499

Replace the O-ring on the dosing stem.

Replace the sleeve O-ring.

Insert the metal

Thread the adjusting nut

Thread the conical nut onto the dosing

Replace and slide the check valve

Remove, replace and Thread the barbed fitting onto

Align the metal retaining

Reseat or replace the lid O-ring.

The dispenser is now

Return to Main Menu

DOSATRON INTERNATIONAL, INC. 800-523-8499

Actuate the piston so the piston

Pull the valve support up and slide back to separate it

On the top of the piston shell, Pull the actuator assembly

Remove the 2 springs. When changing

Remove the push rod by

Carefully remove the inlet

Replace the inlet valve O-ring.

Insert the plunger in the housing of the actuator assembly.

Inspect the condition of the

The ridge of the push

Install the 2 actuator springs with

The actuator assembly is now

Position the actuator assembly in the

Align the push rod and valve with the

Push the actuator assembly into the

Align the top inlet valve with the

Position the valve support retainer Replace the plunger seal by

The piston is ready to be reinstalled.

AIR BLEED MAINTENANCE

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DOSATRON INTERNATIONAL, INC. 800-523-8499

Using a small flat blade Remove the ribbed collar

Remove the air bleed button by pushing it through the lid.

Replace the O-ring.

Position the air bleed Install the air bleed button

Install the ribbed collar so that