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777C2
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INSTALLATION INSTRUCTIONS
REPAIR SEAL KIT
PowerSurvivor 160E
Print No.: 8012543/0 Katadyn North A merica Inc. Katadyn Products Inc.
4830 Azelia Avenue North Pfäffikerstrasse 37
Minneapolis, MN 554429 U.S.A. 8310 Kemptthal Switzerland
Tel +1 800 755 6701 Fax +1 763 746 3540 Tel +41 44 839 21 11 Fax +41 44 830 21 99
marine@katadyn.com www.katadyn.us info@katadyn.ch www.katadyn.ch
PURPOSE OF THE KIT
The Repair Seal Kit should be installed after 500 hours of operation. It should be installed regardless of
whether or not there is leakage or a reduction of fresh water. Learning to perform this procedure will
ensure optimal performance of your watermaker.
NOTE: If the unit has been operating in water with silt or higher than normal salinity, the Seals will
wear somewhat faster.
Before beginning the Repair Kit procedure, note the following precautions:
1. Keep the work area clean of dirt, hair, and other contaminants.
2. Avoid scratching Pump Components when removing or replacing O-rings.
3. Never use petroleum-based lubricants on Seals and O-rings as a substitute for Silicone
Grease.
4. When installing O-rings do not roll or twist them.
NOTE: Average time to replace all seals is 1 hour. If you are performing this maintenance for the first
time, expect 3 hours.
KIT CONTENTS (See Figs. A-3 and A-4)
TOOLS REQUIRED
Piston Seal Installation Tool supplied with kit –
Needle-nosed pliers
¼-inch Allen wrench
½-inch open-end wrench
11/16-inch open-end wrench
7/8-inch open-end wrench
½-inch deep socket and socket wrench
small flat-blade screwdriver
small scissors

Disassembly:
1. Before beginning disassembly, run the watermaker and stop it when the piston shaft is at its
farthest point of travel away from the pump (toward the drive assembly). This provides enough
room for sliding the rubber boot
back toward the pump in Step 3.
2. Use the 11/16" open-end
wrench to disconnect the two
high-pressure hoses (coming
from the membrane housing)
from the tube connectors on the
check valve plate and the valve
assembly. Loosen the hose
clamps and remove the
reinforced plastic seawater
intake and reject brine hoses.
See Figure R-1.
3. Use the 1/2" open-end wrench
to remove the four hex nuts
securing the pump back plate to
the drive assembly. Then pull the
pump away from the drive assembly to expose as much of the piston shaft as possible. Slide the
black rubber boot on the piston shaft toward the pump to expose the shaft coupling pin. Use a
small screwdriver or allen wrench to push the coupling pin out of the shaft. (Note: the coupling
pin is a loose fit and may fall out
on its own. Do not lose it.) Sepa-
rate the pump from the drive
assembly and set the drive
assembly aside in a safe place.
Slide the black rubber boot off
the piston shaft. Move the pump
to a clean work surface for
further disassembly. See Figure
R-2.
4. Use a large crescent wrench to
remove the plastic intake hose
barb from the check valve plate.
Use the same wrench to loosen
the outlet adaptor in the check
valve plate. Then use the 1/4"
allen wrench to remove the six
sockethead flange bolts that hold
the check valve plate to the
pump body. Separate the check
valve plate from the pump body and remove the large o-ring (8012532) seal between them. See
Figure R-2.

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 . This completes the disassembly of all user-serviceable parts of the Figure R-4
Katadyn watermaker. PowerSurvivor 160E
Produktspecifikationer
Varumärke: | Humminbird |
Kategori: | Inte kategoriserad |
Modell: | 777C2 |
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