Servicing a Katadyn PUR40E

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1 Servicing a Katadyn PUR40E ABOUT THE ASSOCIATION OF OCEAN ROWERS The Association of Ocean Rowers is open to anyone interested in the sport of Ocean Rowing. It is strictly independent of all other bodies and companies in Ocean Rowing and is completely free to join. We will never ask you for any money, for anything, ever. The aim of the Association is set out in the club s constitution (available in full here) as follows: The primary objective of The Club shall be to promote the sport of Ocean Rowing by offering assistance and advice to those who choose to participate in the sport. The secondary objective of The Club shall be to maintain an enjoyable social network of Ocean Rowers and any interested parties. We would urge any persons interested in Ocean Rowing to join the site and contribute to the user generated (wiki) information base. Our intention is to build up a body of information which will always be free to view and which will act as a how to guide for new Ocean Rowers. COPYRIGHT NOTICE Any material whose copyright subsides with The Association of Ocean Rowers may be reproduced in whole or in part by anyone furthering the aims and the spirit of the Association. We would be grateful for the following caption being added, if you wish to do so: Reproduced by kind permission of The Association of Ocean Rowers.

2 Before you Begin Ladies and Gentlemen know thy watermaker. You re going to need it for making water. There have been a number of people who have failed to row an ocean simply because they did not know how to fix their watermaker when at sea. The following pages contain photos of a PUR40E being taken apart. They are intended to act as an aid to performing the servicing instructions provided by Katadyn, but show only the steps the author believes you are likely to need to perform at sea. NOTES: Always take a seal kit with you on your voyage. They are inexpensive and may save your life. Work out all the tools you ll need to completely strip a PUR40E (a ½ inch spanner, a 6mm and 4mm hex key and a screwdriver) and put them together with the seal kit and the manual operation handle. Cable tie the lot together and put them somewhere sensible. You will need to grease each o-ring as you put the system back together. Use only grease supplied by Katadyn as petroleum grease will ruin the membrane. The PUR40E is a simple machine and can be serviced underway. Before you leave port, it is highly advisable to have disassembled it and to understand the contents of the service manual. Use these photos as an additional guide READ THE PROPER MANUAL FIRST

3 Step 1 Run the motor and stop it when the piston is at its mid stroke. You ll see a black rubber boot in the middle of the inspection window as above. This motor is about ¼ of a horse power and will easily sever your fingers without even slowing down so keep all appendages clear of this area. I would suggest removing the fuse at this stage to prevent any possible appendagendectomy by accidental operation of the motor. Use a screwdriver to gently move the boot and expose the link pin.

4 Then push the pin out from one side using your screwdriver and remove the pin which connects the motor to the pump assembly. Keep everything you remove in a secure tin with a top on if you lose anything at all you re stuffed. Step 2 Using a ½ inch spanner (closed one side, open the other) and a 6mm hex key, remove the two long bolts (left) and two nuts (right) which hold the motor to the filter assembly.

5 Then the motor will easily separate from the filter assembly. If you are not fitting the manual operation handle move to Step 5.

6 Step 3 Using your favorite screwdriver, rotate the pump shaft through 90 degrees.

7 Step 4 The handle simply bolts on to the two long bolts, thusly. Connect the lever to the pump shaft with the pin and split ring. You can now operate the watermaker manually. It is important that you pump the system at an even 30 strokes per minute, that is one second down, one second up. I did this for 40 out of 50 days. Enjoy. There s nothing quite like finishing a rowing shift knowing you have an hour of water pumping left to go before, yup, you guessed it folks, an hour rowing. Whoopee. Even thinking about it makes me want to die. Hopefully this fate won t befall you.

8 Step 5 You can t adjust this relief valve, but you can take it off and clean / replace the o-rings which may be leaking. Make a careful note of the correct way to refit it the relief valve fits back on either way but only works when put on as above. It s also next to impossible to fault find because it looks right either way round. An easy way to check is that the black plastic prong fits through the o-ring. Take it off, give it a good clean and put it somewhere safe.

9 Step 6 The rear piston housing easily pulls off. If the retaining bolts are not tightened properly the o-ring does not seal and water leaks out. This has happened in the above unit as can be seen by the staining. It s not a big deal, clean / replace the o-ring and sealing surfaces and put it back together. The rear piston housing contains a number of parts which may need to be changed in a full service it s unlikely you ll need to do this in an emergency service (when underway) so I won t show how it comes apart. Consult the user manual for this step.

10 Step 7 The piston now pulls out with moderate force. A bit of dirty grease is ok and quite usual.

11 Check the piston bore for pitting and wear. This should be a perfectly smooth surface. Any problems here whatsoever when you do your onshore checks MUST be replaced with new parts from Katadyn. The PUR40E uses a very high pressure pump and if the bore is pitted or scored the water will simply escape and the only use for your PUR40E will be to throw at passing ships such that you can attract their attention and ask them for some drinking water.

12 Step 8 Separating the front piston housing can be difficult. Rotate it slightly and use a screwdriver to carefully prize it from the main piston housing. Work on both sides to gradually free it.

13 When it comes apart it ll look like this. On this unit there is some pitting in the swirl pot (top right) but this is NOT where any o-ring seals contact and so isn t a problem. I believe this is fairly common so don t be alarmed if yours looks like this. When you come to put this back together, it doesn t matter where the hole in the nylon fitting (top right) ends up on the clock face.

14 Step 9 The piston bore makes a handy make-believe telescope.

15 Step 10 Removing this part is really tricky. It gets very well stuck in place and it can easily take ten minutes of gradual prying to separate it. A knife is a useful tool, but be VERY CAREFUL not to damage the really delicate fiberglass housing containing the membrane.

16 Eventually you ll get it free.

17 Sometimes the membrane will come out at this stage, other times (if you re changing the membrane) you ll need to remove the circlip from the end the fresh water comes out and push the membrane out. Be very careful with the membrane and do not touch the yellow surface. A spare membrane is really expensive; if you can afford one, however, take it.

18 Step 11 Parts Check So far, these are all the bits we ve removed (motor not shown). Step 12 notes. If you need to change the piston seal, it takes a while. The grey PVC taper fits on the piston shaft and enables you to slide the new piston rings (left) on to the piston until the slot in to the gap (right). To remove the old seals you need to cut them away so be sure you have the spares before you begin. Use a lot of grease to make this easier.

19 Only put the piston in this way round, if you try to force it the other way you may damage it because the piston seal is flared one way. Plenty of grease on the shaft. As they say in the Haynes manuals, assembly is the reverse of removal. This series of photos are intended only to add to the PUR40E manual. They are really simple bits of kit; anyone with their head on the right way round should be able to fully service the unit using the manual and the above photos.

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