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Katadyn REPAIR SEAL KIT PowerSurvivor 80E Manual

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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. Remove the tube fitting, reject check valve retainer, valve spring and poppet valve from their
bore in the outside surface of the check valve plate. To remove the 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 unlikely that the two parts will
separate easily. Insert the wide end of the piston seal installation tool into the pump body cylinder
from the check valve side of the pump body 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 80E watermaker.
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