operating instructions and parts manual...

THE HOTSY CORPORATIONSERIAL NUMBER: 21 INVERNESS WAY EAST

ENGLEWOOD, CO 80112(303) 792-5200

DATE PURCHASED:

FOR SALES AND SERVICE, PLEASE CONTACT:

OPERATING INSTRUCTIONSAND PARTS MANUAL

Read instructions carefully before attempting to assemble, install, operate or service this pressurewasher. Failure to comply with instructions could result in personal injury and/or property damage!

SPECIFICATIONS● Pump Volume At Pump Head: 2.2 GPM/132 GPH● Pump Pressure At Pump Head: 1000 PSI● Burner Type: Fuel Oil Fired, 197,000 BTU/Hr● Burner Fuel Pressure: 110 PSI● Machine Voltage: 115VAC/60Hz/1Ph● Total Machine Amperage: 20 Amps● Machine Weight: 270 Lbs.● Shipping Weight: 305 Lbs.● Exhaust Stack Size: 8”● Machine Dimensions: Length = 44”, Width = 26”, Height = 38”

MODEL B2030V/1MODEL 550D

WARNINGRead and observe to prevent severe personal injury or property damage.

Hotsy 550D

● Check hoses, guns, fittings and fuel con-nections daily for signs of wear, cracks andlooseness, and replace as required.

● Make sure all switches and controls are inthe OFF position prior to plugging in.

● Do not stand in water while plugging andunplugging electrical cord.

● Use UL grounded type receptacles ofproper voltage and amperage rating at alltimes.

● Keep all electr ical components onmachine dry.

● Do not point wand or gun at yourself or atany person. Bodily injury may result fromwater under high pressure.

● Wear eye, ear, hand, foot, and skin pro-tection at all times while operating equip-ment.

● Avoid contact with non-insulated areas ofpressure washer to prevent the possibilityof severe burns.

● Do not allow machine to run unattended.

● Do not run machine indoors or in anenclosed area, as exhaust fumes may behazardous to your health.

● Do not operate machine in areas whereflammable vapors, (gasoline, solvents,etc.) may be present, as this machine mayignite the vapors.

● Do not store flammable liquids (gasoline,diesel fuel, solvents, etc.) near pressurewasher or in non-ventilated areas.

● Use extreme caution when movingmachine over rough or uneven surfaces.

● For permanent installation consult localbuilding codes for installation require-ments. Licensed contractor may berequired.

● Disconnect power supply prior to perform-ing any maintenance.

● Troubleshoot machine prior to usingreset buttons. See TroubleshootingGuide.

● Pressure washers produce a kickback. Toprevent personal injuries due to falls useauxiliary safety equipment.

● Do not block or tie trigger of gunjet in openposition.

● When applying detergents follow thesafety rules on the detergent label.

● Cleaning area should be provided withadequate slopes and drainage. This willreduce the possibility of a fall due to slip-pery surface.

● Unauthorized machine modifications oruse of non-approved replacement partsmay cause personal injury and/or prop-erty damage and will void the pressurewasher warranty.

● This machine has been provided withWarning and Instruction decals for thesafety of the operator. If these decals areremoved or become damaged they shouldbe replaced. Contact your dealer forreplacement decals.

● Use detergent from a covered D.O.T.approved container.

Hotsy 550D

Figure 1 - Machine Component Layout

PRESSURE NOZZLE WAND

BURNER EXHAUST VENT

HANDLE

HOSE HANGER

PRESSURE HOSE

DETERGENTMETERING VALVE

TRIGGER GUN

POWER CORDW/GFCI

OIL BURNER

COIL DRAIN PLUG

DETERGENTINLET LINE

BURNER SWITCHPUMP SWITCH THERMOSTAT

RELIEF VALVE

PUMP

FUEL TANK

FUEL TANK DRAIN

GARDEN HOSE CONNECTOR

MOTOR

GFCI CORD HANGER

Hotsy 550D

Figure 2 - Pressure Hose Installation

Figure 3 - Wand Assembly

Figure 4 - Handle/Hose Hanger Installation

ASSEMBLY

UnpackingUnpack carefully. Wear safety glasses or goggles whileunpacking, assembling or operating pressure washer.If there are missing components or hidden damageimmediately contact distributor or carrier concerningdiscrepancies.

1. Cut strapping band from pressure washer and pallet.2. Remove pressure washer from pallet.

Parts Included• Pressure Washer• Pressure Hose• Hose Hanger• Wand• 10” Rubber Wheel (4 ea.)• Axle (2 ea.)• Handle• Parts Bag Containing:

■ Bolt 5/16” - 18 x 1-1/2” (5 ea.)■ Flange Nut 5/16” - 18 (5 ea.)■ GFCI Cord Hanger■ Vinyl Cap■ Trigger Gun■ Quick Disconnect■ Quick Disconnect Plug■ Adjustable Pressure Nozzle■ Flat Washer 5/8” (8 ea.)■ Push Nut (4 ea.)■ Hubcap (4 ea.)

• Operating Instructions and Parts Manual

Tools Required• 10” Adjustable Wrench (2 ea.)• 11/16” Socket• Hammer• 7/16” Open End Wrench• Teflon Tape

Pressure Hose, Trigger Gun and Wand1. When assembling, use teflon tape on all threaded

plumbing connections to prevent leakage.2. Install pressure hose on machine as shown in

Figure 2.

PRESSURE HOSE

RELIEF VALVE

3. Assemble wand components and pressure hose asshown in Figure 3.

WAND QUICK DISCONNECT PLUG

QUICK DISCONNECT

TRIGGER GUN

PRESSURE HOSE

4. Make sure that all plumbing connections are tight.

Handle, GFCI Cord Hanger and HoseHanger1. Insert the handle through the holes in the chassis and

secure with 5/16” bolts and flange nuts. SeeFigure 4.

2. Install hose hanger as shown in Figure 4.

HANDLE

HOSE HANGER

5/16” BOLT AND FLANGE NUT

Hotsy 550D

3. Attach the GFCI cord hanger to the handle using a5/16” bolt and flange nut. Install the vinyl cap on theend of the hanger, use water as a lubricant if needed.See Figure 5.

Figure 5 - GFCI Cord Hanger

HANDLE GFCI CORDHANGER

VINYL CAP

5/16” BOLT ANDFLANGE NUT

Axles and Wheels1. Carefully raise the pressure washer off of the floor by

using blocks or ramps. Secure the pressure washerbefore proceeding.

2. Install wheel on end of axle as shown in Figure 6.

Figure 6 - Wheel Assembly

WHEEL

5/8” WASHER 5/8” WASHER

AXLE

THIS SIDE IN PUSH NUT

HUBCAP

3. Install a push nut on the end of the axle. For properinstallation of the push nut use an 11/16” socket overthe end of the axle. Carefully use a hammer to pushthe push nut into place. Do not install deeper than3/8” See Figure 7.

Figure 7 - Push Nut Installation

NOTE: You will need to block or secure the axle whileinstalling the push nut and to complete step 3.

4. Carefully use a hammer to install the black plastichubcap over the end of the axle. See Figure 6.

5. Slide the front axle assembly through the front holesof the chassis. See Figure 8.

Figure 8 - Axle Installation

USE 11/16” SOCKETAND HAMMER

DO NOT INSTALLDEEPER THAN 3/8”

PUSH NUT

AXLE

AXLE

THIS SIDE TOWARDS CHASSIS

Hotsy 550D

6. Install the 5/8” washers and wheel on the open axleend after it has been installed through the chassis.See Figure 9.

Figure 9 - Wheel Assembly

5/8” WASHER WHEEL

5/8” WASHER

AXLETHIS SIDETOWARDS

CHASSIS

PUSH NUT

HUBCAP

7. Install push nut. See Figure 7. Again, use the 11/16”socket over the end of the axle. Carefully use a ham-mer to push the push nut into place. Install the pushnut snug against the washer wheel.

NOTE: You will need to block the axle in place whileinstalling the push nut and hubcap.

8. Carefully use a hammer to install the black plastichubcap over the end of the axle that now has the wheelassembly. See Figure 9.

9. The rear axle is installed and secured in the samemanner as the front axle. Repeat steps 2 through 8,referring to Figures 6 through 9.

10. Carefully remove the blocks from under the presserwasher and lower it to the floor.

INSTALLATION

Getting Started

IMPORTANT: Proper initial installation of equipmentwill assure more satisfactory performance, longer ser-vice life, and lower maintenance cost.

IMPORTANT: The use of a backflow peventer on thewater supply hose is recommended and may berequired by local code.

The pressure washer should be run on a level surfaceand in a protected area where it is not readily influencedby outside forces such as strong winds, freezingtemperatures, rain, etc. The pressure washer should belocated to assure easy assess for filling of fluids,adjustments and maintenance. Normal precautions shouldbe taken by the operator to prevent moisture from reachingthe pressure washer. It is recommended that a partitionbe made between the wash area and the pressure washerto prevent direct spray from the wand from coming incontact with the pressure washer. Moisture reaching theequipment will reduce the pressure washer’s service life.All installations must comply with the local codes coveringsuch installations.

Venting

DANGER: Do not run machine indoors or in anenclosed area, as exhaust fumes may be hazardousto your health.

DANGER: Do not operate machine in areas whereflammable vapors (gasoline, solvents, etc.) may bepresent, as this machine may ignite the vapors.

CAUTION: All venting must be in accordance withapplicable federal and state laws, and local ordi-nances. Consult local heating contractors.

If the pressure washer is to be used in an enclosed area,a flue must be installed to vent burner exhaust to theoutside atmosphere. Be sure the flue is the same size asthe burner exhaust vent on the pressure washer lid. Poordraft will cause the pressure washer to soot and notoperate properly. When selecting the location forinstallation, beware of poorly ventilated locations or areaswhere exhaust fans may cause an insufficient supply ofoxygen. Proper combustion can only be obtained whenthere is a sufficient supply of oxygen available for theamount of fuel being burned. If it is necessary to installthe machine in a poorly ventilated area, outside fresh airmay have to be provided to the machine. Locate thepressure washer so that the flue will be as straight aspossible and protrude through the roof at a proper heightand location to provide adequate draft. This oil firedpressure washer must have a draft regulator installed inthe flue (available from most heating contractors). A draftregulator will permit proper upward flow of exhaust fluegases.

Oil BurnerBurner Air Adjustment: The oil burner on this machineis preset for operation at altitudes below 3000 feet. Ifoperated at higher altitudes, it may be necessary to adjustthe air band setting. Adjust the air band for a #1 or #2smoke spot on the Bacharach scale.

To adjust, start machine and turn burner switch ON (referto Operation for details). Loosen locking screw (refer toFigure 10) and close air band until black smoke appearsfrom burner exhaust vent. Note air band position. Next,slowly open the air band until white smoke just starts toappear. Turn air band halfway back to the black smokeposition previously noted. Tighten locking screw.

Figure 10 - Oil Burner Adjustment

OIL BURNER

AIR BAND

LOCKING SCREW

Hotsy 550D

CAUTION: If white smoke appears from burnerexhaust vent during start-up or operation, discontinueuse and readjust air bands.

NOTE: If a flue is installed, have a professional ser-viceman adjust your burner for a #1 or #2 smoke spoton the Bacharach scale.

OPERATION

Before Starting

WARNING: Check hoses, guns, fittings, and fuel con-nections daily for signs of wear, cracks and loose-ness, and replace as required.

1. Read all manuals provided with this pressure washer.Become familiar with location and function of alloperating and safety controls.

2. Connect water supply hose to the standard gardenhose connector. The water faucet and supply hosemust be capable of providing 2.2 GPM.

3. Fill fuel tank. Use kerosene, #1 grade home heatingoil, or #1 or #2 diesel fuel. DO NOT USE GASOLINE,CRANKCASE OIL DRAININGS OR WASTE OIL.

4. Check pump oil level.5. If detergents are to be used, only use detergents

intended for pressure washers. Follow instructions onthe detergent container.

Electrical Connections

WARNING: Make sure all switches and controls arein the OFF position prior to plugging in.

WARNING: DO NOT stand in water while plugging andunplugging electrical cord.

CAUTION: This cleaner is equipped with a UL approvedground fault circuit interrupter (GFCI) power cord. UseUL grounded type receptacles of proper voltage andamperage ratings. Where a properly grounded recep-tacle is not available, it is the personal responsibilityof the owner to have one installed. Always discon-nect power before servicing your cleaner.

Connect electrical cord and test the GFCI using the resetand test procedures conveniently located on the GFCIdevice. The GFCI must be reset and tested with everyuse. Do not use machine if the GFCI device fails test.

Nozzle Installation

IMPORTANT: Before installing on initial start-up turnon the water supply, and allow water to run from theend of the wand until clear to prevent the nozzle fromclogging.

IMPORTANT: If the pressure washer has not been usedfor an extended period of time, remove the nozzle from

the end of the wand and turn on water supply. Allowwater to run from the end of the wand until clear.

1. Install adjustable pressure nozzle on end of the wand.See Figure 11.

Figure 11 - Nozzle Installation/Manual Trigger Lock

ADJUSTABLE PRESSURE NOZZLE

WAND

MANUAL TRIGGER LOCK

IMPORTANT: The trigger gun provided with this pres-sure washer is equipped with a manual trigger lockto prevent accidental operation of the trigger gun,refer to Figure 11. The trigger lock should be usedwhenever the trigger gun is not in use.

To Start

DANGER: Do not point wand or gun at yourself orat any person. Bodily injury may result from waterunder high pressure.

WARNING: Wear eye, ear, hand, foot, and skin protec-tion at all times while operating equipment.

IMPORTANT: The water must be turned on beforestarting. Running the pump dry will cause damage topump seals and void warranty.

IMPORTANT: Do not allow the machine to run inbypass for more than 10 minutes at any one time ordamage to pump may occur.

1. Turn water on.2. Hold gun firmly, squeeze trigger of trigger gun and

turn pump switch ON. Allow air to purge from system.3. If HOT water is desired, turn burner switch ON.

Adjust thermostat to desired temperature. The burnerwill fire immediately with a small puff of smoke.If smoke continues refer to the TroubleshootingGuide in this manual. When the trigger gun is closedthe burner will turn off.

To Clean

DANGER: Do not put hand or fingers in spray fromwand. Bodily injury may result from water under highpressure.

The detergent injector valve operates by reducing thevolume of water, thus a vacuum is achieved and detergentis drawn into the system. DO NOT reduce the water inlet

Hotsy 550D

flow so the pump cavitates due to water starvation.Operating a pump with insufficient water will damage thepump seals.

1. Insert detergent line and screen into container ofdetergent.

2. Completely open detergent control knob located onthe side of the detergent injector valve.

3. Start the detergent suction by rotating the wateradjustment knob of the detergent injector valve. SeeFigure 12. Turning the knob counterclockwise will pulldetergent into the system. The flow may beobserved through the clear detergent line. Secure theknob position with the knurled nut.

Figure 12 - Detergent Injector Valve

WATER ADJUSTMENT KNOBWATER INCREASE

WATER DECREASE

DETERGENTOFF

DETERGENTON

DETERGENT INJECTOR VALVE

4. The side control knob can now be adjusted to meterthe desired amount of detergent.

5. Select the width of your nozzle spray pattern by turn-ing the black knob on the nozzle. See Figure 13. Pat-tern can be from 0° through 80° fan spray. Releasethe trigger of the trigger gun prior to making any spraypattern adjustments.

Figure 13 - Nozzle Spray Pattern

6. Wash from the bottom to the top, using side to sidemotions. This washes away heavy dirt and allows thedetergent to soak as you work toward the top.

7. Do not wash at a 90° angle to the work (straight at it).This will allow water to splash back at you andreduces your cleaning power. Wash at a 30° to 60°angle to the work. This will allow the water to splashaway from you and the water will wash the dirt awayfaster and easier.

OUTER HOUSING

SOLIDSTREAM

FANSPRAY

8. Use the width of the spray pattern to wash in a widepath. Overlap spray paths for complete coveragewashing from side to side, using slow, steadymotions.

9. The nozzle should be 12” to 24” from work, closer fortough areas. Be careful on painted or delicate sur-faces, the pressure may damage surface if nozzle istoo close.

10. Small parts should be washed in a basket so the pres-sure does not push them away. Larger, lightweightparts should be clamped down so the pressure doesnot push them away.

11. Turn the side detergent control knob clockwise (CW)for detergent decrease. Wait for detergent to clear.Always rinse with cold water after using detergent.Rinse from the top to the bottom to prevent detergentfrom dripping onto a rinsed area. For the best results,contact your Hotsy dealer to help you select the bestdetergent for your application.

To Stop1. If detergents were used, draw clear water through the

detergent line to purge detergent.2. If burner was used, turn off burner switch and allow

pump to run cold water through coil.3. Push OFF pump switch.4. Turn OFF water supply.5. Squeeze trigger gun open to relieve system pressure.

NOTE: If the machine is unplugged from receptacle,you must reset the GFCI power cord when machineis plugged in. Always test GFCI before each use. Seeinstructions in the Electrical Connections section ofthis manual.

STORAGE & MAINTENANCE

Storage

DANGER: Do not store flammable liquids (gasoline,diesel fuel, solvents, etc.) near pressure washer, orin non-ventilated areas.

1. Protect from freezing by storing in a heated area, orby flushing the system with antifreeze (use an auto-motive engine antifreeze or windshield washer sol-vent to antifreeze). To flush the system with antifreeze,attach a short length of hose to the garden hose con-nector located on the pump. Place the other end ofthe hose into a container of antifreeze. Start machineand allow to run until antifreeze flows from the end ofthe wand. Squeeze and release the trigger of the trig-ger gun several times to antifreeze the unloader sys-tem. Also draw antifreeze through the detergent inletline to antifreeze the detergent system. For addedprotection after antifreezing, disconnect the pressurehose from machine and remove the coil drain plug(refer to Figure 1 for location). After coil has drained,

Hotsy 550D

replace pressure hose and coil drain plug. If the pres-sure washer is not to be used for an extended lengthof time, it is recommended that the system be flushedwith antifreeze for rust protection.

Maintenance

WARNING: Unauthorized machine modification or useof non-approved replacement parts may cause per-sonal injury and/or property damage and will void themanufacturer warranty.

PumpLubrication: To lubricate pump, use 30W non-detergentoil for pump crankcase. Crankcase must be filled to centerof sight glass window found on the side of the pump, referto Figure 14. During the break-in period, make sure theoil is changed after the first 25 hours of operation. Afterthat, replace oil every 3 months or 300 hours of operation,whichever comes first.

Fuel Tank1. When reinstalling or replacing the drain plug in the

fuel tank, refer to Figure 15 for proper installation.2. Insert the drain plug in the hole so that the face of the

expansion plug is flush against the tank.3. Tighten the wing nut to 1/2” to 5/8” as shown.

Figure 14 - Pump Lubrication

Proper Pump Care• DO NOT pump acids.

• DO NOT allow pump to run dry.

• Winterize if storing in freezing temperatures, referto Storage for details.

• Use a water softener on the water system if knownto be high in mineral content.

• Use only high quality detergents and follow manu-facturer’s mix recommendations.

• Flush the system with clean water immediatelyafter using detergent solutions.

• Clean filter screen on detergent inlet line periodi-cally.

• Flush the pressure washer system with antifreezeif storing for an extended period of time, refer toStorage for details.

Figure 15 - Fuel Tank Drain Plug Installation

Pump MotorOn a yearly basis, oil pump motor per instructions onmotor nameplate.

Relief Valve

WARNING: The relief valve on this pressure washerhas been factory set and sealed and is a field nonad-justable part. Tampering with the factory setting maycause personal injury and/or property damage, andwill void the manufacturer warranty. For replacementparts refer to Figure 20.

Unloader Valve

WARNING: The unloader valve on this pressurewasher has been factory set and sealed and is a fieldnonadjustable part. Tampering with the factory set-ting may cause personal injury and/or property dam-age, and will void the manufacturer warranty. Forreplacement parts refer to Figure 24.

Burner Fuel FilterDrain any water which has accumulated in fuel filter andclean or replace elements as needed. For replacementparts refer to Figure 21.

Heating Coil:Coil Descaling: In hard water areas, scale buildup withinthe heating coil will occur. Scale deposits will decreasethe water temperature rise and may eventually clog theheating coil. Contact your local service center whendescaling is needed.

Coil Desooting: Poor grades of fuel or inadequatecombustion air will cause heavy soot buildup on theoutside surface of the heating coil. These deposits willinsulate the coil. This will restrict the air flow through thecoil, further aggravating the soot buildup. Contact yourlocal service center when desooting is needed.

EXPANSION PLUG

WING NUT

1/2” TO 5/8”

FUEL TANK

OIL FILL

SIGHT GLASS OIL DRAIN

Hotsy 550D

TROUBLESHOOTING GUIDE

SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION

Pump motor will notrun.

GFCI tripped. Reset and test GFCI with every use.Follow instructions under Operation.

No voltage to machine Test power supply and correct.

Pump motor reset button (thermaloverload protector) tripped.

Push reset button on pump motor. Iftripped, check for proper voltage orclogged pressure nozzle.

Excessive pressure due to cloggedpressure nozzle.

Clean pressure nozzle.

Pressure washer runsbut won't spray.

Tigger of trigger gun released. Squeeze trigger.

Water supply not turned on. Open water supply valve.

Clogged nozzle. Clean nozzle opening.

Low spray pressure atnozzle.

Inlet water screen clogged. Check screen and clean if necessary.

Inadequate water supply. Fully open faucet. Check for kinked ordamaged hose. Use 5/8 inch minimumhose. Check for debris clogging inletscreen.

Partially clogged or damagednozzle.

Clean or replace.

Air being drawn through detergentinlet line.

Refill detergent container. Ensure thatpickup screen is fully immersed.

Uneven spray pattern. Partially clogged or damagednozzle.

Clean or replace.

Pressure washer will notproduce hot water.

Burner switch in OFF position. Place switch in ON position.

Inadequate fuel supply. Refill fuel tank. Use only recom-mended fuels. Refer to Before Start-ing under Operation.

Pump switch turned OFF. Pump must be running before burnerwill light.

Inadequate water supply. Fully opened faucet. Check for kinkedor damaged hose. Use 5/8 inch min-imum hose. Check for debris clogginginlet screen.

Trigger of trigger gun released. Squeeze trigger. Water must be spray-ing for burner to light.

Defective pressure switch. Replace pressure switch.

Fuel valve closed. Check that fuel valve on fuel tank isopen.

Hotsy 550D

IMPORTANTIf the pressure washer demonstrates other symptoms or the corrective actionslisted do not correct the problem, contact the local authorized Hotsy ServiceCenter. The Hotsy Service Center can be identified by contacting:

Customer Service DepartmentThe Hotsy Corporation

21 Inverness Way East • Englewood, Colorado 80112(303) 792-5200

TROUBLESHOOTING GUIDE

SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION

Pressure washer will notproduce hot water. ...continued

Burner motor reset button (thermaloverlaod protector) tripped.

Push reset button on burner motor. Iftripped, check for proper voltage.

Clogged fuel filter. Replace fuel filter.

Thermostat set too low. Adjust thermostat to desired tem-perature.

Burner smokes. Air bands need to be adjusted. Readjust air band per the Oil Burnersection under Installation.

Improper fuel. Use proper fuel.

Poor or no detergent flow. Inadequate detergent supply. Refill detergent container. Ensure thatpickup screen is fully immersed.

Detergent screen or hose clogged. Clean. Always start with a clean deter-gent container.

Clogged detergent injector checkvalve.

Clean check valve at detergent injectorinlet.

Detergent injector valve not setcorrectly.

Refer to To Clean for settings.

Poor cleaning. Improper detergent concentration ormixing.

Mix detergent per manufacturer'sinstructions. Ensure that powdereddetergents are fully dissolved.

Wrong detergent for the application. Select appropriate detergent.

Rinsing with hot water. A final rinse with cold water will reducewater spotting.

Hotsy 550D

FOR HELP OR ADDITIONAL INFORMATION, CONTACT:Customer Service DepartmentThe Hotsy Corporation21 Inverness Way EastEnglewood, CO 80112(303) 792-5200

When ordering from your dealer, please provide the following:

Model Number: 550D

Machine Serial Number: ________________________________

Component Part Number: _______________________________

Description: __________________________________________

Hotsy 550D

Figure 16 - Machine Assembly, Side View

Ref. No. Part No. Description Qty.

15 983020 Wheel 4

16 220361 Axle 2

17 ■ Flat Washer 5/8” 8

18 848616 Push Nut 4

19 817322 Hubcap 4

20 ■ Bolt 5/16" - 18 x 1-1/2" 5

21 ■ Flange Nut 5/16" - 18 8

22 Fig. 21 Burner Assembly 1

23 873778 Pancake Insulation 1

24 646012 Decal Warnings 1

25 262020 GFCI Cord hanger 1

NS 646011 Decal Operating Instructions 1

NS = Not Shown

■ Standard hardware item available locally.


1 210001 Handle 1

2 630610 Vinyl Cap 1

3 873776 Coil Insulation 1

4 834385 Decal Hotsy Logo 2

5 824115 Lid Clip 4

6 801102 Hex Nipple 3/8” x 1-1/2” 1

7 954631 Tee 3/8” 1

8 715744 Coil Drain Plug 1

9 826020 Strain Relief 1

10 Fig. 19 Water Inlet Assembly 1

11 375346 Chassis 1

12 ■ Bolt 1/4” - 20 x 1/2” 2

13 ■ Flat Washer 1/4” 2

14 834086 Decal Chassis 2

1 2 3 4 5 6,7,8

20,21,25

24

23

21,22

20,21

15,16,17,18,19 14 12,13

11

10

9

Hotsy 550D


10 834159 Decal Hotsy Detergent 1

11 824102 Snap-In Wire Clip 1

12 834154 Decal Winterize 1

13 630609 Cord Clamp 1

14 ■ Screw #10 - 24 x 1/2" 2

15 ■ Flange Nut #10 - 24 2

16 861644 Hose Hanger 1



1 859806 Grommet 1

2 226222 Coil 1

3 815328 Snap Bushing 1

4 815329 Snap Bushing 1

5 Fig. 24 Pump Assembly 1

6 444438 Decal Detergent Metering 1

7 823932 Retaining Clamp 1

8 ■ Flange Nut 1/4" - 20 2

9 444437 Decal Water Metering 1

Figure 17 - Machine Assembly, Top View

1 2 3 4 5

6

7,8

9

10111213,14,1516

Hotsy 550D


8 784297 Motor 1

9 ■ Fender Washer 5/16” 3

10 375347 Coil Tank 1

11 867207 Pressure Hose 1

12 Fig. 27 Trigger Gun/Wand Assembly 1



1 213044 Burner Exhaust Vent 1

2 268004 Insulation 1

3 860102 Retaining Ring 1

4 Fig. 26 Control Box Assembly 1

5 Fig. 20 Coil Outlet Assembly 1

6 Fig. 23 Fuel Tank Assembly 1

7 ■ Flange Nut 5/16” – 18 7

Figure 18 - Machine Assembly, Front View

1211

541,2,3

7,9,10

8

7

6

Hotsy 550D


7 867395 Hose 3/8" ✽

8 823989 Hose Clamp 1

9 961534 Tubing 1/4" ✽

10 935159 Filter Screen 1

✽ Order amount needed in feet.


1 801126 Garden Hose Connector 1

2 856035 Garden Hose Connector Gasket 1

3 875575 Garden Hose Connector Spring 1

4 873596 Detergent Injector 1

5 844753 Street Elbow 3/8" 1

6 898035 Nipple 3/8" x 3/8" Hose 1

Figure 19 - Water Inlet Assembly

1,2 3 4 5

6

7

8

910

Hotsy 550D

Figure 20 - Coil Outlet Assembly


7 630717 Relief Valve Cartridge 1

8 ■ Screw 4 mm x 6 mm 1

9 780565 Copper Washer 2

10 915630 Plug 3/8" 2




1 698247 Hex Nipple 1/2” x 2” 1

2 961532 Hose 3/8" ✽


4 799501 Elbow 1/4” x 3/8” Hose 1

5 875555 Relief Valve Seat 1

6 783845 Manifold 1

9,10 8

4

3

2

5 6 7

1

Hotsy 550D


7 799131 Nipple 3/8" x 1/4" Hose 1

NS 826167 Strain Relief 1

NS 703127 Strain Relief Nut 1

NS = Not Shown.

Replacement Parts

✪ 875490 Filter Screen Replacement


1 615617 Oil Burner Fig. 22 1

2 698020 Nipple 1/4" x 1/4" Hose 1

3 644750 Street Elbow 1/4" 1

4 698200 Pipe Nipple 1/4" x 2-1/2" 1

5 615279 Bushing Reducer 3/8" x 1/4" 1

6 ✪ 851080 Fuel Filter 1

Figure 21 - Burner Assembly

12

3 4 5 6 7

AIR CONE

5/16”1/8”

ELECTRODE NOZZLE

ELECTRODESETTINGS

5/16”1/8”

Hotsy 550D


7 880806 Fuel Line 1

8 676865 Blower Fan 1

9 825924 Coupling 1

10 890134 Motor 1

NS 877667 Tune-up Repair Kit 1

NS = Not Shown


1 919791 Fuel Pump 1

2 944412 Solenoid Valve 1

3 901230 Solenoid Metering Bolt 1

4 661302 Electrode (Pair) 1

5 900784 Nozzle 1

6 722447 Ignitor Assembly 1

Figure 22 - Burner Parts Breakdown

1 2 3 4 5

109876

Hotsy 550D

Figure 23 - Fuel Tank Assembly


9 707116 Green Hose 1/4" ✽

10 915620 Expansion Plug 1

11 ■ Carriage Bolt 5/16" - 18 x 1-1/2" 1

12 ■ Flat Washer 5/16" 1

13 ■ Wing Nut 5/16 "- 18 1




1 952733 Fuel Tank 1

2 834153 Decal Fuel Type 1

3 817312 Fuel Tank Cap 1

4 815230 Bushing 2

5 309294 Nipple 3/8" Hose x 1/4" Hose 1

6 867368 Hose 1/4" Black ✽


8 971511 Fuel Shut-off Valve 1

1 2 3

4 5 6 7

4 8 9 7

10,11,12,13

Hotsy 550D


9 651485 Banjo Bolt 2

10 936633 Washer 4

11 783654 Vibration Mount 1

Replacement Parts

✪ 753026 Discharge Repair Kit 1

✪ 753025 O-Ring Repair Kit 1

✪ 753027 Stem Repair Kit 1


1 HC165LA Pump Fig. 25 1

2 707221 Hose 3/8" x 24" 1

3 644802 Street Elbow 3/8" 1

4 829596 Manifold Plug 1

5 644751 Elbow 3/8" 1

6 844753 Street Elbow 3/8" 1

7 898035 Nipple 3/8" x 3/8" Hose 1

8 ✪ 921370 Unloader Valve 1

Figure 24 - Pump Assembly

1 23 4

5

6

7

89,1011

Hotsy 550D

6,43

34 35 13 14 9 17 4 15

10 1 2 3 7

4 5

16

4038

3642413937

8

35 34

1114919212321

18202222

512

27

5

122526

2423

28

27

28

29

30313233

Figure 25 - Pum

p, Exploded V

iew

Hotsy 550D


27 915631 Manifold Plug 4

28 926656 Manifold Plug O-Ring 4

29 ★ Valve Cage 4

30 ★ Valve Spring 4

31 ★ Valve Plate 4

32 ★ Valve Seat 4

33 ★ Valve Seat O-Ring 4

34 735317 Hex Screw 8

35 780561 Washer Hex Screw 8

36 928463 Connecting Rod Pin 2

37 ✤ Plunger Assembly Bolt 2

38 ✤ Plunger Bolt O-Ring 2

39 ✤ Teflon Ring 2

40 ✤ Copper Spacer 2

41 ✤ Ceramic Plunger Sleeve 2

42 ✤ Copper Spacer 2

43 818575 Sight Glass O-Ring 1

NS 935292 Setscrew 6 mm x 10 mm 2

NS = Not Shown

Replacement Parts Qty/Pump

◆ 877686 Seal Packing Kit 20 mm 2 Cyl 1

▼ 877685 Complete Seal Packing Kit 2

★ 877648 Complete Valve Assembly Kit 4

❖ 877687 Plunger Seal Kit 2 Cyl 1

✤ 877684 Ceramic Sleeve Kit 2

918430 Hawk Tool Kit 1


1 928706 Connecting Rod Assembly 2

2 855889 Crankcase Cover Gasket 1

3 827324 Crankcase Cover 1

4 855893 Gasket 2

5 915630 Plug 3/8" 3

6 878575 Sight Glass 1

7 735313 Allen Crankcase Screw 4

8 827319 Crankshaft Seal 1

9 808895 Bearing 2

10 630712 Crankshaft HC165 1

11 808896 Bearing Flange 1


13 867008 Bearing Housing 1

14 926648 Bearing Housing O-Ring 2

15 906532 Oil Dipstick 1

16 915835 Plunger Rod 2

17 827318 Crankcase 1

18 ▼ ❖ Plunger Seal 2

19 ▼ ◆ Pressure Ring O-Ring 2

20 ▼ Pressure Ring 20 mm 2

21 ▼ ◆ V-Sleeve 20 mm 4

22 ▼ ◆ Support Ring 20 mm 4

23 ▼ Intermediate Ring 2

24 884477 Manifold Housing 1

25 780560 Washer 6

26 612699 Manifold Stud Bolt 6

Hotsy 550D


13 825951 Power Cord w/GFCI 1

14 825989 Cord 12/3 SJO ✽

15 826009 Cord 16/4 SJO ✽

16 ✪ 875651 Pressure Switch 1


18 847750 Wire Cover ✽



Replacement Parts

✪ 753134 O-Ring Kit 1

✪ 875653 Switch 1

Figure 26 - Control Box Assembly

15

14

13

12

1716

18

1 2 3 4 5 6 7 8 9

10

11


1 950187 Rocker Switch 2

2 645930 Control Box Decal 1

3 835150 Thermostat Dial 1

4 915390 Thermostat Mounting Plate 1

5 ■ Screw 4 mm x 6 mm 2

6 615412 Control Box Front 1

7 955930 Thermostat 1

8 630649 Control Box Channel 2

9 615414 Control Box Back 1

10 ■ Flange Nut 1/4" - 20 4

11 ■ Bolt 1/4" - 20 x 3/4" 4

12 826184 Strain Relief 4

Hotsy 550D


5 860447 Trigger Gun Fig. 28 1

Replacement Parts

✪ 859762 Insulator Grip Assembly 1

✪ 859763 Side Handle Grip 1


1 799102 Adjustable Pressure Nozzle 1

2 ✪ 878917 Wand 1

3 826169 Quick Disconnect 1

4 915786 Quick Disconnect Plug 1

Figure 27 - Trigger Gun/Wand Assembly

1 2 3 4 5

Hotsy 550D


1 817320 Valve Cap 1

2 ✪ Valve Cap O-Ring 1

3 ✪ Valve Seat Spring 1

4 ✪ Valve Spring 1

5 ✪ Ball 1

6 ✪ Valve Seat 1

7 ✪ Valve Seat O-Ring 1

8 812801 Valve Body 1

9 ✪ Plunger Guide Seat O-Ring 1

10 ✪ Plunger Guide Backring 2

11 ✪ Plunger Guide O-Ring 1

12 ✪ Plunger Guide 1

13 ✪ Plunger Rod 1


14 ✪ Plunger Seat 1

15 914141 Trigger Pin 1

16 860495 Left Gun Shelf 1

17 735316 Phillips Screw 6

18 914142 Trigger Lock Pin 1

19 960271 Trigger 1

20 881941 Trigger Lock Lever 1

21 936460 Inlet Pipe Seat 2

22 914285 Inlet Pipe 1

23 851190 Inlet Fitting 1

24 860496 Right Gun Shell 1

Replacement Parts

✪ 877471 Trigger Gun Repair Kit

Figure 28 - Trigger Gun, Exploded View

12

34

56

78

1011

10

1213

14

15

16

1718

1920

21

22

21

24

9

23

Hotsy 550D

Figure 29 - Wiring Diagram

MOTOR JUNCTION BOX

SMALLCAPACITOR

LARGECAPACITOR

“E” WHT

“J” W

HT#4

YLW

#1 W

HT

“J” W

HT#4

YLW

#1 W

HT

TOMOTOR

MOTOR RESET BUTTON

TO BURNERIGNITOR

TO FUELSOLENOID

ORN

WHT

WHT

BLK

OIL BURNER

TO BURNERMOTOR

20 AMP/115 VOLTPOWER CORD

W/GFCI

THERMOSTAT

BURNER

BLK

“E” WHT WHTWHT RED

GRNBLKWHT

RED

GRN

BLK

WHT

BLK

WHT

GRN

BLKWHT

GRNBLKWHT

GRNBLKWHTRED

REDBRN

CAPILLARY TUBE

BLK

WHT

GRN

GRN

GRN

GRN

CAPI

LLAR

Y

TU

BEBR

NBL

KW

HTBL

KW

HT

PUMP BLK

WHT

BLK

WHT

BLK

WHT

BLK

WHT

GRN

CAPILLARY TUBE

BRN

12

C

784302-6-98

WARRANTYHOTSY LIMITED WARRANTY:

Hotsy products are warranted by the Hotsy Corporation (Hotsy) to be free of defects in material andworkmanship under normal use, for a period of ONE YEAR from the date of the original purchase.Items that fail due to normal wear such as o-rings hoses, seals, quick couplers, nozzles, gunjets, etc.or damage resulting from neglect, abuse, tampering, or modification are not covered under this war-ranty. Hotsy will at its option repair or replace any part covered by this warranty which is defectiveunder normal use for one year at no charge for parts or labor. All defects must be verified by anauthorized Hotsy service location.

EXCEPTIONS TO THE ONE YEAR WARRANTY FOR PARTS ONLY ARE:Hawk Pumps: SEVEN YEAR Warranty (LIFETIME Brass Manifold Warranty-

Even Against Freezing)

Heating Coils: FOUR YEAR Warranty

LIMITATION OF LIABILITY:To the extent allowable under applicable law, Hotsy liability for consequential and incidental damages isexpressly disclaimed. Hotsy liability in all events is limited to, and shall not exceed, the purchase pricepaid for the equipment. Hotsy liability is limited to repair or replacement of defective parts only, at theoption of the Hotsy Corporation.

WARRANTY DISCLAIMER:Hotsy has made a diligent effort to illustrate and describe the product in this literature accurately;however, such illustrations and descriptions are for the sole purpose of identification, and do notexpress or imply a warranty that the product is merchantable or fits a particular purpose, or that theproduct will necessarily conform to the illustrations or descriptions.

PRODUCT SUITABILITY:Many states and localities have codes and regulations governing sales, construction, installation, and/or use of products for certain purposes, which may vary from those in neighboring areas. Whileattempts to assure that its products comply with such codes, it cannot guarantee compliance andcannot be responsible for how the product is installed or used. Before purchase and use of a product,please review the product application, and national and local codes and regulations, and be sure thatthe product, installation, and use will comply with them.

PROMPT DISPOSITION:Hotsy will make a good faith effort for prompt correction or other adjustments with respect to anyproduct which proves to be defective within limited warranty. For any product believed to be defectivewithin limited warranty, contact dealer from whom product was purchased. Dealer will give additionaldirections. If unable to resolve satisfactorily, write to Hotsy at address below, giving dealer's name,address, date of purchase, model, serial number, and describing the nature of the defect. If productwas damaged in transit to you, file claim with freight carrier.

The Hotsy Corporation21 Inverness Way EastEnglewood, Colorado 80112(303) 792-5200

operating instructions and parts manual...

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