dosatron D40MZ2 Instructions Manual Download Page 1 | Manualshive

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Rebuild Kit

D40MZ2

Extend the Life of Your Dosatron

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Summary of Contents for D40MZ2

Page 1: ...Rebuild Kit D40MZ2 Extend the Life of Your Dosatron ...

Page 2: ...DI1092 Lower Flange Remember to wear proper protection when performing maintenance such as gloves eyewear and apron This kit is for the Dosatron D40MZ2 and consists of two parts Part MKD40MZ2AF MKD40MZ2K MKD40MZ2VF Part 1 Piston Kit Part 2 Seal Kit Part 2 Seal Kit Contents PJDI118 Check Valve JDI100 Injection Sleeve O ring JDI122 Injection Stem O ring JDI121 Plunger Seal ...

Page 3: ...sing you may use a universal strap wrench Pull the piston out of the body and set the bell housing and body aside Remove the plunger from the piston by rotating it a quarter of a turn counterclockwise Dislodge the 4 black upper valves by pushing out on the top tab of each valve 1 2 3 1 D40MZ2 ...

Page 4: ...ack piston shell It will probably come out in either two or three pieces The first is the valve guide and the others are the push rod Omega Spring and Connecting Rod Remove the Piston Maintenance Kit PPDI065 items from the bag and set aside 4 5 6 2 VALVE GUIDE PUSH ROD OMEGA SPRING CONNECTING ROD PUSH ROD ...

Page 5: ...d Slide the NEW Push Rod Seal PDI1085 onto the push rod with the tapered end on the push rod When in position rotate the Push Rod Seal a quarter turn clockwise to lock into place Next pick up the beige Omega Spring PDI1216 and black Connecting Rod PDI1086 from the new kit Slide one end of the Omega Spring into the channel on the Connecting Rod parts in the kit may already be connected 9 8 7 3 ...

Page 6: ...ngs into the push rod as shown Set the parts aside and pick up the piston assembly TO CHANGE THE PISTON FLANGES UPPER FLANGE On the Upper Flange locate the white tooth on the inside of the lock ring Press down on the lock lever directly next to the tooth 10 11 12 4 ...

Page 7: ... tooth slides above the black lever Slide the white lock ring and Upper Flange up and off the black piston shell Pick up the NEW Upper Flange PDI1093 and slide it onto the piston shell with the V shape opening facing downward and flat edge facing up Push down until it sits on the ledge of the black piston shell 14 13 15 5 ...

Page 8: ...align with the gaps around the edge of the piston Shell and the white tooth and black lock lever should be close together Push down on the lock ring so that the flat edge touches the top of the white Flange Then rotate the lock ring of an inch turn clockwise to lock it into place LOWER FLANGE Hold the piston upside down On the Lower Flange locate the white tooth on the inside of the lock ring 16 1...

Page 9: ...n on the lock lever directly next to the tooth Rotate the lock ring about of an inch clockwise to unlock making sure the white tooth slides on top of the lever Slide the lock ring and Lower Flange up and off the black piston shell 20 19 21 7 ...

Page 10: ...with the flat edge facing down towards the Piston and place the lock ring on top of the NEW Lower Flange The tabs on the inside of the lock ring should align with the gaps around the edge of the piston shell and the white tooth and black lock lever should be close together Push down on the lock ring so that the flat edge touches the top of the white Flange Then rotate the lock ring 1 2 of an inch ...

Page 11: ...8 holes the same size 4 for the Lower valves center holes and 4 for the upper valves top holes There is also a single smaller hole for the push rod assembly Insert the push rod assembly inside the smaller hole with the top curved portion facing outward following the curve of the piston 25 26 27 9 ...

Page 12: ... the lower valves align with the 4 center openings NOTE You may have to lift the push rod assembly and reposition both assemblies inside the piston shell simultaneously Make sure the Connecting Rod drops into the notches inside the piston shell again 28 10 Carefully begin pressing the mechanism both assemblies into place inside the piston shell and double check the alignment of both sections 30 29...

Page 13: ...s into the valve guide Now test the piston assembly by carefully pulling the push rod up until you hear a click then snap the last 3 Valves back on Insert the plunger back into the piston and rotate it a quarter of a turn clockwise to lock it into place 31 33 32 ...

Page 14: ...injector and screw the bell housing back on You have completed the steps to replace the Piston Flange Kit on your D40 Dosatron injector Continue with Part 2 Seal Kit instructions 34 12 If you have any questions call 1 800 523 8499 or to CHAT visit www dosatronusa com 35 ...

Page 15: ...4 Part 2 Seal Kit Instructions Unscrew the suction hose nut and remove the suction hose Unscrew the injection stem nut slide it down and set aside Pull the injection stem straight down from the body of the injector 1 2 3 D40MZ2 13 ...

Page 16: ...CHAT at www dosatronusa com Unscrew and remove the check valve nut Grab the barb and pull the check valve assembly straight out and discard Unscrew and remove the lock nut 4 5 6 14 ...

Page 17: ...9 1 727 443 5404 Remove the C clamp by spreading the opening and sliding it down over the threads Unscrew and remove the adjusting nut Push the white injection stem up and out of the black injection sleeve 9 8 7 15 ...

Page 18: ...e Injection Sleeve O Ring Part JDI100 Remove and replace the Injection Stem O Ring Part JDI122 Align the groove in the white stem with the tooth inside the lower portion of the black injection sleeve Slide the stem down as far as possible 10 11 12 16 ...

Page 19: ...9 1 727 443 5404 Thread the adjusting nut back onto the black injection sleeve Replace the C clamp by sliding it over the threads Rotate until it clicks into place Thread on the lock nut and hand tighten 14 13 15 17 ...

Page 20: ...sembly Part PJDI118 into the stem Reinstall the check valve nut Set the stem aside and pick up the blue body Remove the Plunger Seal by pinching and rolling it off the plunger Install the new Plunger Seal Part JDI121 into the groove on the plunger 16 17 18 18 ...

Page 21: ...ody with the teeth on the top of the injection stem assembly Reinstall the nut hand tight If the scale you prefer is not facing out just loosen the stem nut and remove Pull the stem down slightly rotate 180 degrees and push it back up then reinstall the nut hand tight 20 19 21 19 ...

Page 22: ...all If the suction hose is cracked rigid or looks really old just replace it Thread the suction hose nut onto the hose Slide the hose onto the barb Reattach the hose nut NOTE Make sure to set your Dosatron unit to the desired setting 22 23 20 If you have any questions call 1 800 523 8499 or to CHAT visit www dosatronusa com ...

Page 23: ...1 800 523 8499 1 727 443 5404 ...

Page 24: ...2090 Sunnydale Blvd Clearwater FL 33765 1 800 523 8499 www dosatronusa com ...

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