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Summary of Contents for dosatron D40MZ3000
- Page 1 Extend the Life of Your Dosatron Rebuild Kit D40MZ3000...
- Page 2 Dosatron D40MZ3000 Rebuild Kit Part #: MKD40MZ3000AF • MKD40MZ3000K • MKD40MZ3000VF This kit is for the Dosatron D40MZ3000 and consists of two parts: • Part 1 - Piston Kit • Part 2 - Seal Kit Part 1 - Piston Kit Contents:...
- Page 3 D40MZ3000 Part 1 - Piston Kit Instructions Unscrew and remove the bell housing, you may 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...
- Page 4 PUSH ROD Raise the push rod carefully and pull the piston's mechanism up and out of black piston shell. It will probably come out in PUSH ROD VALVE GUIDE either two or three pieces. The first is the valve guide and the others are the push rod, Omega Spring and Connecting Rod.
- Page 5 CHANGING THE PUSH ROD SEAL, OMEGA SPRING AND CONNECTING ROD: Locate the Push Rod Seal and twist it a quarter turn counterclockwise and slide down and off the push rod. Slide the NEW Push Rod Seal (PDI1085) onto the push rod with the tapered end on the push rod.
- Page 6 Snap the other end of the Omega Springs 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.
- Page 7 Rotate the white lock ring about ¾ of an inch counterclockwise to unlock, making sure the white 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...
- Page 8 Hold the white lock ring with the flat edge facing down towards the piston, and place the lock ring on top of the NEW Upper Flange. The tabs on the inside of the lock ring should align with the gaps around the edge of the piston shell;...
- Page 9 Press down on the lock lever directly next to the tooth. Rotate the lock ring about ½ 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.
- Page 10 Pick up the NEW Lower Flange (PDI1092) 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 edge of the black piston shell. Hold the white lock ring with the flat edge facing down towards the piston, and place the lock ring on top of the NEW Lower Flange.
- Page 11 TO ASSEMBLE THE INSIDE OF THE PISTON Inside the piston shell are 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...
- Page 12 Make sure the Connecting Rod drops into the notches inside the piston shell. Align the valve rack next to the push rod assembly making sure PUSH ROD the guide aligns with the black ASSEMBLY VALVE GUIDE posts on the piston shell, and the lower valves align with the 4 center openings.
- Page 13 Snap one of the upper valves 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 with the use of the 8mm wrench, rotate it a quarter of a turn clockwise to...
- Page 14 Insert the piston back into the Dosatron 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. If you have any questions, call 1-800-523-8499 or to CHAT visit www.dosatronusa.com.
- Page 15 Part 2 - Seal Kit Instructions 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 straight down from the body of the injector.
- Page 16 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 remove the lock nut. CHAT at www.dosatronusa.com...
- Page 17 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 injection sleeve. 1-800-523-8499 • 1-727-443-5404...
- Page 18 Remove and replace the Injection Sleeve O-Ring (Part #: JDI100). Unscrew the upper insert from UPPER the top of the injection stem, then INSERT flip the injection stem upside down so the Upper Insert O-ring UPPER comes off. INSERT O-RING Discard and replace with the NEW Upper Insert O-Ring (Part #: 20J006)
- Page 19 Screw the upper insert 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 adjusting nut back onto the injection sleeve.
- Page 20 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 stem. CHAT at www.dosatronusa.com...
- Page 21 Reinstall the check valve nut. Set the stem aside and pick up the blue body. Remove and replace the Plunger Seal (Part #: JDI200), by pinching it and rolling out of the plunger or using a small flat blade screwdriver. Be careful not to damage the tip of the plunger.
- Page 22 Reinstall the injection stem 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.
- Page 23 Thread the suction hose nut and ferrule onto the hose. 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.
- Page 24 2090 Sunnydale Blvd. • Clearwater, FL 33765 1-800-523-8499 • www.dosatronusa.com...
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