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5. Disassemble the two check valve assemblies. Use the needlenose pliers to lift the intake valve
retainer, valve spring and poppet valve out of their bore in the inside surface of the check valve
plate. Finish removing the outlet adaptor (leave the tube fitting screwed into it), reject check valve
retainer, valve spring and poppet valve from their bore in the outside surface of the check valve
plate. To remove the intake and reject check valve seats, use an allen wrench (or similar flat-
ended tool) to push each valve seat out of its bore, working from the opposite side of the bore
from which the rest of the valve assembly was removed. See Figure R-3.
6. Separate the pump back plate from the pump body by first using the 1/4" allen wrench to re-
move the four sockethead flange bolts that hold them together. It is possible that the two parts will
not separate easily. If that is the case, insert the wide end of the piston seal installation tool into
the check valve side of the pump body cylinder until it contacts the exposed end of the piston. Use
a soft mallet to tap the small end of the installation tool and drive the piston and pump back plate
away from the pump body. When the back plate has separated from the pump body, pull the
piston out of the back body and remove the two old o-rings (8012830) and (8012444). Be
careful not to lose the large
relief valve spring that is
exposed when the pump parts
separate.
7. Remove the old PIP ring and
cup seal from the piston. One
method to accomplish this is to
wedge a small screwdriver
underneath the cup seal and
pry it up far enough that it can
be cut with a pair of small
scissors or a razor blade.
Repeat the process for the PIP
ring.
8. Remove the wiper block from the pump back plate, and use a pair of needle-nose pliers to pull the
old wiper block seal out of the wiper block. Remove the spacer washer, if present. Working from
the side of the back plate that faces the pump body, use a flat-ended tool or a small socket on an
extension to press out the two backup washers, two piston shaft seals and shaft bushing from the
back plate. Refer to Figure R-4. This completes the disassembly of all user-serviceable parts of the
Katadyn PowerSurvivor 160E watermaker.
3


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