Katadyn PowerSurvivor 80E, Owner'S Manual

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5. Disassemble the two check valve assemblies. Use the needle nose 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 socket head 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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