Owner’s Manual
HK3819 / HK5523
Page 11
Fig # 4
Fig # 6
Fig # 5
6. Using the 5/8” socket end of the Uni-Tool, remove the entire fluid section assembly as shown in Fig # 4 and #
5 by turning it counter clockwise until it is fully removed from connecting rod and manifold.
The entire fluid section is now removed, awaiting further repairs or service. Refer to the various service repairs on
the pages to follow. See page below for intake valve repairs, pages 10-11 for piston rod, cylinder, packing kit
assembly repairs, page 11-12 for whole piston rod, cylinder, packing kit assembly replacement and unit
re-assembly.
REPAIR PROCEDURES
DIS-ASSEMBLY
Using the flat hex sides, place Inlet Fitting (Ref # 27) in a vise or hold securely with
adjustable wrench. Use the Uni-Tool or a 3/8 allen key to remove the intake housing
(Ref # 34) from the inlet fitting. Inspect all part for wear or damage.
RE-ASSEMBLY
1.
Install intake crush washer (Ref # 33) into the intake housing (Ref # 34).
2.
Insert Intake Seat (Ref # 32) into the intake housing, ensuring The beveled
side of seat faces upwards.
3.
Place the intake ball (Ref # 31) on to the intake seat. (Ref # 32)
4.
Install the ball stop (Ref # 30) into the ball guide (Ref # 29), and place entire
assembly into the intake housing (Ref # 34).
5.
Apply Teflon pipe sealant or Teflon tape to the threads of the intake housing.
(Ref # 34).
6.
Drop inlet washer (Ref # 28) into the intake fitting (Ref # 27).
7. Screw the intake housing assembly into the intake fitting. Tighten to 100 foot
pounds. Slide the O-ring (Ref # 26) onto the intake fitting.
If the removal and repair of the intake valve is the only service preformed, continue by
threading the intake valve assembly into the intake manifold (Ref # 39). Secure to 30
foot pounds. If piston valve repairs are to be performed, complete these before
performing.
INTAKE VALVE ASSEMBLY REPAIRS
Simple cleaning and debris removal can be undertaken without dismantling the entire intake valve
assembly. For component replacement, see disassembly and re-assembly instruction to follow