dosatron D40MZ3000 User manual

Rebuild Kit
D40MZ3000
Extend the Life of Your Dosatron

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Dosatron D40MZ3000 Rebuild Kit
Part 1 - Piston Kit Contents:
PDI1216 - Omega Spring
PDI1086 - Connecting Rod
PDI1085 - Push Rod Seal
PDI1093 - Upper Flange
PDI1092 - Lower Flange
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
• MKD40MZ3000VF
• Part 1 - Piston Kit • Part 2 - Seal Kit
Part 2 - Seal Kit Contents:
PJDI215 - Check Valve
JDI100 - Injection Sleeve O-ring
JDI120 - Injection Stem O-ring
JDI200 - Plunger Seal
20J006 - Upper Insert O-ring

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Part 1 - Piston Kit Instrucons
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
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.
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D40MZ3000

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Raise the push rod carefully and
pull the piston's mechanism up
and out of black piston shell.
It will probably come out in
either two or three pieces. The
rst 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.
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2
VALVE GUIDEPUSH ROD
OMEGA
SPRING &
CONNECTING ROD
PUSH ROD

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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 o󰀨 the push rod.
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).
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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.
Press down on the lock lever
directly next to the tooth.
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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 o󰀨 the
black piston shell.
Pick up the NEW Upper Flange
(PDI1093) and slide it onto the
piston shell with the Vshape
opening facing downward, and
at edge facing up. Push down
until it sits on the ledge of the
black piston shell.
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Hold the white lock ring with the
at 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; and the white tooth
and black lock lever should be
close together.
Push down on the lock ring so
that the at edge touches the top
of the white Flange.
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.
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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 o󰀨 the black
piston shell.
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Pick up the NEW Lower Flange
(PDI1092) and slide it onto the
piston shell, with the Vshape
opening facing downward and
at edge facing up. Push down
until it sits on the edge of the
black piston shell.
Hold the white lock ring with the
at 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 at 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.
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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
outward (following the curve
of the piston).
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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
the guide aligns with the black
posts on the piston shell, and 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.
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Carefully begin pressing the
mechanism (both assemblies)
into place inside the piston shell
and double check the alignment
of both sections.
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VALVE GUIDE
PUSH ROD
ASSEMBLY

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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
lock it into place.
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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.
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If you have any questions, call 1-800-523-8499 or
to CHAT visit www.dosatronusa.com.
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Part 2 - Seal Kit Instruc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
straight down from the body
of the injector.
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D40MZ3000
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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.
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Remove the Cclamp 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.
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Remove and replace the
Injection Sleeve O-Ring
(Part #: JDI100).
Unscrew the upper insert from
the top of the injection stem, then
ip the injection stem upside
down so the Upper Insert O-ring
comes o󰀨.
Discard and replace with the
NEW Upper Insert O-Ring
(Part #: 20J006).
Before placing the insert back
into the injection stem, remove
and replace the Injection Stem
O-Ring (Part #: JDI120).
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UPPER
INSERT
UPPER
INSERT
O-RING

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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.
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Replace the Cclamp 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.
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