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PISTON MAINTENANCE

Piston reassembly

PISTON MAINTENANCE

Insert the plunger rod into the

Align the rod pin with the hole on the

actuator

click

for next step

DOSATRON INTERNATIONAL, INC.

•

800-523-8499

actuator assembly.

actuator.

Summary of Contents for D25RE5

Page 1: ...MAINTENANCE MANUAL MAINTENANCE MANUAL D25RE5 1 to 5 1 100 1 20 1 100 to 1 20 Press Ctrl L for full screen DOSATRON INTERNATIONAL INC 800 523 8499 1...

Page 2: ...on ball Optional accessories 200 mesh 80 micron filter check check valve or water hammer arrestor Concentrate Optional accessories Pressure regulator arrestor Concentrate Pressure regulator Solenoid v...

Page 3: ...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 s...

Page 4: ...M Operating Water Pressure 4 3 to 85 PSI 4 3 to 85 PSI Maximum Water Temperature Maximum Water Temperature 104 104 F F 40 40 C C Note Note Normal safety precautions should be practiced when Normal saf...

Page 5: ...APTER 1 REMOVING THE DISPENSER FROM INSTALLATION REMOVING THE DISPENSER FROM INSTALLATION D25RE5 1 to 5 1 100 1 20 1 100 to 1 20 Return to Main Menu click for next slide DOSATRON INTERNATIONAL INC 800...

Page 6: ...FROM INSTALLATION 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 Unscre...

Page 7: ...CHAPTER 2 CHAPTER 2 DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER D25RE5 1 to 5 1 100 1 20 1 100 to 1 20 Return to Main Menu click for next slide DOSATRON INTERNATIONAL INC 800 523 8499 7...

Page 8: ...DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Unscrew and remove the lid click for next step DOSATRON INTERNATIONAL INC 800 523 8499 8...

Page 9: ...DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Unscrew the black nut click for next step DOSATRON INTERNATIONAL INC 800 523 8499 9...

Page 10: ...em assembly out of the body and let the solution drain out of it Caution Caution Stem may be full of dil t d h i l B f undiluted chemical Be aware of hazardous materials and take the necessary precaut...

Page 11: ...DISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Grab the valve support and pull the piston out of the body click for next step DOSATRON INTERNATIONAL INC...

Page 12: ...BLING THE DISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Injection assembly Injection assembly disassembly disassembly Remove the lower stem flange O ring click for next step DOSATR...

Page 13: ...SER Injection assembly Injection assembly disassembly disassembly Put the body upside down on the table and remove the four retaining screws Use Remove the stem flange and the upper stem flange O ring...

Page 14: ...ING THE DISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Injection assembly Injection assembly disassembly disassembly Unscrew and remove the check valve nut click for next step DOSAT...

Page 15: ...SPENSER Injection assembly Injection assembly disassembly disassembly Remove the check valve Remove the check valve bl b i d Remove the check valve barb O ring assembly by grasping and pulling the bar...

Page 16: ...ction assembly Injection assembly disassembly disassembly Remove the check valve seal Gently push the check valve out of the injection stem with a pencil or similar object Do not scratch click for nex...

Page 17: ...SEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Injection assembly Injection assembly disassembly disassembly Remove the check valve retainer Remove the cone and spring from the check valve guide c...

Page 18: ...ISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Injection assembly Injection assembly disassembly disassembly Unscrew and remove the Remove the anti lock ring click for next step DOSA...

Page 19: ...NSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Injection assembly Injection assembly disassembly disassembly Unscrew and remove the adjusting nut j g from the sleeve assembly click for n...

Page 20: ...PENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Injection assembly Injection assembly disassembly disassembly Remove the injection stem from the top of the sleeve assembly click for nex...

Page 21: ...DISPENSER DISASSEMBLING THE DISPENSER DISASSEMBLING THE DISPENSER Injection assembly Injection assembly disassembly disassembly Remove the injection stem O ring Remove the black nut click for next st...

Page 22: ...apy 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 Change seal kit every 12 months S l kit t PJ119 i l d Seal k...

Page 23: ...CHAPTER 3 CHAPTER 3 REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER D25RE5 1 to 5 1 100 1 20 1 100 to 1 20 click for next slide Return to Main Menu DOSATRON INTERNATIONAL INC 800 523 8499 23...

Page 24: ...DISPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER Injection assembly Injection assembly Injection assembly Injection assembly Replace the O ring on the injection stem click for next step...

Page 25: ...E DISPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER Injection assembly Injection assembly Injection assembly Injection assembly Insert the black nut onto the sleeve click for next step D...

Page 26: ...ING THE DISPENSER Injection assembly Injection assembly Make sure that the long groove in the injection stem aligns with the tooth inside the injection sleeve Reinsert the injection stem into the inje...

Page 27: ...SPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER Injection assembly Injection assembly Thread the adjusting nut onto the sleeve j g until it reaches the top of the scale click for next st...

Page 28: ...HE DISPENSER REASSEMBLING THE DISPENSER Injection assembly Injection assembly Align the tooth on the inside of the anti lock ring with the groove in the injection stem and slide it up to the adjusting...

Page 29: ...ENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER Injection assembly Injection assembly Thread the lock nut onto the dosing t It h ld b h d ti ht stem It should be hand tight click for next...

Page 30: ...assembly Injection assembly Replace the check Replace and insert the spring and the cone inside the check valve guide Then insert the retainer and make sure to push them all the way in Replace the ch...

Page 31: ...ENSER REASSEMBLING THE DISPENSER Injection assembly Injection assembly Replace the check valve barb O ring Assemble the check valve with the barbed fitting by putting the cone in the center of the bar...

Page 32: ...ISPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER Injection assembly Injection assembly Slide the check valve into the injection Screw the check valve nut back on click for next step DOSA...

Page 33: ...SER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER Position the stem flange onto the body Replace the upper stem flange O ring click for next step DOSATRON INTERNATIO...

Page 34: ...EASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER Insert the 4 metal rings and the screws on the stem flange Use 2 Phillips screwdriver click for next step DOSATRON INTER...

Page 35: ...SEMBLING THE DISPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER Replace the lower stem flange O ring click for next step DOSATRON INTERNATIONAL INC 800 523 8499...

Page 36: ...the body Insert the injection assembly Be careful to not damage the plunger Screw the black nut back on It should be hand tight Note Note For plunger seal maintenance see page 45 and 52 For plunger s...

Page 37: ...HE DISPENSER REASSEMBLING THE DISPENSER Screw the lid onto the body of the dispenser It should be hand tight Reseat or replace the lid O ring Replace the O ring if leaking click for next step DOSATRON...

Page 38: ...ISPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER REASSEMBLING THE DISPENSER The dispenser is now reassembled The dispenser is now reassembled click for next step DOSATRON INTERNATIONAL I...

Page 39: ...CHAPTER 4 CHAPTER 4 PISTON MAINTENANCE PISTON MAINTENANCE D25RE5 1 to 5 1 100 1 20 1 100 to 1 20 click for next slide Return to Main Menu DOSATRON INTERNATIONAL INC 800 523 8499 39...

Page 40: ...ld 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 th...

Page 41: ...NTENANCE PISTON MAINTENANCE Piston disassembly Piston disassembly Actuate the piston so the piston p p valves are in the up position Unscrew and remove the valve support retaining screw click for next...

Page 42: ...N MAINTENANCE PISTON MAINTENANCE PISTON MAINTENANCE Piston disassembly Piston disassembly Pull the valve support up and slide back to separate it from the valve click for next step DOSATRON INTERNATIO...

Page 43: ...ton disassembly PISTON MAINTENANCE PISTON MAINTENANCE Pull the actuator assembly from under the piston shell On the top of the piston shell unscrew the 4 retaining screws click for next step DOSATRON...

Page 44: ...uator assembly Piston disassembly actuator assembly PISTON MAINTENANCE PISTON MAINTENANCE y y y y Remove the 2 springs When changing a broken spring it is best to replace both springs both springs cli...

Page 45: ...actuator assembly PISTON MAINTENANCE PISTON MAINTENANCE y y y y Remove the plunger rod by sliding it straight up Unscrew the plunger from the plunger rod Do not lose the metal Remove the plunger seal...

Page 46: ...actuator assembly Piston disassembly actuator assembly PISTON MAINTENANCE PISTON MAINTENANCE y y y y Remove the push rod by sliding it straight down This separates the actuator assembly entirely click...

Page 47: ...sembly actuator assembly Piston disassembly actuator assembly PISTON MAINTENANCE PISTON MAINTENANCE Carefully remove the inlet valve O ring k t t d th l make sure not to damage the valve click for nex...

Page 48: ...PISTON MAINTENANCE Piston reassembly Piston reassembly PISTON MAINTENANCE PISTON MAINTENANCE Replace the inlet valve O ring Replace the inlet valve O ring click for next step DOSATRON INTERNATIONAL I...

Page 49: ...he 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 d t b li d Insert the push rod with the long end up rod must...

Page 50: ...TON MAINTENANCE PISTON MAINTENANCE Piston reassembly Piston reassembly PISTON MAINTENANCE PISTON MAINTENANCE Install the 2 actuator springs click for next step DOSATRON INTERNATIONAL INC 800 523 8499...

Page 51: ...ton reassembly Piston reassembly PISTON MAINTENANCE PISTON MAINTENANCE Insert the plunger rod into the Align the rod pin with the hole on the actuator click for next step DOSATRON INTERNATIONAL INC 80...

Page 52: ...INTENANCE Piston reassembly Piston reassembly PISTON MAINTENANCE PISTON MAINTENANCE y y Replace the plunger seal Make sure the metal washer is on top of the plunger click for next step DOSATRON INTERN...

Page 53: ...NCE PISTON MAINTENANCE Reassembly of piston Reassembly of piston PISTON MAINTENANCE PISTON MAINTENANCE y p y p Screw the plunger back on the plunger rod click for next step DOSATRON INTERNATIONAL INC...

Page 54: ...ace if necessary Align the o ring in the groove on the bottom of the piston shell Inspect the exterior piston shell flanges They should not be worn or scored If they are scored the click for next step...

Page 55: ...ton reassembly PISTON MAINTENANCE PISTON MAINTENANCE Align the push rod and valve with the valve with the corresponding holes in the piston shell Position the actuator assembly in the piston shell cli...

Page 56: ...ly Piston reassembly PISTON MAINTENANCE PISTON MAINTENANCE Push the actuator assembly into the piston shell and align the screw with the holes Install the 4 screws Use 2 Phillips screwdriver click for...

Page 57: ...on reassembly Piston reassembly Align the top inlet valve with the center groove of the valve support and push forward until the outlet and push forward until the outlet valves reach their openings in...

Page 58: ...PISTON MAINTENANCE PISTON MAINTENANCE PISTON MAINTENANCE Piston reassembly Piston reassembly Position the valve support retainer d i t ll and install screw click for next step DOSATRON INTERNATIONAL I...

Page 59: ...n reassembly Piston reassembly PISTON MAINTENANCE PISTON MAINTENANCE Piston reassembly Piston reassembly The piston is ready to be reinstalled The piston is ready to be reinstalled click for next step...

Page 60: ...push the piston all the way down it may li k ll th i t ll th H ldi it i iti h d click pull the piston all the way up Holding it in up position push down on the vertical rod and it should click Push th...

Page 61: ...CHAPTER 5 CHAPTER 5 AIR BLEED MAINTENANCE AIR BLEED MAINTENANCE D25RE5 1 to 5 1 100 1 20 1 100 to 1 20 click for next slide Return to Main Menu DOSATRON INTERNATIONAL INC 800 523 8499 61...

Page 62: ...ENANCE Air bleed Air bleed disassembly disassembly Using a small flat blade screwdriver gently pry loose the rubber cap and remove it from the top of the air bleed button click for next step DOSATRON...

Page 63: ...ENANCE AIR BLEED MAINTENANCE Air bleed Air bleed disassembly disassembly Remove the ribbed collar by pulling it straight up Using a small flat blade screwdriver gently pry loose the ribbed collar clic...

Page 64: ...eed Air bleed disassembly disassembly Align the two tabs on the air bleed with the corresponding grooves in the lid Align a 7 8 socket with the plastic nut on the underside of the lid and gently twist...

Page 65: ...BLEED MAINTENANCE AIR BLEED MAINTENANCE AIR BLEED MAINTENANCE Air bleed Air bleed disassembly disassembly Remove the air bleed button by pushing it through the lid click for next step DOSATRON INTERNA...

Page 66: ...TENANCE Air bleed reassembly Air bleed reassembly AIR BLEED MAINTENANCE AIR BLEED MAINTENANCE Replace the O ring p g The only serviceable part on the air bleed is the O ring click for next step DOSATR...

Page 67: ...ED MAINTENANCE Air bleed reassembly Air bleed reassembly Install the air bleed button from the inside of the cover Turn the socket turn to lock the button in the lid Position the air bleed button in t...

Page 68: ...CE AIR BLEED MAINTENANCE AIR BLEED MAINTENANCE Air bleed reassembly Air bleed reassembly Install the ribbed collar so that the slots align with the tabs on g the air bleed button click for next step D...

Page 69: ...NANCE AIR BLEED MAINTENANCE Air bleed reassembly Air bleed reassembly Re install the rubber cap on the air bleed button Using a small flat blade screwdriver gently put back in place the rubber cap cli...

Page 70: ...CHAPTER 6 CHAPTER 6 BY BY PASS MAINTENANCE PASS MAINTENANCE D25RE5 1 to 5 1 100 1 20 1 100 to 1 20 click for next slide Return to Main Menu DOSATRON INTERNATIONAL INC 800 523 8499 70...

Page 71: ...ENANCE By By pass disassembling pass disassembling BY BY PASS MAINTENANCE PASS MAINTENANCE Use needle nose pliers or awl to push pin out Set the by pass button to ON click for next step DOSATRON INTER...

Page 72: ...AINTENANCE By By pass disassembling pass disassembling Remove the ON OFF knob by firmly snapping it out of the collar Remove the pin from the ON OFF knob and the stainless steel stem of the by pass cl...

Page 73: ...TENANCE PASS MAINTENANCE By By pass disassembling pass disassembling Using a small flat blade screwdriver gently pry loose the ribbed collar Remove the ribbed collar by lifting it straight up click fo...

Page 74: ...sassembling pass disassembling Align a 7 8 socket with the plastic nut th d id f th lid d tl on the underside of the lid and gently twist the by pass turn Align the two tabs on the by pass with the co...

Page 75: ...PASS MAINTENANCE PASS MAINTENANCE By By pass disassembling pass disassembling Remove the by pass by pushing it through the lid The O ring is the only serviceable part on the by pass click for next st...

Page 76: ...eassembling BY BY PASS MAINTENANCE PASS MAINTENANCE Install the by pass from the inside of the lid With the socket turn the by pass turn to lock it in the lid Slide the stainless steel stem into the b...

Page 77: ...INTENANCE PASS MAINTENANCE By By pass reassembling pass reassembling Install the ribbed collar so that the slots Install the ribbed collar so that the slots align with the tabs on the bypass click for...

Page 78: ...AINTENANCE PASS MAINTENANCE By By pass reassembling pass reassembling Lightly tap on the top of the knob with a mallet to snap it in place Carefully position by pass knob in the collar click for next...

Page 79: ...y pass reassembling pass reassembling Install the pin When completed the pin should not protrude on either side of the lever With the lever in the ON position align the holes of the lever and stainles...

Page 80: ...CHAPTER 7 CHAPTER 7 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE D25RE5 1 to 5 1 100 1 20 1 100 to 1 20 click for next slide Return to Main Menu DOSATRON INTERNATIONAL INC 800 523 8499 80...

Page 81: ...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 60 for instructions screw lid back on Water hammer Reset piston see page...

Page 82: ...t 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 solution container Check valve...

Page 83: ...racks 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...

Page 84: ...ing Leaks between adjusting nut and the anti lock ring Injection stem O ring damaged improperly Clean and replace injection stem O ring the anti lock ring damaged improperly positioned or missing Leak...

Page 85: ...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 click for next step DOSATRON INTERN...

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