Hotsy 1.107-153.0, CD-232336, CD-232437, ZG3-23236 Service Manual
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SERVICE MANUAL 98004160-1 MODEL # ■ HC-232439 ■ HC-232336 ■ ZG3-24334 ■ ZG3-23236 ■ HD 2.3/24 P ■ HD 2.3/23 P ■ CD-232437 ■ CD-232336 ORDER # 1.107-036.0 1.107-035.0 1.107-081.0 1.107-018.0 1.575-350.0 1.575-351.0 1.107-152.0 1.107-153.0 9.800-416.0 CONTENTS 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 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. 2 9.800-416.0 • Rev. 11/17 PRESSURE WASHER SERVICE MANUAL HOSE & SPRAY GUN ASSEMBLY 11 1 5 4 10 8 9 6 7 2 3 HD 2.3/24 P 11 1 5 10 4 8 9 3 6 2 7 HOSE & SPRAY GUN ASSEMBLY PARTS LIST ITEM PART NO. DESCRIPTION QTY 1 9.802-166.0 9.802-100.0 8.707-182.0 Coupler, 3/8" Female 1 (2400 PSI) ▲ Quick Coupler O-Ring 1 (2400 PSI ▲ Coupler, Twist Connect, 1 M22-F x 3/8" FNPT (2300 PSI) 2 8.925-137.0 8.925-136.0 Hose, 3/8" X 25' 1W 1 4000PSI SW/SO/CPL Hose, 3/8" X 25' 1W 1 4000PSI SW/SO/M22 (-018.0) 3 8.754-769.0 4.775-054.0 MV925 Gun 4500 PSI, 1 3/8" NPT INLET (Only 050.0 ) EASY!Force Advanced 1 KNA (Only 050.0 ) 4 9.112-533.0 8.783-039.0 Lance-AL Quick Connect-Male 3000 psi Wand 30" Zinc Plated, Handle & Coupler 5 Coupler, 1/4" Female Quick Coupler O-Ring 1 1 9.802-164.0 9.802-096.0 ITEM PART NO. DESCRIPTION 6 8.712-333.0 8.753-991.0 Nozzle, 3.0 15° Yellow (2400 PSI) Nozzle, 3.25 15° Yellow (2300 PSI) 7 Nozzle, Brass Soap 8.712-398.0 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) QTY 1 1 1 6 ft. 6 ft. 9 8.707-057.0 5.731-652.0 Strainer, 1/4" Plastic (2400 PSI) Strainer, Plastic (2300 PSI) 1 Lance-AL Quick Connect-Male 3000 psi Wand 30" Zinc Plated, Handle & Coupler 1 1 4 9.112-533.0 8.783-039.0 1 10 Clamp, Hose (2400 PSI) 2 Injector, Chem., Non-Adj, 3-5 GPM, .083 (2400 PSI) 1 6.390-126.0 11 9.802-216.0 1 1 ▲ Not Shown 3 9.800-416.0 • Rev. 11/17 SERVICE MANUAL PRESSURE WASHER EXPLODED VIEW 1 (Reversed View) 27 “T his Ca pro lifo rep rni duct a Cr roduc to caconta ea A Spte Sptive use ins ch ha ca Co ark arks rm. nc emica er nta Ar Re ct res That Opera and ls kn lat Lo tor Ca tio bir ow ing ca n Ma n to l Fir y Start of Thth de n to Fir e Ag be fec the e Pr en Re Fires is Eq ts Sta ev cie quire Ar uip or oth te en tio s for d. Thound ment er of n Re La e Dr Ma qu ws Operay Ve y ire or me Re tor getat nts gu Sh ion .” lation ou . ld s WA RN 3 8.91 7-01 5.0 22 18 14 2 26 17 10 (Reversed View) 12 12 15 2300 PSI Models 10 20 23 4 15 7 8 25 11 2 6 10 13 24 10 11 19 16 IN G 5 21 98004160-3 4 9.800-416.0 • Rev. 11/17 ITEM PART NO. DESCRIPTION QTY 1 9.802-316.0 9.194-015.0 Engine, Honda, GX160K1QX2, 163cc (2400 PSI) Engine, Honda, GC1601QHA, 160cc (2300 PSI) 1 1 2 8.923-785.0 9.120-021.0 8.923-771.0 8.923-757.0 8.920-004.0 Pump, Kärcher KP2535G, (3400 RPM) Pump, Kärcher Axial (2600 PSI) Pump, Hotsy HP 2535G, (3400 RPM) Pump, Landa LP 2535G, (3400 RPM) Pump, Legacy 2.6 GPM (2600 PSI) 1 1 1 1 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 8.750-883.0 8.900-893.0 8.900-827.0 Label, Warning/Instructions (HD Models) Label, Warning/Instructions (CB Models) Label, Warning/Instructions (HC Models) Label, Warning/Instructions (ZG Models) 1 1 1 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 8.754-696.0 Unloader, VBA35 6.6 @ 3500 PSI (HC & ZG3 Models) Unloader, VBT Banjo 1/2M 3/8M, 3000PSI 1 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 PRESSURE WASHER SERVICE MANUAL EXPLODED VIEW PARTS LIST ▲ Not Shown 5 9.800-416.0 • Rev. 11/17 8.754-755.0 LP2535G 24 24 25 49 26 27 28 29 31 44 36 45 43 30 SERVICE MANUAL PRESSURE WASHER LP SERIES PUMP EXPLODED VIEW 19 42 40 38 48 41 47 39 46 15 14 22 21 13 20 19 12 18 16 6 5 4 3 2 32 17 8 15 14 13 12 33 7 9 TORQUE SPECS 1 Item # Ft.-lbs 15 65 16 55 24 8 37 10 38 10 45 10 34 35 10 36 37 11 LP SERIES PUMP EXPLODED VIEW PARTS LIST ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 1 8.754-841.0 Crankcase QTY 1 19 8.707-262.0 Plug, Brass G3/8 O-ring Ø1.78 X 72.75 QTY 1 2 8.754-846.0 1 20* See Kits Below Valve Seat 6 3* See Kits Below Plunger Oil Seal 3 21* See Kits Below Valve Plate 6 4* See Kits Below O-ring Ø1.78 X 26.7 3 22* See Kits Below Valve Spring 6 5* See Kits Below Washer, Pressure Ring 14 mm 23* See Kits Below Valve Cage 6 3 24 9.802-939.0 Screw, M6 X 16 12 6* See Kits Below U-Seal, 14 mm 3 25 8.717-137.0 Bearing Cover 2 7* See Kits Below Pressure Ring, 14 mm 3 26 9.803-954.0 Bearing Seal 1 8* See Kits Below U-Seal, 14 mm 3 27 8.754-843.0 Seal Spacer, Crankshaft 1 9 9.803-199.0 Washer, Copper G1/2 1 28 9.802-914.0 Snap Ring, 25 mm 1 10 9.802-926.0 Plug, Brass G1/2 1 29 9.803-955.0 Bearing, Ball 1 11 8.754-853.0 Manifold 1 12* 8.717-233.0 O-ring Ø1.78 X 15.6 6 30 8.754-831.0 8.754-834.0 Shaft, 3/4" Hollow 2535G Shaft, 3/4" Hollow 3035G 1 1 13* See Kits Below Valve Assembly 6 31 8.754-219.0 Oil Dipstick 1 14* 9.803-948.0 O-ring Ø1.78 X 18.77 6 32 8.754-840.0 Bearing Needle 1 15 9.803-949.0 Valve Plug 6 33 8.754-826.0 Seal, Crankshaft 1 16 8.754-854.0 Bolt, Manifold M14 x 40 2 34 8.754-863.0 Flange, Engine 1 17 8.754-850.0 Washer, Lock 2 35 9.803-210.0 Washer 4 18 9.803-198.0 Washer, Cooper G3/8 1 36 9.803-218.0 Washer 6mm 10 6 9.800-416.0 • Rev. 11/17 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 * Available in kit (See below) 1 PRESSURE WASHER SERVICE MANUAL LP SERIES PUMP EXPLODED VIEW PARTS LIST (CONT) LP SERIES PUMP REPAIR KITS REPAIR KIT NUMBER 8.754-860.0 8.754-861.0 8.754-862.0 8.754-859.0 9.803-937.0 KIT DESCRIPTION Plunger Seals 14mm Seal Packing 14mm Plunger 14mm Complete Valve Plunger Oil Seals ITEM NUMBERS INCLUDED 4, 6, 8 4, 5, 6, 7, 8 38, 39, 40, 41 12, 13, 14 3 7 9.800-416.0 • Rev. 11/17 9.120-021.0 8.920-004.0 * SERVICE MANUAL PRESSURE WASHER AXIAL PUMP EXPLODED VIEW AND PARTS LIST ITEM PART NO. DESCRIPTION QTY 1 9.135-015.0 8.762-010.0 Cylinder Head Cylinder Head, Legacy 1 1 17 4.132-007.0 Drain Plug Replacement 1 18 5.003-062.0 Plate 1 2 9.175-004.0 Valve Assy Horizontal 3 19 9.177-301.0 High Pressure Seal 3 3 2.884-916.0 Spare Part List, Set 3 1 20 9.177-310.0 Back Ring 3 4 5.443-448.0 Nipple Chemestry 1 21 6.362-833.0 O-Ring Seal 12.5 x 1.73 3 5 6.362-451.0 O-Ring Seal 8.0 x 1.0 1 22 9.155-011.0 Housing Low Pressure Seal 3 6 6-362-634.0 O-Ring Seal, 5.28 x 1.78 1 23 6.363-058.0 Grooved Ring 3 7 7.401-908.0 Sphere 7 G300 - 1.4301 DIN 5401 PC 1 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 8 5.110-714.0 Sleeve 1 9 5.332-258.0 Helical Spring 1 Spare Part List Nozzle INS 020/021 Pump 1 10 9.139-372.0 ITEM PART NO. DESCRIPTION QTY 11 9.184-018.0 Outlet-Thermal Valve 1 29 9.181-005.0 Filter Seal 1 12 6.362-480.0 O-Ring Seal, 12.42 x 1.78 1 30 9.154-044.0 Nut, Garden hose connector 1 9.178-005.0 Adapter Garden 1 1 13 7.362-507.0 O-Ring Seal 8 x 2 NBR 90 1 31 14 6.413-403.0 Thermo Valve Tin Coated 1 32 9.139-370.0 Spare Part List, Piston 15 5.332-290.0 Helical Spring 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 16 9.175-005.0 Unloader Assembly 1 35 8.752-076.0 8 9.800-416.0 • Rev. 11/17 Valve, Thermal Cover Long 1 9.120-021.0 Housing View 8.920-004.0 Housing View ITEM PART NO. DESCRIPTION PRESSURE WASHER SERVICE MANUAL AXIAL PUMP EXPLODED VIEW PARTS LIST 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 9.800-416.0 • Rev. 11/17 9.803-899.0 9.803-900.0 5-3329 5-3330 SERVICE MANUAL PRESSURE WASHER VBA 35 UNLOADER EXPLODED VIEW VBA 35 UNLOADER EXPLODED VIEW PARTS LIST ITEM PART NO. 1 DESCRIPTION KIT Body Valve (KG) 1 Body Valve (KS) 16 DESCRIPTION Poppet KIT QTY B 1 1 17 9.802-893.0 Seal Washer 3/8 2 1 18 9.803-915.0 Banjo Bolt 3/8" w 1/8" Pilot 1 Seat C 1 9.803-919.0 Banjo Bolt 3/8" Solid Cap 1 Ball, Sub-assy C 1 9.803-920.0 Banjo Bolt 1/2" w 1/4" Pilot 1 O-Ring A O-Ring 3 4 19 1 8.750-105.0 Banjo Bolt 1/2" Solid Cap Guide Bushing 1 9.803-919.0 Banjo Bolt 3/8" Solid Cap 7 Teflon Ring 1 20 9.803-921.0 Seal Washer 1/2 8 O-Ring A 1 21 O-Ring A 2 22 1 23 8.933-021.0 Set Screw 1 6 9.803-907.0 9 10 9.803-911.0 11 10 ITEM PART NO. A,C 2 5 QTY Connector 2 Plate C 1 Spring C 1 Teflon Ring A 1 24 9.803-925.0 Nut 1 C 1 25 9.803-926.0 Brass Handle 1 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 12 70-120207 Stem 13 9.803-941.0 Connector Female 13A 9.702-892.0 Connector Male 14 O-Ring A,B 1 15 Spring B 1 9.800-416.0 • Rev. 11/17 PRESSURE WASHER SERVICE MANUAL VBT UNLOADER EXPLODED VIEW 8.754-696.0 UNLOADER, VBT BANJO 1/2M 3/8M, 3000PSI (SPARE) VBT UNLOADER EXPLODED VIEW PARTS LIST ITEM PART # DESCRIPTION KIT QTY ITEM PART # DESCRIPTION KIT QTY 1* 8.754-929.0 Stem C 1 17 9.803-914.0 Seal Washer 1/2) 1 2* 9.803-912.0 Backup Ring A 1 18 8.754-937.0 Bypass Manifold 1 9.802-892.0 Outlet Connector 3/8 MPT 1 3* 8.754-930.0 O-ring, Ø2.62 x 6.02 A 2 19 4 8.730-882.0 Stem Connector 1 20* 9.803-191.0 O-ring, Ø2.62 X 17.13 A,B 1 8.933-017.0 Poppet Spring B 1 B 1 5* 9.803-193.0 O-ring, Ø2.62 x 20.24 A 1 21* 6* 9.803-908.0 Backup Ring A 1 22* 8.754-939.0 Poppet 7 9.803-907.0 Guide Bushing 1 23* 8.754-940.0 O-ring, Ø3 x 6 A,B 1 8* 9.803-906.0 O-ring, Ø1.78 x 14 A 1 24* 8.754-961.0 Plate C 1 9* 8.754-959.0 Ball SubAssembly C 1 25* 8.933-018.0 Spring 1500-4000 PSI C 1 10* 8.754-933.0 Seat C 1 26 8.933-021.0 Set Screw 1 11* 8.754-934.0 O-ring, Ø1.78 x 12.42 A,C 1 27 9.803-925.0 Nut 1 12 8.754-935.0 Valve Body 1 28 9.803-926.0 Knob, Brass, Unloader 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 1 16 9.803-920.0 Banjo Bolt, 1/2, w/1/4" Port A 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 11 9.800-416.0 • Rev. 11/17 PRESSURE WASHER Troubleshooting Guide 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) 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. 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. 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) FLUCTUATING PRESSURE PRESSURE LOW AFTER PERIOD OF NORMAL USE PUMP NOISE 12 9.800-416.0 • Rev. 11/17 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 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 operation 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. ENGINE STRAINS UNDER LOAD OIL SQUIRTS OUT OF Pump overfilled with oil OIL CAP ON PUMP 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. 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. WATER DRIPPING FROM UNDER PUMP PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING 13 9.800-416.0 • Rev. 11/17 Form # 9.800-416.0 • Revised 11/17 • Printed in U.S.A. or Mexico ">

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