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Rebuild Kit

D40MZ3000

Extend the Life of Your Dosatron

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Summary of Contents for D40MZ3000

Page 1: ...Rebuild Kit D40MZ3000 Extend the Life of Your Dosatron...

Page 2: ...Remember to wear proper protection when performing maintenance such as gloves eyewear and apron This kit is for the Dosatron D40MZ3000 and consists of two parts Part MKD40MZ3000AF MKD40MZ3000K MKD40M...

Page 3: ...use a universal strap wrench Pull the piston out of the body and set the bell housing and body aside Using an 8mm wrench remove the plunger from the piston by rotating it a quarter of a turn counterc...

Page 4: ...ck 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 P...

Page 5: ...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...

Page 6: ...gs 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 Pr...

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...

Page 8: ...lign 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 F...

Page 9: ...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 a...

Page 10: ...ith 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...

Page 11: ...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 smal...

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 dro...

Page 13: ...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 with the use of the 8mm w...

Page 14: ...njector 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...

Page 15: ...ons Unscrew the suction hose nut and remove the suction hose and ferrule from the bottom of the Dosatron unit Unscrew the injection stem nut slide it down and set aside Pull the injection stem straigh...

Page 16: ...om Unscrew and remove the check valve nut Grasp the white threaded barb and pull the Check Valve assembly straight out It might come out in two pieces Discard the old Check Valve parts Unscrew and rem...

Page 17: ...443 5404 Remove the C clamp by spreading the opening and sliding it down over the threads Unscrew and remove the adjusting nut Set aside Push the white injection stem up and out of the graduated injec...

Page 18: ...p of the injection stem then flip the injection stem upside down so the Upper Insert O ring comes off Discard and replace with the NEW Upper Insert O Ring Part 20J006 Before placing the insert back in...

Page 19: ...ert back into the top of the injection stem Align the groove in the white stem with the tooth inside the lower portion of the injection sleeve Slide the stem down as far as possible Thread the adjusti...

Page 20: ...satronusa com Replace the C clamp by sliding it over the threads Rotate until it clicks into place Thread on the lock nut and hand tighten Install the new Check Valve Assembly Part PJDI215 into the st...

Page 21: ...inching it and rolling out of the plunger or using a small flat blade screwdriver Be careful not to damage the tip of the plunger Carefully insert the plunger inside the top of the stem in a vertical...

Page 22: ...t 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 Before installing the suction hose inspect it If it flares out cut...

Page 23: ...onto the hose 25 Slide the hose and ferrule onto the barb at the bottom of the Dosatron unit then tighten the hose nut NOTE Make sure to set your Dosatron unit to the desired setting 26 If you have a...

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

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