dosatron D40MZ3000 User manual

Rebuild Kit
D40MZ3000
Extend the Life of Your Dosatron

CHAT at www.dosatronusa.com
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

1-800-523-8499 • 1-727-443-5404
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.
1
2
3
1
D40MZ3000

CHAT at www.dosatronusa.com
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.
4
5
6
2
VALVE GUIDEPUSH ROD
OMEGA
SPRING &
CONNECTING ROD
PUSH ROD

1-800-523-8499 • 1-727-443-5404
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).
9
8
7
3

CHAT at www.dosatronusa.com
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.
10
11
12
4

1-800-523-8499 • 1-727-443-5404
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.
14
13
15
5

CHAT at www.dosatronusa.com
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.
16
17
18
6

1-800-523-8499 • 1-727-443-5404
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.
20
19
21
7

CHAT at www.dosatronusa.com
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.
22
23
24
8