Hotsy HC-232439 User manual

9.800-416.0
98004160-1
MODEL # ORDER #
■HC-232439 1.107-036.0
■HC-232336 1.107-035.0
■ZG3-24334 1.107-081.0
■ZG3-23236 1.107-018.0
■HD 2.3/24 P 1.575-350.0
■ HD 2.3/23 P 1.575-351.0
■ CD-232437 1.107-152.0
■ CD-232336 1.107-153.0
SERVICE MANUAL

CONTENTS
2
Model Number ______________________________
Serial Number ______________________________
Date of Purchase ____________________________
The model and serial numbers will be found on a decal attached
to the pressure washer.You should record both serial number and
date of purchase and keep in a safe place for future reference.
9.800-416.0 • Rev. 11/17
Hose and Spray Gun Assembly............................................................... 3
Exploded View ......................................................................................... 4
Exploded View Parts List ......................................................................... 5
LP Series Pump Exploded View and Parts List ....................................6-7
Axial Pump Exploded View and Parts List ............................................... 8
Axial Pump, Housing View, Exploded View and Parts List....................... 9
VBA 35 Unloader Exploded View and Parts List ................................... 10
VBT Unloader Exploded View and Parts List......................................... 11
Troubleshooting ................................................................................12-13

9.800-416.0 • Rev. 11/17
3
PRESSURE WASHER
SERVICE MANUAL
5
5
3
1
1
2
2
6
6
11
11
4
4
10
10
9
9
3
8
8
7
7
ITEM PART NO. DESCRIPTION QTY
1 9.802-166.0 Coupler, 3/8" Female 1
(2400 PSI)
9.802-100.0 ▲ Quick Coupler O-Ring 1
(2400 PSI
8.707-182.0 ▲ Coupler, Twist Connect, 1
M22-F x 3/8" FNPT (2300 PSI)
2 8.925-137.0 Hose, 3/8" X 25' 1W 1
4000PSI SW/SO/CPL
8.925-136.0 Hose, 3/8" X 25' 1W 1
4000PSI SW/SO/M22 (-018.0)
3 8.754-769.0 MV925 Gun 4500 PSI, 1
3/8" NPT INLET (Only 050.0 )
4.775-054.0 EASY!Force Advanced 1
KNA (Only 050.0 )
4 9.112-533.0 Lance-AL Quick 1
Connect-Male 3000 psi
8.783-039.0 Wand 30" Zinc Plated, 1
Handle & Coupler
5 9.802-164.0 Coupler, 1/4" Female 1
9.802-096.0 Quick Coupler O-Ring 1
ITEM PART NO. DESCRIPTION QTY
6 8.712-333.0 Nozzle, 3.0 15° Yellow 1
(2400 PSI)
8.753-991.0 Nozzle, 3.25 15° Yellow 1
(2300 PSI)
7 8.712-398.0 Nozzle, Brass Soap 1
8 9.802-251.0 Hose, 1/4" x 1/2" Clear 6 ft.
Vinyl (2400 PSI) 6 ft.
6.388-216.0 Hose, DN5 (2300 PSI) 6 ft.
9 8.707-057.0 Strainer, 1/4" Plastic 1
(2400 PSI)
5.731-652.0 Strainer, Plastic (2300 PSI) 1
4 9.112-533.0 Lance-AL Quick 1
Connect-Male 3000 psi
8.783-039.0 Wand 30" Zinc Plated, 1
Handle & Coupler
10 6.390-126.0 Clamp, Hose (2400 PSI) 2
11 9.802-216.0 Injector, Chem., Non-Adj, 1
3-5 GPM, .083 (2400 PSI)
▲ Not Shown
HD 2.3/24 P
HOSE & SPRAY GUN ASSEMBLY
HOSE & SPRAY GUN ASSEMBLY PARTS LIST

9.800-416.0 • Rev. 11/17
SERVICE MANUAL
PRESSURE WASHER
4
“This product contains chemicals knownto the State of
California to cause cancer and birth defects or other
reproductive harm.Operation of This Equipment May
Create SparksThat Can Start Fires Around Dry Vegetation.
A Spark Arrestor May be Required. The Operator Should
Contact Local Fire Agencies for Laws or Regulations
Relating to Fire Prevention Requirements.”
WARNING
8.917-015.0
98004160-3
EXPLODED VIEW
6
22
2
8
13
4
17
10
12 20
7
23
5
10
11
3
1
16
14
10
11
15
18
(Reversed
View)
10
12
24
21
19
(Reversed
View)
25
2300 PSI Models
26
27
2
15

9.800-416.0 • Rev. 11/17
5
PRESSURE WASHER
SERVICE MANUAL
ITEM PART NO. DESCRIPTION QTY
1 9.802-316.0 Engine, Honda, GX160K1QX2, 163cc (2400 PSI) 1
9.194-015.0 Engine, Honda, GC1601QHA, 160cc (2300 PSI) 1
2 8.923-785.0 Pump, Kärcher KP2535G, (3400 RPM) 1
9.120-021.0 Pump, Kärcher Axial (2600 PSI) 1
8.923-771.0 Pump, Hotsy HP 2535G, (3400 RPM) 1
8.923-757.0 Pump, Landa LP 2535G, (3400 RPM) 1
8.920-004.0 Pump, Legacy 2.6 GPM (2600 PSI) 1
3 9.800-008.0 Label, Danger Cool Engine 1
4 9.802-873.0 Handle Assembly 1
5 9.802-063.0 Mount, Vibration, 5/16"-18 x 9/16" Stud, 30 Duro 4
6 See Page 3 For Nozzle Information
7 See Page 3 For Nozzle Information
8 9.802-064.0 Grommet, Rubber, Nozzle Holder 2
9 9.800-095.0 ▲ Tag, Pump Plug/Vented Cap (2300 PSI) 1
10 8.718-980.0 Washer, 5/16" Flat, SAE 16
11 9.802-776.0 Nut, 5/16", ESNA, NC 8
12 9.800-059.0 Label, Warning/Instructions (HD Models) 1
8.750-883.0 Label, Warning/Instructions (CB Models) 1
8.900-893.0 Label, Warning/Instructions (HC Models) 1
8.900-827.0 Label, Warning/Instructions (ZG Models) 1
13 9.802-170.0 Coupler, 3/8" Plug" Female Steel/Zinc 1
14 9.800-037.0 Label, French Warning 1
15 8.733-007.0 Socket head 5/16"-24 X 3/4" Zinc Plated 4
16 9.804-025.0 Pump Protector, 1/4" 145°(2400 PSI) 1
17 9.802-713.0 Bolt, 5/16" x 1-1/4", 145° 4
18 9.802-958.0 Key, Motor Shaft 1
19 9.802-225.0 Detergent Injector Assy 3-5 GPM 0.83 (2400 PSI) 1
20 9.800-034.0 Label, Clear Lexan, 2-1/4" x 4" 1
21 9.802-146.0 Swivel, 1/2" MP x 3/4" GHF w/Strainer (2400 PSI) 1
22 9.800-006.0 Label, "Hot/Caliente", w/Arrows 1
23 8.932-968.0 Label, Intended For Outdoor Use 1
24 9.803-899.0 Unloader, VBA35 6.6 @ 3500 PSI (HC & ZG3 Models) 1
8.754-696.0 Unloader, VBT Banjo 1/2M 3/8M, 3000PSI 1
25 9.800-049.0 Label, Manufacturers Cleaning Solution 6 ft.
26 9.802-813.0 Lock Washer (2300 PSI) 4
27 8.751-096.0 Label, Regulation 4442.6 1
▲Not Shown
EXPLODED VIEW PARTS LIST

9.800-416.0 • Rev. 11/17
SERVICE MANUAL
PRESSURE WASHER
6
LP SERIES PUMP EXPLODED VIEW
LP SERIES PUMP EXPLODED VIEW PARTS LIST
6
8
13
1
2
3
4
5
7
9
10
11
12
13
14
15
16
17
18
19 12
14
15
24
25
26
27
28
29
30
32
33
34
37
38
39
40
41
42
43
44
36
45
46
47
48
19
24
49
31
20
21
22
35
36
TORQUE
SPECS
Item # Ft.-lbs
15 65
16 55
24 8
37 10
38 10
45 10
ITEM PART NO. DESCRIPTION QTY
1 8.754-841.0 Crankcase 1
2 8.754-846.0 O-ring Ø1.78 X 72.75 1
3* See Kits Below Plunger Oil Seal 3
4* See Kits Below O-ring Ø1.78 X 26.7 3
5* See Kits Below Washer, Pressure Ring
14 mm 3
6* See Kits Below U-Seal, 14 mm 3
7* See Kits Below Pressure Ring, 14 mm 3
8* See Kits Below U-Seal, 14 mm 3
9 9.803-199.0 Washer, Copper G1/2 1
10 9.802-926.0 Plug, Brass G1/2 1
11 8.754-853.0 Manifold 1
12* 8.717-233.0 O-ring Ø1.78 X 15.6 6
13* See Kits Below Valve Assembly 6
14* 9.803-948.0 O-ring Ø1.78 X 18.77 6
15 9.803-949.0 Valve Plug 6
16 8.754-854.0 Bolt, Manifold M14 x 40 2
17 8.754-850.0 Washer, Lock 2
18 9.803-198.0 Washer, Cooper G3/8 1
ITEM PART NO. DESCRIPTION QTY
19 8.707-262.0 Plug, Brass G3/8 1
20* See Kits Below Valve Seat 6
21* See Kits Below Valve Plate 6
22* See Kits Below Valve Spring 6
23* See Kits Below Valve Cage 6
24 9.802-939.0 Screw, M6 X 16 12
25 8.717-137.0 Bearing Cover 2
26 9.803-954.0 Bearing Seal 1
27 8.754-843.0 Seal Spacer, Crankshaft 1
28 9.802-914.0 Snap Ring, 25 mm 1
29 9.803-955.0 Bearing, Ball 1
30 8.754-831.0 Shaft, 3/4" Hollow 2535G 1
8.754-834.0 Shaft, 3/4" Hollow 3035G 1
31 8.754-219.0 Oil Dipstick 1
32 8.754-840.0 Bearing Needle 1
33 8.754-826.0 Seal, Crankshaft 1
34 8.754-863.0 Flange, Engine 1
35 9.803-210.0 Washer 4
36 9.803-218.0 Washer 6mm 10
8.754-755.0 LP2535G

9.800-416.0 • Rev. 11/17
7
PRESSURE WASHER
SERVICE MANUAL
LP SERIES PUMP EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
37 8.752-824.0 Screw, M6 x 20 4
38* 8.754-855.0 Bolt, Plunger 3
39* 8.754-092.0 Spacer, Copper 3
40* 8.754-849.0 Plunger, 14 mm 3
41* 9.803-962.0 Spacer, Copper 3
42 8.754-827.0 Plunger Rod 3
43 9.803-965.0 Connecting Rod Pin 3
44 9.803-966.0 Connecting Rod 3
45 8.933-020.0 Screw, Connecting Rod 6
46 8.754-847.0 O-ring Ø2.62 X 111.62 1
47 8.754-842.0 Cover, Crankcase 1
48 9.803-906.0 O-ring Ø1.78 X 14 1
49 9.803-202.0 Sight Glass, G3/4 1
* Available in kit (See below)
REPAIR KIT
NUMBER 8.754-860.0 8.754-861.0 8.754-862.0 8.754-859.0 9.803-937.0
KIT DE-
SCRIPTION
Plunger Seals
14mm Seal Packing 14mm Plunger 14mm Complete Valve
Plunger Oil
Seals
ITEM NUM-
BERS
INCLUDED
4, 6, 8 4, 5, 6, 7, 8 38, 39, 40, 41 12, 13, 14 3
LP SERIES PUMP REPAIR KITS

9.800-416.0 • Rev. 11/17
SERVICE MANUAL
PRESSURE WASHER
8
AXIAL PUMP EXPLODED VIEW AND PARTS LIST
9.120-021.0
8.920-004.0
*
ITEM PART NO. DESCRIPTION QTY
1 9.135-015.0 Cylinder Head 1
8.762-010.0 Cylinder Head, Legacy 1
2 9.175-004.0 Valve Assy Horizontal 3
3 2.884-916.0 Spare Part List, Set 3 1
4 5.443-448.0 Nipple Chemestry 1
5 6.362-451.0 O-Ring Seal 8.0 x 1.0 1
6 6-362-634.0 O-Ring Seal, 5.28 x 1.78 1
7 7.401-908.0 Sphere 7 G300 - 1.4301 1
DIN 5401 PC
8 5.110-714.0 Sleeve 1
9 5.332-258.0 Helical Spring 1
10 9.139-372.0 Spare Part List Nozzle 1
INS 020/021 Pump
11 9.184-018.0 Outlet-Thermal Valve 1
12 6.362-480.0 O-Ring Seal, 12.42 x 1.78 1
13 7.362-507.0 O-Ring Seal 8 x 2 NBR 90 1
14 6.413-403.0 Thermo Valve Tin Coated 1
15 5.332-290.0 Helical Spring 1
16 9.175-005.0 Unloader Assembly 1
ITEM PART NO. DESCRIPTION QTY
17 4.132-007.0 Drain Plug Replacement 1
18 5.003-062.0 Plate 1
19 9.177-301.0 High Pressure Seal 3
20 9.177-310.0 Back Ring 3
21 6.362-833.0 O-Ring Seal 12.5 x 1.73 3
22 9.155-011.0 Housing Low Pressure Seal 3
23 6.363-058.0 Grooved Ring 3
24 9.134-016.0 Spacer 3
25 6.365-393.0 Oil Sealing 12.20x4/6 3
26 9.133-007.0 Piston Guide 1
27 6.362-390.0 O-Ring Seal 15.6 x 1.8 1
28 9.134-019.0 Male Adapter 1
29 9.181-005.0 Filter Seal 1
30 9.154-044.0 Nut, Garden hose connector 1
31 9.178-005.0 Adapter Garden 1
32 9.139-370.0 Spare Part List, Piston 1
33 6.362-471.0 O-Ring Seal 80.0x3.0 NBR70 1
34 8.752-032.0 Clamp, Tension Spring
OD 11/16" 1
35 8.752-076.0 Valve, Thermal Cover Long 1

9.800-416.0 • Rev. 11/17
9
PRESSURE WASHER
SERVICE MANUAL
9.120-021.0 Housing View
8.920-004.0 Housing View
AXIAL PUMP EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.166-016.0 Grooved Ball Bearing 1
2 9.135-018.0 Swash Plate Hor. 1
3 9.165-356.0 Ball Bearing No 6207 1
4 9.177-314.0 Radial Seal 35 x 52 x 7 1
5 9.135-016.0 Oil Housing 1

9.800-416.0 • Rev. 11/17
SERVICE MANUAL
PRESSURE WASHER
10
VBA 35 UNLOADER EXPLODED VIEW
VBA 35 UNLOADER EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION KIT QTY
1Body Valve (KG) 1
Body Valve (KS) 1
2O-Ring A,C 1
3Seat C 1
4Ball, Sub-assy C 1
5O-Ring A 1
69. 8 0 3 - 9 0 7. 0 Guide Bushing 1
7 Teon Ring 1
8O-Ring A 1
9O-Ring A 2
10 9. 80 3 - 911.0 Connector 1
11 Teon Ring A 1
12 70-120207 Stem C 1
13 9.803-941.0 Connector Female 1
13A 9.702-892.0 Connector Male
14 O-Ring A,B 1
15 Spring B 1
ITEM PART NO. DESCRIPTION KIT QTY
16 Poppet B 1
17 9.802-893.0 Seal Washer 3/8 2
18 9.803-915.0 Banjo Bolt 3/8" w 1/8" Pilot 1
9.803-919.0 Banjo Bolt 3/8" Solid Cap 1
19 9.803-920.0 Banjo Bolt 1/2" w 1/4" Pilot 1
8.750-105.0 Banjo Bolt 1/2" Solid Cap
9.803-919.0 Banjo Bolt 3/8" Solid Cap
20 9.803-921.0 Seal Washer 1/2 2
21 Plate C 1
22 Spring C 1
23 8.933-021.0 Set Screw 1
24 9.803-925.0 Nut 1
25 9.803-926.0 Brass Handle 1
Kit A 8.717-672.0 O-Ring Repair Kit
Kit B 8.717-673.0 Outlet Kit
Kit C 8.717-674.0 Stem Repair Kit
5-3329
5-3330
9.803-899.0
9.803-900.0

9.800-416.0 • Rev. 11/17
11
PRESSURE WASHER
SERVICE MANUAL
ITEM PART # DESCRIPTION KIT QTY
1* 8.754-929.0 Stem C 1
2* 9.803-912.0 Backup Ring A 1
3* 8.754-930.0 O-ring, Ø2.62 x 6.02 A 2
4 8.730-882.0 Stem Connector 1
5* 9.803-193.0 O-ring, Ø2.62 x 20.24 A 1
6* 9.803-908.0 Backup Ring A 1
7 9.803-907.0 Guide Bushing 1
8* 9.803-906.0 O-ring, Ø1.78 x 14 A 1
9* 8.754-959.0 Ball SubAssembly C 1
10* 8.754-933.0 Seat C 1
11* 8.754-934.0 O-ring, Ø1.78 x 12.42 A,C 1
12 8.754-935.0 Valve Body 1
13 9.802-893.0 Seal Washer 3/8 1
14 9.803-919.0 Banjo Bolt 3/8 1
15* 8.754-936.0 O-ring, Ø2.62 x 10.78 A 1
16 9.803-920.0 Banjo Bolt, 1/2, w/1/4" Port 1
VBT UNLOADER EXPLODED VIEW
VBT UNLOADER EXPLODED VIEW PARTS LIST
ITEM PART # DESCRIPTION KIT QTY
17 9.803-914.0 Seal Washer 1/2) 1
18 8.754-937.0 Bypass Manifold 1
19 9.802-892.0 Outlet Connector 3/8 MPT 1
20* 9.803-191.0 O-ring, Ø2.62 X 17.13 A,B 1
21* 8.933-017.0 Poppet Spring B 1
22* 8.754-939.0 Poppet B 1
23* 8.754-940.0 O-ring, Ø3 x 6 A,B 1
24* 8.754-961.0 Plate C 1
25* 8.933-018.0 Spring 1500-4000 PSI C 1
26 8.933-021.0 Set Screw 1
27 9.803-925.0 Nut 1
28 9.803-926.0 Knob, Brass, Unloader 1
* Included in Kit
Kit A 8.754-941.0 O-Ring Repair Kit
Kit B 8.754-942.0 Outlet Repair Kit
Kit C 8.754-957.0 Stem Repair Kit
8.754-696.0
UNLOADER, VBT BANJO 1/2M 3/8M, 3000PSI (SPARE)

9.800-416.0 • Rev. 11/17
PRESSURE WASHER Troubleshooting Guide
12
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
LOW OPERATING
PRESSURE
Faulty pressure gauge Install new gauge.
Insufficient water supply Use larger garden hose; clean filter washer
at water inlet.
Old, worn or incorrect spray nozzle Match nozzle number to machine and/or
replace with new nozzle.
Plumbing or hose leak Check plumbing system for leaks. Retape
leaks with teflon tape.
Faulty or misadjusted unloader valve
(where applicable)
Adjust unloader for proper pressure. Install
repair kit when needed. Note: Tampering
with the factory setting may cause personal
injury and/or property damage, and will void
the manufacturer's warranty.
Worn packing in pump Install new packing kit.
Fouled or dirty inlet or discharge
valves in pump
Clean inlet and discharge valves.
Worn inlet or discharge valves Replace with valve kit.
Slow engine RPM Set engine speed per specifications
(approximately 2800 RPM - 3400 RPM)
FLUCTUATING
PRESSURE
Valves worn Check and replace if necessary.
Blockage in valve Check and clean out if necessary.
Pump sucking air Check water supply and suction line for air
seepage at joints.
Worn piston packing Check and replace if necessary.
PRESSURE LOW
AFTER PERIOD
OF NORMAL USE
Nozzle worn Check and replace if necessary.
Inlet or discharge valves blocked or
worn
Check and clean or replace if necessary.
Unloader valve seat worn Check and replace if necessary.
PUMP NOISE Air suction line Check water supply and connections on
suction line.
Broken or weak inlet or discharge
valve springs
Check and replace if necessary.
Foreign matter in valves Check and clean if necessary.
Worn bearings Check and replace if necessary.
Excessive temperature of liquid Reduce to below 180°F (75°C)

9.800-416.0 • Rev. 11/17
13
PRESSURE WASHER Troubleshooting Guide
PROBLEM POSSIBLE CAUSE SOLUTION
PRESENCE OF
WATER
IN PUMP OIL
Water sprayed at machine Change oil. Direct spray away from
machine.
High humidity in air Check and change oil twice as often.
Piston packing worn. Oil seal worn Check and replace if necessary.
ENGINE STRAINS
UNDER LOAD
Engine governor misadjusted Readjust governor on engine. Take to local
engine representative for adjustment.
Incorrect spray nozzle Install proper nozzle size (See serial plate
for proper size).
Obstruction in spray nozzle Remove obstruction.
Misadjusted unloader valve Contact local dealer or technical support.
Engine low or out of oil Check oil level.
Pump low or out of oil Check oil level.
Obstruction in hose, fitting Clean or replace hose, fitting.
Gasoline engine altitude The gasoline engine is preset for opera-
tion at altitudes below 1000 feet above sea
level. If operated at higher altitudes, it may
be necessary to install a high altitude main
jet carburetor. Contact your local authorized
engine sales and service center for details.
OIL SQUIRTS OUT OF
OIL CAP ON PUMP
Pump overlled with oil Maintain oil level at red dot on sight glass at
rear of pump or at top of notch on dipstick
(where applicable).
ENGINE OPERATES
FOR 15 MINUTES
THEN STOPS
Not enough gas or engine oil Fill tank with gas. Check oil level.
Vapor lock developed by heat of
day
Keep gas tank full to avoid vapor lock.
Obstruction in fuel filter Clean or replace fuel filter.
WATER DRIPPING
FROM UNDER PUMP
Piston packing worn Check and replace if necessary.
O-ring plunger retainer worn Check and replace if necessary.
Cracked piston Check and replace if necessary.
OIL DRIPPING Oil seal worn Check and replace if necessary.
EXCESSIVE
VIBRATION IN
DELIVERY LINE
Irregular functioning of the valves Check and replace if necessary.
WATER LEAKING
FROM PUMP
PROTECTOR
Spray gun closed with machine
running 5 minutes or longer.
Open spray gun or turn off machine.
Excessive water supply pressure Place a pressure regulator at end of 50'
garden hose.
TROUBLESHOOTING

Form # 9.800-416.0 • Revised 11/17 • Printed in U.S.A. or Mexico