Hotsy HD 2.3/23 P 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. 08/12
Hose and Spray Gun Assembly............................................................... 3
Exploded View ......................................................................................... 4
Exploded View Parts List ......................................................................... 5
G.1 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
UU1 Unloader Exploded View and Parts List ........................................ 11
Troubleshooting ................................................................................12-13

9.800-416.0 • Rev. 08/12
3
PRESSURE WASHER
SERVICE MANUAL
98004160-2
ITEM PART NO. DESCRIPTION QTY
1 9.802-166.0 Coupler, 3/8" Female (2400 PSI) 1
9.802-100.0 ▲Quick Coupler O-Ring (2400 PSI) 1
8.707-182.0 ▲ Coupler, Twist Connect, M22-F x 3/8" FNPT (2300 PSI) 1
2 8.739-106.0 Hose, 3/8" x 25', 1 Wire, Tuff-Flex (Hotsy) 1
8.739-124.0 Hose, 3/8" x 30', 1 Wire, Tuff-Flex (Kärcher) 1
8.739-133.0 Hose, 3/8" x 25', 1 Wire Tuff Flex (Landa) 1
3 9.802-223.0 Spray Gun, Shut-Off 1
4 9.802-220.0 Wand, Straight 1
5 9.802-164.0 Coupler, 1/4" Female 1
9.802-096.0 Quick Coupler O-Ring 1
6 8.712-333.0 Nozzle, 3.0 15° Yellow (2400 PSI) 1
9.104-024.0 Nozzle Kit 3.25 (2300 PSI) 1
7 8.712-398.0 Nozzle, Brass Soap (2400 PSI) 1
8 9.802-251.0 Hose, 1/4" x 1/2" Clear Vinyl (2400 PSI) 6 ft.
6.388-216.0 Hose, DN5 (2300 PSI) 6 ft.
9 8.707-057.0 Strainer, 1/4" Plastic (2400 PSI) 1
5.731-609.0 Strainer, Plastic (2300 PSI) 1
10 6.390-126.0 Clamp, Hose (2400 PSI) 2
11 9.802-216.0 Injector, Chem., Non-Adj, 3-5 GPM, .083 (2400 PSI) 1
▲ Not Shown
5
3
1
2
6
11
Pressure Nozzle
Brass Soap
Nozzle
4
10
9
8
7
10
HOSE & SPRAY GUN ASSEMBLY
HOSE & SPRAY GUN ASSEMBLY PARTS LIST

9.800-416.0 • Rev. 08/12
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 Sparks That 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. 08/12
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 9.804-033.0 Pump, Kärcher KG2530G (3000) 1
9.120-021.0 Pump, Kärcher Axial (2600 PSI) 1
8.904-248.0 Pump, Hotsy HE 2530G 1
8.904-893.0 Pump, Landa LG 2530G 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 15 For Nozzle Information
7 See Page 15 For Nozzle Information
8 9.802-064.0 Grommet, Rubber, Nozzle Holder 2
9 9.800-017.0 ▲Tag, Pump Plug/Dipstick (2400 PSI) 1
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 9.802-171.0 Nipple, 3/8" x 3/8" NPT ST Male 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
9.175-018.0 UU1 3500PSI, Universal Unloader (HD Model) 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. 08/12
SERVICE MANUAL
PRESSURE WASHER
6
G.1 SERIES PUMP EXPLODED VIEW
G.1 SERIES PUMP EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.803-938.0 Crankcase 1
2*
See Kit Below Plunger Oil Seal 3
3*
See Kit Below O-Ring Ø1.78 x 28.30 3
4*
See Kit Below Pressure Ring, 15mm 3
5*
See Kit Below U-Seal, 15mm 3
6*
See Kit Below Intermediate Ring 15mm 3
7*
See Kit Below Backup Ring 15mm 3
8*
See Kit Below U-Seal, 15mm 3
9*
See Kit Below Support Ring, 15mm 3
10 9.802-926.0 Brass Plug, 1/2" 1
11 9.803-199.0 Copper Washer 1/2" 1
12 9.803-946.0 Manifold Housing 1
13*
9.803-947.0 O-Ring Ø1.78 x 15.54 6
14*
See Kit Below Valve Assembly 6
15*
9.803-948.0 O-Ring Ø2.62 x 18.77 6
16 9.803-949.0 Valve Plug 6
17 9.803-950.0 Washer, Copper 1
18 9.803-951.0 Brass Plug G1/4 1
ITEM PART NO. DESCRIPTION QTY
19 9.803-952.0 Manifold Stud Bolt 8
20 9.802-884.0 Washer 8
21 9.803-198.0 Copper Washer 3/8" 1
22 9.802-925.0 Brass Plug 3/8" 2
27 9.802-939.0 Hexagonal Screw 9
28 9.803-953.0 Bearing Cover 1
29 9.803-954.0 Seal Bearing 1
30 9.802-914.0 Snap Ring 1
31 9.803-955.0 Ball Bearing 1
32 8.717-069.0 Crankshaft (2530G) 1
8.717-070.0 Crankshaft (3030G) 1
33 9.803-957.0 Oil Dip Stick 1
34 9.804-581.0 O-Ring 3.53 x 55.56 1
35 9.804-582.0 Needle Roller Bearing 1
36 8.717-212.0 Engine Flange 1
37 9.803-210.0 Spring Washer 4
38 9.804-584.0 Flange Screw 4
TORQUE
SPECS
Item # Ft.-lbs
16 65
19 18
27 7.6
38 8
40 7
50 13

9.800-416.0 • Rev. 08/12
7
PRESSURE WASHER
SERVICE MANUAL
G.1 SERIES PUMP EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
39 9.804-585.0 Crankshaft Seal 1
40*
See Kit Below Plunger Nut 3
41*
See Kit Below Copper Spacer 3
42* See Kit Below Plunger, 15mm 3
43*
See Kit Below Copper Spacer 3
44*
See Kit Below O-Ring Ø1.78x5.28 3
45*
See Kit Below Teflon Ring 3
46 9.803-964.0 Plunger Rod 3
47 9.803-965.0 Connecting Rod Pin 3
45 9.803-966.0 Connecting Rod 3
49 9.803-218.0 Spring Washer 6
50 8.933-020.0 Connecting Rod Screw 6
54 9.803-969.0 O-Ring 2.62 x 107.62 1
53 9.803-968.0 Crankcase Cover 1
52 9.803-197.0 Gasket, G3/4 1
51 9.803-202.0 Sightglass G3/4 1
* Part available in kit (See below)
REPAIR KIT NUMBER 8.725-354.0 8.725-355.0 9.803-934.0 9.803-936.0 9.803-937.0
KIT DESCRIPTION
Plunger Seal
15mm
Complete
Seal Packing
15mm Plunger 15mm Complete Valve
Plunger Oil
Seals
ITEM NUMBERS
INCLUDED 3, 5, 7, 8, 9 3, 4, 5, 6, 7, 8, 9
40, 41, 42,
43, 44, 45 13, 14, 15 2
NUMBER OF
CYLINDERS KIT
WILL SERVICE
31163

9.800-416.0 • Rev. 08/12
SERVICE MANUAL
PRESSURE WASHER
8
AXIAL PUMP EXPLODED VIEW AND PARTS LIST
9.120-021.0
8.920-004.0
35
34
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 7.401-909.0 Sphere 7 G40 - 1.4401 1
8 5.110-714.0 Sleeve 1
9 5.332-258.0 Helical Spring 1
10 9.139-372.0 Spare Part List Nozzle
INS 020/021 Pump 1
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 9.155-013.0 Female House Conn 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. 08/12
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. 08/12
SERVICE MANUAL
PRESSURE WASHER
10
VBA 35 UNLOADER EXPLODED VIEW
VBA 35 UNLOADER EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION KIT QTY
1 Body Valve (KG) 1
Body Valve (KS) 1
2O-RingA,C1
3Seat C1
4 Ball, Sub-assy C 1
5O-RingA1
69.803-907.0GuideBushing 1
7Teflon Ring 1
8O-RingA1
9O-RingA2
10 9.803-911.0 Connector 1
11 Teflon 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. 08/12
11
PRESSURE WASHER
SERVICE MANUAL
UU1 UNLOADER EXPLODED VIEW
UU1 UNLOADER EXPLODED VIEW PARTS LIST
ITEM PART # DESCRIPTION KIT QTY
1 8.751-394.0 Piston Housing D 1
2 Piston C, D 1
3 Piston O-Ring Back Up A, D 1
4 8.749-796.0 Main Block 1
5 9.152-372.0 Piston Ring D 1
6 Ball Seat C, D 1
7 O-Ring 10.5 ID x 1.5 CS A,C,D 1
8 Plunger B 1
9 9.152-016.0 Plunger Housing 1
10 Bypass Spring C, D 1
11 9.149-001.0 Low Pressure Port 1
12 9.152-017.0 Sliding Connector, 30mm 1
8.762-005.0 Sliding Connector, 40mm, Long 1
13 9.149-002.0 Sliding Connector H 1/2" 1
9.149-005.0 Sliding Connector H 3/8" 1
14 9.196-011.0 Plug 5/8 -18 UNF D 1
15 O-Ring 12 ID x 2 CS A, D 2
16 O-Ring 6 ID X 2 CS A, D 1
ITEM PART # DESCRIPTION KIT QTY
17 9.149-006.0 Sliding Connector Guide 1
18 O-Ring Backup A, D 1
6 x 1.45 x 1.68
19 Ball Housing Assy C, D 1
20 O-Ring 6.75 x 1.78 BN80 A, D 1
21 Spring Seat C, D 2
22 Plunger Spring B 1
23 8.917-699.0 Banjo Bolt 1/2" Short 1
8.917-700.0 Banjo Bolt 1/2"-1/4" NPT Short 1
24 8.917-698.0 Banjo Bolt 3/8" Short 1
25 9.802-893.0 Seal Washer 3/8" 2
26 9.803-921.0 Seal Washer 1/2" 2
9.802-893.0 Seal Washer 3/8" 2
27 O-Ring 15 ID x 2CS A,B,D 3
28 8.706-865.0 Plug, 1/4" Countersunk 1
Kit A 9.104-038.0 O-Ring Repair Kit
Kit B 9.104-039.0 Outlet Kit
Kit C 9.104-040.0 Stem Basic Kit
Kit D 8.920-045.0 UU1 Complete Stem Kit
9.175-018.0
UU1 3500PSI, UNIVERSAL UNLOADER (SPARE)
21
2
3
20
16
18
5
15
19
6
7
25
4
8
22
27
9
15
12
17
11
27
23
13
26
26
24
25
27
1
10
14
21
28
23

9.800-416.0 • Rev. 08/12
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. 08/12
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 overfilled 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 08/12 • Printed in U.S.A. or Mexico