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Hotsy HSS-503089E Operator's Manual

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

Made by: Hotsy
Type: Operator's Manual
Category: Pressure Washer
Pages: 22
Size: 3.81 MB

 

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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

C

H

A

UD

!

C

H

A

U

D

!

89144120-1

 


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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)

 


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CONTENTS

4

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 

8

Assembly Instruction 

9

Operating Instructions 

10-11

Detergents and Cleaning Tips 

12

Shut Down and Clean-Up 

13

Maintenance 

14-16

Troubleshooting 

17-20

Maintenance and Oil Change Chart  

21

7ARRANTY

 

 

 

 

 

 


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Hotsy HSS  •   #8.914-412.0   •   Rev. 10/11

5

  

PRESSURE 

W

ASHER

   

OPERA

TOR’S MANU

AL
  

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

U

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.

 


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Hotsy HSS  •   #8.914-412.0   •  Rev. 10/11

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 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.

 

 


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Hotsy HSS  •   #8.914-412.0   •   Rev. 10/11

7

  

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. 

 


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Hotsy HSS  •   #8.914-412.0   •  Rev. 10/11

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TOR’S MANU

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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

D!

89144120-2

Steam 

Valve

Pump

High Pressure 

Hose

Spray Gun

Pressure 

Nozzle

Wand

Inlet 

Connection

Adjustable 

Thermostat

Detergent 

Metering 

Valve

 


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Hotsy HSS  •   #8.914-412.0   •   Rev. 10/11

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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

 


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Hotsy HSS  •   #8.914-412.0   •   Rev. 10/11

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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

 


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Hotsy HSS  •   #8.914-412.0   •   Rev. 10/11

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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

 


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Hotsy HSS  •   #8.914-412.0   •  Rev. 10/11

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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

 


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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

 


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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.

 


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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"

1/16"

 


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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.

 


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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.

 


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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.

 


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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.

 


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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.

 


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Hotsy HSS  •   #8.914-412.0   •   Rev. 10/11

21

  

PRESSURE 

W

ASHER

   

OPERA

TOR’S MANU

AL
  

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

Yearly

Check Oil

Pump

x

Engine

x

Change Oil

Pump

x

Engine

x

Air Cleaner

Check

Clean

Spark Plug

x

Check Valve Clearance

x

Fuel Tank Filter

x

Water Filter/Clean

Check

x

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

 


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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.

 


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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.