Horizon Reverse Osmosis Seafari Versatile Series, Owner'S Manual

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Seafari Versatile 450 - 1800
Page 9-7
9
1) Remove the manifold bolts and
locking washers
2) To separate the manifold from the
crankcase, grasp the manifold with both
hands and pull straight off.
3) Normally the seal assemblies remain
in the manifold, however part of the
assembly may remain on the plunger.
CAREFULLY side off these pieces.
To remove the seals insert a slide
hammer/extraction collet into the seal.
Tighten and pull up on the slide hammer
weight. The seal assembly should come
completely out.
4) Thoroughly clean the seal cavity.
5) Inspect the seal cavity for signs of damage.
c.
Packing Installation:
Tools required: Seal Insertion Tool
1) Ensure that the seal cavities are clean and
dry. Do not use lubricant.
2) Place a seal insertion tool in the seal
cavity, and place one high-pressure seal
squarely into the tool. The high-pressure
seal consists of two pieces, the inner seal
and the outer retainer. These parts are
fragile so handle them with care.
Place the seal push tool on top of the seal and
push the seal assembly into place. Repeat the
process for the remaining cylinders.
3) Install the O-Ring in the outside groove
on the low-pressure seal retainer. Next,
install the low-pressure seal into the
retainer with the closed portion of the
seal being placed into the retainer, and
push into place. Install the entire housing
into the seal cavity with the seal opening
in first.
4) Finally, install the seal retainer with the
smooth side against the low-pressure seal
retainer. The manifold is now fitted with
new seals.
d.
Plunger Inspection and removal
:
Tools required: 3/8” Ratchet Driver; 13mm
Socket; O-Ring Pick.
1) Inspect the plunger for any sign of
damage (Surface scuffing/ scoring,
cracks, or pitting). The surface must be
absolutely smooth.
2) Remove the plunger retaining nut
and stainless steel washer (Note: This
is the only area in the pump where a
thread locker is used.) The washer may
be stuck to the plunger. Use the O-Ring
pick to clean off the thread locker and
free the washer.
3) To remove the plunger, twist in either
direction and pull straight off. DO NOT
USE any type of pliers or metal tools on
the plunger as they are ceramic and are
brittle. Inspect the plunger again for any
sign of damage also look into the bore
of the plunger for any sign of rust. Rust
here indicates that the plunger retainer
O-Rings have failed, allowing water to
leak between the manifold and crankcase
and allowing for water to enter the
crankcase section. Check the Crankcase
Section for signs of water intrusion.
4) Remove the plunger O-Ring and anti-
extrusion ring (Note: The anti-extrusion
ring is cut at an angle) with the O-Ring
pick. Once these are off, remove the
slinger using needle nose pliers.
NOTE
: Discard the slingers, DO NOT reuse
them. They lose their original dimensions
after use.
e.
Plunger Installation:
Tools required: 3/8" drive Ratchet; 13mm
socket; Torque Wrench; Medium Strength
Thread Lock
1) Clean the old thread lock off the plunger
rods. Do not use assembly lubricant.
2) Push the new slingers into place at the
bottom of the plunger rods.
3) Carefully slide the new O-Ring into the
groove on the plunger rods
4) Slide the anti-extrusion ring into the
groove behind the O-Rings
5) Push the plungers onto the rods with
a twisting motion until they are seated
completely on the rods.
6) Place a new washer on the rod and apply
a small amount of Loctite Medium thread