Hotsy HSS-503089E Operator's Manual

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OPERATOR’S MANUAL

For technical assistance or the dealer nearest you,

consult our web page at

www.hotsy.com

8.914-412.0

HSS

89144120-1

HSS-503089E SPECIFICATIONS

  • Pump Volume at Pump Head: 4.8 GPM/288 GPH
  • Pump Pressure at Pump Head: 3000 PSI
  • Burner Type: Fuel Oil Fired
  • Burner BTU's: 620,000 Btu/Hr
  • Burner Exhaust Stack: 10"
  • Engine: Kohler KDW702 (686 CC)

HSS-803089E SPECIFICATIONS

  • Pump Volume at Pump Head: 7.8 GPM/468 GPH
  • Pump Pressure at Pump Head: 3000 PSI
  • Burner Type: Fuel Oil Fired
  • Burner BTU's: 920,000 Btu/Hr
  • Burner Exhaust Stack: 12"
  • Engine: Kohler KDW1003 (1028 CC)

HSS-603289E SPECIFICATIONS

  • Pump Volume at Pump Head: 6.3 GPM/378 GPH
  • Pump Pressure at Pump Head: 3200 PSI
  • Burner Type: Fuel Oil Fired
  • Burner BTU's: 620,000 Btu/Hr
  • Burner Exhaust Stack: 10"
  • Engine: Kohler KDW1003 (1028 CC)

HSS-102589E SPECIFICATIONS

  • Pump Volume at Pump Head: 9.5 GPM/468 GPH
  • Pump Pressure at Pump Head: 2500 PSI
  • Burner Type: Fuel Oil Fired
  • Burner BTU's: 920,000 Btu/Hr
  • Burner Exhaust Stack: 12"
  • Engine: Kohler KDW1003 (1028 CC)

CONTENTS

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.

Hotsy HSS • #8.914-412.0 • Rev. 5/11

Introduction and Important Safety Information

5-7

Component Identification

Assembly Instruction

Operating Instructions

10-11

Detergents and Cleaning Tips

Shut Down and Clean-Up

Maintenance

14-16

Troubleshooting

17-20

Maintenance and Oil Change Chart

7ARRANTY

Hotsy HSS • #8.914-412.0 • Rev. 10/11

PRESSURE

ASHER

OPERA

TOR’S MANU

INTRODUCTION & IMPORTANT SAFETY INFORMATION

Thank you for purchasing this Pressure Washer.
We reserve the right to make changes at any time
without incurring any obligation.

Owner/User Responsibility:

The owner and/or user must have an understanding of
the manufacturer’s operating instructions and warnings
before using this pressure washer. Warning information
should be emphasized and understood. If the operator
is not fluent in English, the manufacturer’s instructions
and  warnings  shall  be  read  to  and  discussed  with
the operator in the operator’s native language by the
purchaser/owner, making sure that the operator com-
prehends its contents.
Owner and/or user must study and maintain for future
reference the manufacturers’ instructions.
The  operator  must  know  how  to  stop  the  machine
quickly  and  understand  the  operation  of  all  controls.
Never  permit  anyone  to  operate  the  engine  without
proper instructions.

This manual should be considered a permanent

part of the machine and should remain with it if
machine is resold.
When ordering parts, please specify model and
serial number. Use only identical replacement
parts.
This machine is to be used only by trained op-
erators.

IMPORTANT SAFETY

INFORMATION

READ OPERATOR’S

MANUAL THOROUGHLY

PRIOR TO USE.

WARNING: To reduce the risk of

injury, read operating instruc-
tions carefully before using.
1. Read the owner's manual

thoroughly.  Failure  to  follow
instructions could cause mal-
function  of  the  machine  and
result in death, serious bodily
injury  and/or  property  dam-
age.

2. Know how to stop the machine and bleed pressure

quickly. Be thoroughly familiar with the controls.

3. Stay alert — watch what you are doing.

WARNING

KEEP WATER

SPRAY AWAY FROM

ELECTRICAL WIRING.

WARNING: Keep wand, hose, and

water spray away from electric
wiring or fatal electric shock may
result.
4. All installations must comply

with local codes. Contact
your electrician, plumber,
utility company or the selling
distributor for specific details.

WARNING

EAR PROTECTION

MUST BE WORN

WARNING: This machine exceeds

85 db appropriate ear protection
must be worn.

WARNING

SE PROTECTIVE

EYE WEAR

AND CLOTHING

WHEN OPERATING

THIS EQUIPMENT.

WARNING: High pressure spray

can cause paint chips or other
particles  to  become  airborne
and fly at high speeds. To avoid
personal  injury,  eye,  hand  and
foot  safety  devices  must  be
worn.
  5.   Eye, hand, and foot protection

must be worn when using this
equipment.

6. Keep operating area clear of all persons.

RISK OF EXPLOSION:

OPERATE ONLY WHERE

OPEN FLAME OR TORCH

IS PERMITTED

WARNING

WARNING: Flammable liquids

can create fumes which can ig-
nite,  causing  property  damage
or severe injury.
WARNING:  Risk  of  explosion
—  Operate  only  where  open
flame or torch is permitted.

RISK OF FIRE.

DO NOT ADD FUEL
WHEN OPERATING

MACHINE.

WARNING

WARNING: Risk of fire — Do not

add  fuel  when  the  product  is
operating or still hot.
WARNING: Do not use gasoline
crankcase  draining  or  oil  con-
taining  gasoline,  solvents  or
alcohol. Doing so will result in
fire and/or explosion.
WARNING: Risk of fire — Do not

Spray flammable liquids.
7. Allow engine to cool for 1-2 minutes before refu-

eling. If any fuel is spilled, make sure the area is
dry before testing the spark plug or starting the
engine. (Fire and/or explosion may occur if this is
not done.)

Gasoline engines on mobile or portable equipment

shall be refueled:

    a.  outdoors;
    b.  with the engine on the equipment stopped;
    c.  with  no  source  of  ignition  within  10  feet  of

the dispensing point; and

d. with an allowance made for expansion of the

fuel should the equipment be exposed to a

higher ambient temperature.

Hotsy HSS • #8.914-412.0 • Rev. 10/11

OPERA

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PRESSURE

ASHER

15. Be certain all quick coupler fittings are secured

before using pressure washer.

RISK OF INJECTION

OR SEVERE INJURY TO

PERSONS. KEEP CLEAR

OF NOZZLE.

WARNING

WARNING: High pressure devel-

oped  by  these  machines  will
cause personal injury or equip-
ment  damage.  Keep  clear  of
nozzle. Use caution when oper-
ating.  Do  not  direct  discharge
stream at people, or severe in-
jury or death will result.

WARNING

PROTECT FROM

FREEZING

WARNING: Protect machine from

freezing.

16. To keep machine in best

operating conditions, it is

important you protect machine

from freezing. Failure to protect

m a c h i n e f r o m f r e e z i n g

could cause malfunction of the

machine and result in death,

serious bodily injury, and/or property damage. Fol-
low storage instructions specified in this manual.

17. Inlet water must be clean fresh water and no hotter

then 90°F.

WARNING

RISK OF

ASPHYXIATION.

USE THIS PRODUCT

ONLY IN A WELL

VENTILATED AREA.

WARNING: Risk of asphyxiation.

Use this product only in a well
ventilated area.
18. Avoid installing machines in

small  areas  or  near  exhaust
fans.  Adequate  oxygen  is
needed  for  combustion  or
dangerous  carbon  monoxide
will result.

19. Manufacturer will not be liable for any changes

made to our standard machines or any components
not purchased from us.

20. The best insurance against an accident is precau-

tion and knowledge of the machine.

WARNING

RISK OF INJURY FROM

FALLS WHEN USING

LADDER.

WARNING: Be extremely careful

when using a ladder, scaffolding
or any other relatively unstable
location. The cleaning area
should have adequate slopes
and drainage to reduce the pos-
sibility of a fall due to slippery
surfaces.

IMPORTANT SAFETY INFORMATION

In an overfilling situation, additional precautions are

necessary to ensure that the situation is handled
in a safe manner.

WARNING: Risk of injury. Disconnect battery
ground terminal before servicing.
8. When in use , do not place machine near flammable

objects as the engine is hot.

9. Oil burning appliances shall be installed only in

locations where combustible dusts and flammable
gases or vapors are not present. Do not store or
use gasoline near this machine.

10. Use No. 1 or No. 2 heating oil (ASTM D306) only.

NEVER use gasoline in your fuel oil tank. Gasoline
is more combustible than fuel oil and could result
in a serious explosion.

NEVER use crankcase or

waste oil in your burner. Fuel unit malfunction could
result from contamination.

11. Do not confuse gasoline and fuel oil tanks. Keep

proper fuel in proper tank.

WARNING

RISK OF INJURY.

HOT SURFACES

CAN CAUSE BURNS

WARNING: Risk of injury. Hot

surfaces can cause burns. Use
only designated gripping areas
of spray gun and wand. Do not
place hands or feet on non-insu-
lated areas of the pressure
washer.

12. Transport/Repair with fuel tank EMPTY or with fuel

shut-off valve OFF.

HOT DISCHARGE FLUID:

DO NOT TOUCH OR

DIRECT DISCHARGE

STREAM AT PERSONS.

CAUTION: Hot discharge fluid.
Do not touch or direct discharge
stream at persons.
WARNING: This machine pro-
duces hot water and must have
insulated components attached
to protect the operator.

13. To reduce the risk of injury, close supervision is

necessary when a machine is used near children.
Do not allow children to operate the pressure
washer.

This machine must be attended during

operation.

TRIGGER GUN KICKS

BACK - HOLD WITH

BOTH HANDS

WARNING

WARNING: Grip cleaning wand

securely with both hands before
starting. Failure to do this could
result in injury from a whipping
wand.
14. Never make adjustments on

machine while in operation.

Hotsy HSS • #8.914-412.0 • Rev. 10/11

PRESSURE

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IMPORTANT SAFETY INFORMATION

21. Do not allow acids, caustic or abrasive fluids to pass

through the pump.

22. Never run pump dry or leave spray gun closed

longer than 1-2 minutes.

23. Machines with shut-off spray gun should not be

operated with the spray gun in the off position for
extensive periods of time as this may cause dam-
age to the pump.

24. Protect discharge hose from vehicle traffic and

sharp objects. Inspect condition of high pressure
hose before using or bodily injury may result.

25. Before disconnecting discharge hose from water

outlet, turn burner off and open spray gun to al-
low water to cool below 100° before stopping the
machine. Then open the spray gun to relieve pres-
sure. Failure to properly cool down or maintain the
heating coil may result in a steam explosion.

26. Do not overreach or stand on unstable support.

Keep good footing and balance at all times.

27. Do not operate this machine when fatigued or under

the influence of alcohol, prescription medications,
or drugs.

28. In oil burning models, use only kerosene, No. 1

home heating fuel, or diesel. If diesel is used, add
a soot remover to every tankful.

Follow the maintenance instructions speci-
fied in the manual.

Hotsy HSS • #8.914-412.0 • Rev. 10/11

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PRESSURE

ASHER

COMPONENT IDENTIFICATION

Pump — Develops high pressure by pumping water
volume through nozzle.
Spray Gun — Controls the application of water and
detergent onto cleaning surface with trigger device.
Includes safety latch.
Detergent Metering Valve — Controls detergent
mixture.
Wand — Must be connected to the spray gun.

High Pressure Hose — Connect one end to water
pump discharge nipple and the other end to spray
gun.
Pressure Nozzle — Inserted into wand quick coupler
to develop pressure
Adjustable Thermostat — Prevents water tempera-
ture from exceeding high temperatures. Is not used to
maintain constant temperature setting.

CHAUD!

CHAU

89144120-2

Steam

Valve

Pump

High Pressure

Hose

Spray Gun

Pressure

Nozzle

Wand

Inlet

Connection

Adjustable

Thermostat

Detergent

Metering

Valve

Hotsy HSS • #8.914-412.0 • Rev. 10/11

PRESSURE

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ASSEMBLY INSTRUCTIONS

STEP 1: Attach the high pressure
hose to the spray gun using teflon
tape on hose threads.

STEP 3: Release the coupler collar
and push the nozzle until the collar
clicks. Pull the nozzle to make sure
it is seated properly.

STEP 5: Connect the high pressure
hose to the pump discharge fitting.
Push coupler collar forward until
secure.

STEP 2: Pull the spring-loaded col-
lar of the wand coupler back to insert
your choice of pressure nozzle.

STEP 6: Connect one end of garden
hose to the cold water source.

STEP 7: Connect the other end of
the garden hose to pump water inlet.
Inspect inlets.

CAUTION: Do not

run the pump without water or
pump damage will result.

Safety

Latch

Spray

Gun

High Pressure

Hose

Wand

Coupler

Pressure

Nozzle

Pressure

Nozzle

Wand Coupler

Cold Water

Source

Garden Hose

Water

Inlet

Garden

Hose

Dip Stick

STEP 4: Remove shipping cap and
install  oil  dipstick.  Check  pump  oil
level  by  using  dipstick  or  observe
oil level in oil window (if equipped).
Use 30 wt. non detergent oil.

89144120-5

Coupler Collar

Discharge

Fitting

Hotsy HSS • #8.914-412.0 • Rev. 10/11

OPERA

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PRESSURE

ASHER

The five color-coded quick connect
nozzles  provide  a  wide  array  of
spray widths from 0° to 40° and are
easily accessible when placed in the
convenient  rubber  nozzle  holder,
which  is  provided  on  the  front  of
the machine.
NOTE:    For  a  more  gentle  rinse,
select  the  white  40°  or  green  25°
nozzle.  To scour the surface, select
the yellow 15° or red 0° nozzle. To
apply  detergent  select  the  black
nozzle.

WARNING! Never replace

nozzles without engaging the
safety latch on the spray gun
trigger.

Safety

Latch

OPERATING INSTRUCTIONS

STEP 1: Check engine oil level. Oil level should be level with the bottom of the oil filler neck. (Refer to the engine's
operating manual included with machine.) We recommend that the oil be changed after the first 5 hours of use,
then once every 50 hours.

NOTE: Improper oil levels will cause low oil sensor to shut off engine. IMPORTANT!

Do not run engine with high or low oil levels as this will cause engine damage.

STEP 2: Fill engine fuel tank with
fuel.

Oil Dipstick

Fuel

Tank

STEP  3:  Before  installing  nozzle,
trigger  the  spray  gun  to  eliminate
trapped  air  then  wait  for  a  steady
flow  of  water  to  emerge  from  the
wand  coupler  when  engine  starts.
Run machine allowing water to flush
through the system until clear.

STEP 4: Read engine operators
manual before starting. Turn the
engine switch to "Start" position.

Engine

On-Off
Switch

Oil Filler Cap

NOZZLES

Oil Filler Cap

Nozzles

Hotsy HSS • #8.914-412.0 • Rev. 10/11

PRESSURE

ASHER

OPERA

TOR’S MANU

STEAM COMBINATION

Thermostat

Step 1: For steam, open the steam
valve counterclockwise.
This lowers the pressure and raises
the temperature.

Step 2: Turn the thermostat knob
to the 270° mark, (The thermostat
is a high limit device and does not
regulate temperature.

Step 3: To stop, reverse steps and
set all controls to their original set-
tings.
Step 4: Turn burner switch off, open
trigger on spray gun and allow water
to cool.

Burner Switch

Steam

Valve

Hotsy HSS • #8.914-412.0 • Rev. 10/11

OPERA

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PRESSURE

ASHER

WARNING: Some detergents
may be harmful if inhaled or in-
gested, causing severe nausea,
fainting or poisoning. The harm-
ful elements may cause property
damage or severe injury.

STEP  1:  Use  detergent  de-
signed specifically for pressure
washers.  Household  deter-
gents could damage the pump.
Prepare  detergent  solution  as
required  by  the  manufacturer.
Fill  a  container  with  pressure
washer  detergent.  Place  the
filter  end  of  detergent  suction

tube into the detergent container.
STEP 2: Open detergent valve knob to desired mixture
ratio.

STEP 3: With the engine run-
ning,  pull  trigger  to  operate
machine.  Liquid  detergent  is
drawn  into  the  machine  and
mixed with water. Apply deter-
gent to work area. Do not allow
detergent to dry on surface.
IMPORTANT: You must flush

the detergent line after each use by placing the
suction tube into a bucket of clean water, then run
the pressure washer for 1-2 minutes.

THERMAL PUMP PROTECTION

If you run the engine on your pressure washer for 3-5
minutes without pressing the trigger on the spray gun,
circulating water in the pump can reach high tempera-
tures. When the water reaches this temperature, the
pump protector engages and cools the pump by dis-
charging the warm water onto the ground. This thermal
device prevents internal damage to the pump.

CLEANING TIPS

Pre-rinse cleaning surface with fresh water. Place de-
tergent suction tube directly into cleaning solution and
apply to surface (for best results, limit your work area to
sections approximately 6 feet square and always apply
detergent from bottom to top). Allow detergent to remain
on surface 1-3 minutes. Do not allow detergent to dry
on surface. If surface appears to be drying, simply wet
down surface with fresh water. If needed, use brush to
remove stubborn dirt. Rinse from top to bottom in an
even sweeping motion keeping the spray nozzle ap-
proximately 1 foot from cleaning surface. Use overlap-
ping strokes as you clean and rinse any surface. For
best surface cleaning action spray at a slight angle.

Recommendations:

• Before cleaning any surface, an inconspicuous

area should be cleaned to test spray pattern and

distance for maximum cleaning results.

• If painted surfaces are peeling or chipping, use

extreme caution as pressure washer may remove

the loose paint from the surface.

• Keep the spray nozzle a safe distance from the

surface you plan to clean. High pressure wash a

small area, then check the surface for damage. If no
damage is found, continue to pressure washing.

CAUTION - Never use:
• Bleach, chlorine products and other corrosive

chemicals

• Liquids containing solvents (i.e., paint thinner,

gasoline, oils)

  •  Tri-Sodium phosphate products
  •  Ammonia products
  •  Acid-based products
These chemicals will harm the machine and will dam-
age the surface being cleaned.

RINSING

It  will  take  a  few  seconds  for  the  detergent  to  clear.
Apply safety latch to spray gun. Open detergent valve.
Select  and  install  the  desired  high  pressure  nozzle.
NOTE:  You  can  also  stop  detergent  from  flowing  by
simply removing detergent siphon tube from bottle.

WARNING

APPLYING DETERGENTS & GENERAL CLEANING TECHNIQUES

Detergent Knob

Detergent Valve

To Pump

Hotsy HSS • #8.914-412.0 • Rev. 10/11

PRESSURE

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SHUTTING DOWN AND CLEAN-UP

STEP 1: Remove detergent suction
tube from container and insert into
one gallon of fresh water. Open
detergent mixing valve. Pull trigger
on spray gun and siphon water for
one minute.

STEP 2: Read engine operator
manual.

STEP 3: Turn off water supply.

STEP 5: Disconnect the garden
hose from the water inlet on the
machine.

STEP 6: Disconnect the high
pressure hose from pump dis-
charge fitting.

STEP 7: Engage
t h e s p r a y g u n
safety lock.

STEP 4: Press
trigger to release
water pressure.

STORAGE

Water Inlet

Safety

Latch

Measures should be taken to protect your FOCS series
engine if the engine is not operated for a period of 30
days or more. Proper storage will protect the engine
from corrosion and prevent costly repairs due to storage
induced problems.

Storage - 1 to 6 months

1. Start and idle the engine at a no-load condition for

15 minutes.

2. Stop the engine, allow the engine to cool enough

to safely drain the oil as shown Re-install the oil
drain plug, then fill the crankcase with MIL-L-644-
P9 protectant oil. Fill the fuel tank with a high grade
fuel preservative (add mix) such as STA-BIL per the
manufacturer recommendations.

3. Start and operate the engine at 3/4 speed for 5-10

minutes.

4. Stop the engine, allow to cool enough to safely

drain the engine oil as shown. Re-install the oil
drain plug.

5. Refill the engine with standard recommended lu-

bricating oil.

6. Drain the fuel tank. Remove the fuel filter. Install a

new fuel filter.

7. Carefully clean all debris from the radiator fins.

8. Remove the intake manifold. Rotate the engine

until the intake valve opens at each cylinder. Using
suitable means, pour approximately t tsp. of engine
oil into each cylinder. Rotate the engine several
revolutions. Spray the inside of the intake manifold
with SAE 10 W oil. Replace the intake manifold
using a new gasket.

9. Spray the inside of the exhaust manifold with SAE

10W oil.

10. Cover all openings with tape and apply grease to

any and all unpainted surfaces.

11. Loosen the fan belt before wrapping the engine in

plastic film and storing in a dry place away from
high voltage sources and off the ground.

Storage - In excess of 6 months

Perform the storage preparation procedures approxi-
mately as detailed, except with the following changes.
1. Replace the oil in step 2 above with MIL-L-21260,

grade 2, SAE 30W rustproof oil.

2. Delete steps 5 and 11 above.
3. Coat any and all unpainted surfaces with MIL-C

16173D, grade 3 anti-rust grease.

4. Replace anti-freeze every 2 years.

Engine

On-Off
Switch

89144120-6

Pump

Discharge

Fitting

Hotsy HSS • #8.914-412.0 • Rev. 10/11

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PRESSURE

ASHER

MAINTENANCE

PREVENTATIVE

MAINTENANCE

1. Check to see that water pump is properly

lubricated.

2. Follow winterizing instructions to prevent freeze

damage to pump and coils.

3. Always neutralize and flush detergent from system

after use.

4. If water is known to have high mineral content, use

a water softener in your water system, or de-scale
as needed.

5. Do not allow acidic, caustic or abrasive fluids to be

pumped through system.

   6.  Always use high grade quality cleaning products.
   7.  Never run pump dry for extended periods of time.
   8.  Use clean fuel: kerosene, No. 1 fuel oil, or Clean

or replace fuel filter every 100 hours of operation.
Avoid water contaminated fuel as it will damage the
fuel pump.

9. If machine is operated with smoky or eye burning

exhaust, coils will soot up, not letting water reach
maximum operating temperature.

10. Never allow water to be sprayed on or near the

engine or burner assembly or any electrical com-
ponent.

11.  Periodically delime coils as per instructions.
12.  Check to see that engine is properly lubricated.
It  is  advisable,  periodically,  to  visually  inspect  the
burner. Check air inlet to make sure it is not clogged
or blocked. Wipe off any oil spills and keep equipment
clean and dry.
The flow of combustion and ventilating air to the burner
must not be blocked or obstructed in any manner.
The  area  around  the  washer  should  be  kept  clean
and free of combustible materials, gasoline and other
flammable vapors and liquids.

MAINTENANCE & SERVICE

Unloader Valves:

Unloader valves are preset and tested at the factory
before shipping. Tampering with the factory setting may
cause personal injury and/ or property damage, will void
the manufactuers warranty.

Winterizing Procedure:

Damage due to freezing is not covered by warranty. Ad-
here to the following cold weather procedures whenever
the washer must be stored or operated outdoors under
freezing conditions.
During winter months, when temperatures drop below
32°F, protecting your machine against freezing is neces-

sary. Store the machine in a heated room. If this is not
possible then mix a 50/50 solution of anti-freeze and
water in the float tank. Turn the engine on to siphon the
anti-freeze mixture through the machine. If compressed
air is available, an air fitting can be screwed into the
float tank by removing the float tank strainer and fitting.
Then inject the compressed air. Water will be blown
out of the machine when the trigger on the spray gun
is opened.

High Limit Hot Water Thermostat:

For safety, each machine is equipped with a tempera-
ture sensitive high limit control switch. In the event that
the water should exceed its operating temperature,
the high limit control will turn the burner off until the
water cools, then it will automatically reset itself. The
thermostat sensor is located on the discharge side of
the heating coil. The thermostat control dial is located
on the control panel.

Pumps:

Use only SAE 30 weight non-detergent oil. Change oil
after first 50 hours of use. Thereafter, change oil every
three months or at 500 hour intervals. Oil level should be
checked through use of dipstick found on top of pump,
or the red dot visible through the oil gauge window. Oil
should be maintained at that level.

Cleaning of Coils:

In alkaline water areas, lime deposits can accumulate
rapidly inside the heating coil. This growth is increased
by the extreme heat build up in the coil. The best pre-
ventative for liming conditions is to use high quality
cleaning detergents. In areas where alkaline water is an
extreme problem, periodic use of Deliming Powder (Part
#112028) will remove lime and other deposits before
coil becomes plugged. (See Deliming instructions for
use of Deliming Powder.)

Deliming Coils:

Periodic flushing of coils or optional float tank is recom-
mended.
Step 1 Fill a container with 4 gallons of water, then ..

add 1 lb. of deliming powder. Mix thoroughly. .
Pour mixture into float tank.

Step 2 Remove wand assembly from spray gun and

put spray gun into float tank. Secure the trigger
on the spray gun into the open position.

Step 3 Turn engine on, allowing solution to be pumped

  through  coils  back  into  the  float  tank. The
  solution  should  be  allowed  to  circulate  2-4
  hours or until the color changes.

Step 4 After circulating solution, flush the entire sys-

tem with fresh water. Clean out float tank and
then reinstall wand assembly to spray gun.

Hotsy HSS • #8.914-412.0 • Rev. 10/11

PRESSURE

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MAINTENANCE

Removal of Soot from Heating Coil:

In the heating process, fuel residue in the form of soot
deposits may develop between the heating coil pipes,
and block air flow which will affect burner combustion.
When soot has been detected on visual observation, the
soot on the coil must be washed off after following the
coil removal steps (See Coil Removal on page 14).

Relief Valve

WARNING: The relief valve on this pressure washer
has been factory set and sealed and is a field non-
adjustable part. Tampering with the factory setting
may cause personal injury and/or property dam-
age and will void the manufacturer warranty. For
replacement parts refer to coil outlet assembly
exploded views.

Fuel:

Use clean fuel oil that is not contaminated with water
and debris. Replace fuel filter and drain the tank every
100 hours of operation.
Use  No.1  or  No  2  Heating  Oil  (ASTM  D306)  only.
NEVER  use  gasoline  in  your  fuel  tank.  Gasoline  is
more  combustible  than  fuel  oil  and  could  result  in  a
serious explosion.

NEVER use crankcase or waste oil

in your burner. Fuel unit malfunction could result from
contamination.

Fuel Control System:

This machine utilizes a fuel solenoid valve located on
the fuel pump to control the flow of fuel to the combus-
tion chamber. The solenoid, which is normally closed,
is activated by a flow switch when water flows through
it. When the operator releases the trigger on the spray
gun, the flow of water through the flow switch stops,
turning off the electrical current to the fuel solenoid.
The  solenoid  then  closes,  shutting  off  the  supply  of
fuel  to  the  combustion  chamber.  Controlling  the  flow
of fuel in this way gives an instantaneous burn-or-no-
burn situation, thereby eliminating high and low water
temperatures  and  the  combustion  smoke  normally
associated with machines incorporating a spray gun.
Periodic  inspection,  to  insure  that  the  fuel  solenoid
valve functions properly, is recommended. This can be
done by operating the machine and checking to see
that the burner is not firing when the spray gun is in
the OFF position.

Fuel Pressure Adjustment:

To control water temperature, adjust fuel pressure by
turning the regulating pressure adjusting screw clock-
wise to increase, counterclockwise to decrease. Do not
exceed 200 psi.

NOTE: When changing fuel pump,

a bypass plug must be installed in return port or fuel
pump will not prime.

Burner Nozzle:

Keep the tip free of surface deposits by wiping it with a
clean, solvent saturated cloth, being careful not to plug
or enlarge the nozzle. For maximum efficiency, replace
the nozzle each season.

Air Adjustment:

Machines  are  preset  and  performance  tested  at  the
factory.  A  one-time  initial  correction  for  your  location
will  pay  off  in  economy,  performance,  and  extended
service life. If a smoky or eye-burning exhaust is being
emitted from the stack, two things should be checked.
First, check the fuel to be certain that kerosene or No.
1 home heating fuel is being used. Next, check the air
adjustment on the burner.
To adjust: start machine and turn burner ON. Loosen
two locking screws found in the air shutter openings
(refer  to  illustration)  and  close  air  shutter  until  black
smoke appears from burner exhaust vent. Note air band
position. Next, slowly open the air shutter until white
smoke  just  starts  to  appear. Turn  air  shutter  halfway
back  to  the  black  smoke  position  previously  noted.
Tighten locking screws.
If the desired position cannot be obtained using only
the air shutter, lock the air shutter in as close a position

5/32"

7/16"

Periodically Check Wiring Connections. If Necessary

To Adjust Electrodes, Use Diagram.

Electrode Setting: Top View

Electrode Setting: Side View

1/16"

Hotsy HSS • #8.914-412.0 • Rev. 10/11

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MAINTENANCE

as can be obtained, then repeat the above procedure
on the air band setting.

Coil Removal:

Removal of coil because of freeze breakage, or to clean
soot from it can be done quickly and easily.
1. Disconnect hose from pump to inlet side of the

coil.

2. Carefully disconnect the thermostat sensor making

sure you do not crimp the capillary tube.

3. Remove burner assembly from combustion cham-

ber.

4. Remove the 3-3/8" bolts from each side of coil and

tank assembly (these bolts are used to fasten tank
to chassis).

5. Remove fittings connected to the 1/2" pipe nipples

from inlet and discharge sides of coil.

6. Remove top tank wrap, bend back insulation tabs

and fold back blanket.

   7.  Remove bolts that hold down coil to bottom wrap.
   8.  Remove coil.
   9.  Replace or repair any insulation found to be torn

or broken.

1 0. Remove insulation retainer plates.

Coil Reinstallation:

Reinstall new or cleaned coil reversing Steps 9 through
1.

Hotsy HSS • #8.914-412.0 • Rev. 10/11

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leshooting Guide

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

SOLUTION

LOW OPERATING
PRESSURE

Faulty pressure gauge

Install new gauge.

Insufficient water supply

Use larger supply hose; clean filter
at water inlet.

Old, worn or incorrect spray nozzle

Match nozzle number to machine
and/or replace with new nozzle.

Belt slippage

Tighten or replace; use correct belt.

Plumbing or hose leak

Check plumbing system for leaks.
Re-tape leaks with teflon tape.

Faulty or mis-adjusted unloader
valve

Adjust unloader for proper pressure.
Install repair kit when needed.

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.

Obstruction in spray nozzle

Remove obstruction.

Leaking pressure control valve

Rebuild or replace as needed.

Slow engine RPM

Set engine speed at proper specifications.

Pump sucking air

Check water supply and possibility
of air seepage.

Valves sticking

Check and clean or replace if necessary.

Unloader valve seat faulty

Check and replace if necessary.

BURNER WILL

NOT LIGHT

Little or no fuel

Fill tank with fuel.

Improper fuel or water in fuel

Drain fuel tank and fill with proper fuel.

Clogged fuel line

Clean or replace.

Plugged fuel filter

Replace as needed.

Mis-adjusted burner air bands

Readjust air bands for clean burn.

Little or no fuel pressure from fuel
pump

Increase fuel pressure to specification and/or
replace fuel pump. Test with pressure gauge.

Faulty burner transformer

Test transformer for proper arc between
contacts. Replace as needed.

Hotsy HSS • #8.914-412.0 • Rev. 10/11

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TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

SOLUTION

BURNER WILL
NOT LIGHT
(continued from
previous page)

Flex coupling slipping on fuel
pump shaft or burner motor shaft

Replace if needed.

On-Off switch defective

Check for electrical current reaching burner
assembly with burner switch on.

Heavy sooting on coil and burner
can cause interruption of air flow
and shorting of electrodes

Clean as required.

Improper electrode setting

Check and reset according to diagram in
Operator's Manual.

Fuel not reaching
combustion chamber

Check fuel pump for proper flow. Check solenoid
flow switch on machines with spray gun control
for proper on-off fuel flow control.

Clogged burner nozzle

Replace.

Thermostat faulty or
slow engine speed

Increase engine RPM to increase voltage.

Flow switch malfunction

Remove, test for continuity and replace
as needed.

Flow solenoid malfunction

Replace if needed.

FLUCTUATING
PRESSURE

Valves worn

Check and replace if necessary.

Blockage in valve

Check and replace if necessary.

Pump sucking air

Check water supply and air seepage at
joints in suction line.

Worn piston packing

Check and replace if necessary.

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 in the carburetor.
Contact your local authorized engine sales and
service center for details.

MACHINE SMOKES Improper fuel or water in fuel

Drain tank and replace contaminated fuel.

Improper air adjustment

Readjust air bands on burner assembly.

Low fuel pressure

Adjust fuel pump pressure to specifications.

Plugged or dirty burner nozzle

Replace nozzle.

Faulty burner nozzle spray pattern Replace nozzle.

Heavy accumulation of soot on
coils and burner assembly

Remove coils and burner assembly, clean
thoroughly.

Misaligned electrode setting

Realign electrodes to specifications.

Obstruction in smoke stack

Check for insulation blockage or
other foreign objects.

Hotsy HSS • #8.914-412.0 • Rev. 10/11

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TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

SOLUTION

MACHINE SMOKES

Low engine RPM

Increase RPM.

LOW WATER
TEMPERATURE

Improper fuel or water in fuel

Replace with clean and proper fuel.

Low fuel pressure

Increase fuel pressure.

Weak fuel pump

Check fuel pump pressure.
Replace pump if needed.

Fuel filter partially clogged

Replace as needed.

Soot build-up on coils not
allowing heat transfer

Clean coils.

Improper burner nozzle

See burner specifications.

WATER
TEMPERATURE
TOO HOT

Incoming water to machine
warm or hot

Lower incoming water temperature.

Fuel pump pressure too high

See specifications for proper fuel pressure.

Fuel pump defective

Replace fuel pump.

Detergent line sucking air

Tighten all clamps.
Check detergent lines for holes.

Defective temperature switch

Replace.

Incorrect fuel nozzle size

See burner specifications.

Insufficient water supplied

Check water G.P.M. to machine.

Restrict water flow

Check nozzle for obstruction, proper size.

PUMP NOISY

Air in suction line

Check water supply and
connections on suction line.

Broken or weak inlet or discharge
valve springs

Check and replace if necessary.

Excessive matter in valves

Check and clean if necessary.

Worn bearings

Check and replace if necessary.

PRESENCE OF
WATER IN OIL

Oil seal worn

Check and replace if necessary.

High humidity in air

Check and change oil twice as often.

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.

Pump protector

Lower water supply pressure. Do not run with
spray gun closed longer than 2 minutes.

Hotsy HSS • #8.914-412.0 • Rev. 10/11

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leshooting Guide

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

SOLUTION

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.

DETERGENT NOT
DRAWING

Air leak

Tighten all clamps. Check detergent
lines for holes.

Restricter in float tank is missing

Replace restricter. Check for proper
orifice in restricter.

Filter screen on detergent
suction hose plugged

Clean or replace.

Dried up detergent plugging metering
valve

Disassemble and clean thoroughly.

High viscosity of detergent

Dilute detergent to specifications.

Hole in detergent line(s)

Repair hole.

Low detergent level

Add detergent, if needed.

PUMP RUNNING
NORMALLY BUT
PRESSURE LOW
ON INSTALLATION

Pump sucking air

Check water supply and possibility
of air seepage.

Valves sticking

Check and clean or replace if necessary.

Nozzle incorrectly sized

Check and replace if necessary
(See serial plate for proper size).

Unloader valve seat faulty

Check and replace if necessary.

Worn piston packing

Check and replace if necessary.

BURNER MOTOR
WILL NOT RUN

Fuel pump seized

Replace fuel pump.

Burner fan loose or misaligned

Position correctly, tighten set screw.

Defective control switch

Replace switch.

Loose wire

Check and replace or tighten wiring.

Defective burner motor

Replace motor.

RELIEF VALVE
LEAKS WATER

Relief valve defective

Replace or repair.

Hotsy HSS • #8.914-412.0 • Rev. 10/11

PRESSURE

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OPERA

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MAINTENANCE

Date Oil Changed

Month/Day/Year

No. of Operating Hours

Since Last Oil Change

Brand Name and

Type of Oil (see above)

Maintenance Operation

Every 8 Hrs

or Daily

25 Hrs or

Weekly

50 Hrs or

Monthly

100 Hrs or

Yearly

Check Oil

Pump

Engine

Change Oil

Pump

Engine

Air Cleaner

Check

Clean

Spark Plug

Check Valve Clearance

Fuel Tank Filter

Water Filter/Clean

Check

This pressure washer was produced with the best available materials and quality craftsmanship. However, you
as the owner have certain responsibilities for the correct care of the equipment. Attention to regular preventative
maintenance procedures will assist in preserving the performance of your equipment. Contact your dealer for
maintenance. Regular preventative maintenance will add many hours to the life of your pressure washer. Perform
maintenance more often under severe conditions.
Check pump oil level before first use of your new pressure washer. Change pump oil after first 50 hours and
every 3 months or 500 hours thereafter. Use SAE 30 weight oil, non-detergent.

PREVENTATIVE MAINTENANCE

OIL CHANGE RECORD

If you are looking for replacement parts for your Hotsy, please contact your local dealer. You
can find a dealer by calling Hotsy at 800-525-1976 or by visiting www.hotsy.com.

Form #8.914-412.0 • Revised 10/11 • Printed in U.S.A. by Hotsy

If you need service on your pressure washer, contact your local Hotsy

dealer or visit www.Hotsy.com. Smart phone users scan the code below to

link directly to the Service Request page.

PDF User Manual

HSS-603289E HSS-803089E HSS-102589E

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