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Summary of Contents for dosatron MKD40MZ1000
- Page 1 Extend the Life of Your Dosatron Rebuild Kit MKD40MZ1000...
- Page 2 Dosatron D40MZ1000 Rebuild Kit Part #: MKD40MZ1000AF • MKD40MZ1000K • MKD40MZ1000VF • Part 1 - Piston Kit • Part 2 - Seal Kit Part 1 - Piston Kit Contents: PDI1216 - Omega Spring PDI1086 - Connecting Rod PDI1085 - Push Rod Seal...
- Page 3 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. Remove the plunger from the piston by rotating it a quarter of a turn counterclockwise.
- Page 4 The first is the valve guide and the others are the push rod, Omega Spring and Connecting Rod. OMEGA SPRING & CONNECTING ROD Remove the Piston Maintenance Kit (PPDI065) items from the bag and set aside. CHAT at www.dosatron.com...
- 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 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. CHAT at www.dosatron.com...
- 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 Then, rotate the lock ring ¾ 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. CHAT at www.dosatron.com...
- 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 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 turn counterclockwise to lock it into place. CHAT at www.dosatron.com...
- 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 again. Carefully begin pressing the mechanism (both assemblies) into place inside the piston shell and double check the alignment of both sections. CHAT at www.dosatron.com...
- 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 rotate it a quarter of a turn clockwise to lock it into place.
- 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.dosatron.com.
- Page 15 Part 2: Seal Kit Instructions - PJDI236 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. 1-800-523-8499 •...
- Page 16 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. CHAT at www.dosatron.com...
- Page 17 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 injection sleeve. 1-800-523-8499 • 1-727-443-5404...
- Page 18 Remove and replace the Injection Stem O-Ring (Part #: JDI120). 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. TOOTH GROOVE CHAT at www.dosatron.com...
- Page 19 Thread the adjusting nut back onto the 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. 1-800-523-8499 • 1-727-443-5404...
- Page 20 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 #: J009) into the groove on the plunger. CHAT at www.dosatron.com...
- Page 21 Insert the plunger inside the top of the stem in a vertical motion to NOTCH avoid bending the plunger. Align the notches in the lower TOOTH part of the blue body with the teeth on the top of the injection stem assembly.
- Page 22 Slide the hose onto the barb. Reattach the hose nut. NOTE: Make sure to set your Dosatron unit to the desired setting. If you have any questions, call 1-800-523-8499 or to CHAT visit www.dosatron.com. CHAT at www.dosatron.com...
- Page 23 1-800-523-8499 • 1-727-443-5404...
- Page 24 2090 Sunnydale Blvd. • Clearwater, FL 33765 1-800-523-8499 • www.dosatron.com...
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