900/1400 OIL-FIRED SERIES OPERATING INSTRUCTIONS AND PARTS MANUAL THE HOTSY CORPORATION ENGLEWOOD, CO (303) DATE PURCHASED:

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1 900/1400 OIL-FIRED SERIES OPERATING INSTRUCTIONS AND PARTS MANUAL Thank you for purchasing a Hotsy Pressure Washer. This manual covers the operation and maintenance of the 900/1400 Series, Oil Fired pressure washer. All information in this manual is based on the latest product information available at the time of printing. Hotsy, Inc. reserves the right to make changes at any time without incurring any obligation. Read instructions carefully before attempting to assemble, install, operate or service this pressure washer. Failure to comply with instructions could result in personal injury and/or property damage! NOTE: This manual is intended for use with the following models only: LISTED 980SS 990SS 990SS SS 1410SS 1420SS 1420SS SS c SERIAL NUMBER: THE HOTSY CORPORATION 21 INVERNESS WAY EAST ENGLEWOOD, CO (303) DATE PURCHASED: FOR SALES AND SERVICE, PLEASE CONTACT:

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3 980SS SPECIFICATIONS Pump Volume At Pump Head: 4.0 GPM/240 GPH Pump Pressure At Pump Head: 2000 PSI Burner Type: Fuel Oil Fired, 342,900 BTU/Hr. Burner Fuel Pressure: 150 PSI Machine Voltage: 230VAC/60Hz/1Ph Total Machine Amperage: 29 Amps Machine Weight: 465 Lbs. Shipping Weight: 515 Lbs. Exhaust Stack Size: 8" Machine Dimensions: Length=45", Width=18", Height=48" 1410SS SPECIFICATIONS Pump Volume At Pump Head: 4.0 GPM/240 GPH Pump Pressure At Pump Head: 3000 PSI Burner Type: Fuel Oil Fired, 342,900 BTU/Hr. Burner Fuel Pressure: 150 PSI Machine Voltage: 230VAC/60Hz/1Ph Total Machine Amperage: 37 Amps Machine Weight: 535 Lbs. Shipping Weight: 585 Lbs. Exhaust Stack Size: 8" Machine Dimensions: Length=45", Width=18", Height=48" 990SS SPECIFICATIONS Pump Volume At Pump Head: 4.0 GPM/240 GPH Pump Pressure At Pump Head: 2000 PSI Burner Type: Fuel Oil Fired, 342,900 BTU/Hr. Burner Fuel Pressure: 150 PSI Machine Voltage: 230VAC/60Hz/3Ph Total Machine Amperage: 19 Amps Machine Weight: 460 Lbs. Shipping Weight: 510 Lbs. Exhaust Stack Size: 8" Machine Dimensions: Length=45", Width=18", Height=48" 1420SS SPECIFICATIONS Pump Volume At Pump Head: 4.0 GPM/240 GPH Pump Pressure At Pump Head: 3000 PSI Burner Type: Fuel Oil Fired, 342,900 BTU/Hr. Burner Fuel Pressure: 150 PSI Machine Voltage: 230VAC/60Hz/3Ph Total Machine Amperage: 25 Amps Machine Weight: 525 Lbs. Shipping Weight: 575 Lbs. Exhaust Stack Size: 8" Machine Dimensions: Length=45", Width=18", Height=48" 990SS-208 SPECIFICATIONS Pump Volume At Pump Head: 4.0 GPM/240 GPH Pump Pressure At Pump Head: 2000 PSI Burner Type: Fuel Oil Fired, 342,900 BTU/Hr. Burner Fuel Pressure: 150 PSI Machine Voltage: 208VAC/60Hz/3Ph Total Machine Amperage: 20 Amps Machine Weight: 460 Lbs. Shipping Weight: 510 Lbs. Exhaust Stack Size: 8" Machine Dimensions: Length=45", Width=18", Height=48" 1420SS-208 SPECIFICATIONS Pump Volume At Pump Head: 4.0 GPM/240 GPH Pump Pressure At Pump Head: 3000 PSI Burner Type: Fuel Oil Fired, 342,900 BTU/Hr. Burner Fuel Pressure: 150 PSI Machine Voltage: 208VAC/60Hz/3Ph Total Machine Amperage: 25 Amps Machine Weight: 525 Lbs. Shipping Weight: 575 Lbs. Exhaust Stack Size: 8" Machine Dimensions: Length=45", Width=18", Height=48" 993SS SPECIFICATIONS Pump Volume At Pump Head: 4.0 GPM/240 GPH Pump Pressure At Pump Head: 2000 PSI Burner Type: Fuel Oil Fired, 342,900 BTU/Hr. Burner Fuel Pressure: 150 PSI Machine Voltage: 460VAC/60Hz/3Ph Total Machine Amperage: 10 Amps Machine Weight: 485 Lbs. Shipping Weight: 535 Lbs. Exhaust Stack Size: 8" Machine Dimensions: Length=45", Width=18", Height=48" 1423SS SPECIFICATIONS Pump Volume At Pump Head: 4.0 GPM/240 GPH Pump Pressure At Pump Head: 3000 PSI Burner Type: Fuel Oil Fired, 342,900 BTU/Hr. Burner Fuel Pressure: 150 PSI Machine Voltage: 460VAC/60Hz/3Ph Total Machine Amperage: 14 Amps Machine Weight: 550 Lbs. Shipping Weight: 600 Lbs. Exhaust Stack Size: 8" Machine Dimensions: Length=45", Width=18", Height=48" Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 3

4 TRIGGER GUN WAND PRESSURE NOZZLE BURNER EXHAUST VENT HOSE HANGER RELIEF VALVE BURNER SWITCH THERMOSTAT PUMP SWITCH PRESSURE HOSE CAUTION WAND HOLDER OIL BURNER NOZZLE HOLDERS DETERGENT CONTROL HOSE REEL MOUNT Figure 1 - Machine Component Layout, Front View Page 4 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

5 PUMP MOTOR ELECTRICAL SUPPLY CORD PUMP BELT TENSIONER WATER INLET DETERGENT INLET LINE FUEL TANK FLOAT TANK Figure 2 - Machine Component Layout, Side View Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 5

6 ASSEMBLY Unpacking Unpack carefully. Wear safety glasses or goggles while unpacking, assembling or operating pressure washer. If there are missing components or hidden damage immediately contact distributor or carrier concerning discrepancies. 1. Cut strapping band from pressure washer and pallet. 2. Remove pressure washer from pallet. Parts Included Pressure Washer Pressure Hose Hose Hanger Wand Wand Holder Female Electrical Plug (3 Phase Machines) Hose Reel Mount W/Hardware Parts Box Containing: Pressure Nozzles (3 ea.) Quick Disconnects (2 ea.) Quick Disconnect Plug Trigger Gun 5/16" - 18 x 3/4" Bolts (2 ea.) 5/16" - 18 Flange Nuts (2 ea.) Detergent Metering Orifice Plugs (2 ea.) Operating Instructions and Parts Manual Tools Required 10" Adjustable Crescent Wrenches (2 ea.) Teflon Tape Blade Screwdriver Pressure Hose 1. Use teflon tape on plumbing connections to prevent leakage. 2. Install pressure hose on machine as shown in Figure 3. Wand Components 1. Assemble wand components as shown in Figure 4. Connect pressure hose to trigger gun. QUICK DISCONNECT PLUG QUICK DISCONNECT TRIGGER GUN PRESSURE HOSE Figure 4 - Assembling Wand Components NOTE: The nozzle is not to be installed at this time. 2. Make sure that all plumbing connections are tight. Wand Holder 1. Mount wand holder to chassis as shown in Figure 5. 5/16" -18 FLANGE NUT Figure 5 - Installing Wand Holder Hose Reel Mount WAND WAND HOLDER 5/16"-18 x 3/4" BOLT 1. Install hose reel mount to chassis as shown in Figure 6. HOSE REEL MOUNT RELIEF VALVE CAUTION 5/16" - 18 x 2" BOLT FLAT WASHER AND LOCKNUT PRESSURE HOSE Figure 3 - Installing Pressure Hose Figure 6 - Hose Reel Mount Installation Page 6 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

7 Hose Hanger 1. Install the hose hanger on the machine coil tank as shown in Figure 7. HOSE HANGER Figure 7 - Hose Hanger Installation INSTALLATION Responsibility The owner and/or user must have an understanding of the manufacturer s operating instructions and warnings before using this Hotsy 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 comprehends its contents. Owner and/or user must study and maintain for future reference the manufacturers 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. Getting Started POCKET ON COIL TANK IMPORTANT: Proper initial installation of equipment will assure more satisfactory performance, longer life and lower maintenance cost. The pressure washer should be run on a level surface and in a protected area where it is not readily influenced by outside sources such as strong winds, freezing temperatures, rain, etc. The pressure washer should be located to assure easy access for filling of fluids, adjustments and maintenance. Normal precautions should be taken by the operator to prevent moisture from reaching the pressure washer. It is recommended that a partition be made between the wash area and the pressure washer to prevent direct spray from the wand coming in contact with the pressure washer. Moisture reaching the equipment will reduce the pressure washer s life. All installations should comply with the local codes covering such installations. Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 GENERAL SAFETY INFORMATION WARNING READ OPERATOR S MANUAL THOROUGHLY PRIOR TO USE. CAUTION: To reduce the risk of injury, read operating instructions carefully before using. 1. Read the owner's manual thoroughly. Failure to follow instructions could cause malfunction of the machine and result in death, serious bodily injury and/or property damage. 2. Know how to stop the machine and bleed pressures quickly. Be thoroughly familiar with the controls. 3. Stay alert watch what you are doing. 4. All installations must comply with local codes. Contact your electrician, plumber, utility company or the selling distributor for specific details. WARNING: Risk of asphyxiation. WARNING Use this product only in a well ventilated area. RISK OF ASPHYXIATION. USE ONLY IN A WELL VENTILATED AREA. WARNING KEEP WATER SPRAY AWAY FROM ELECTRICAL WIRING. 5. Risk of explosion do not spray flammable liquids or operate in an explosive location. Operate only where open flame or torch is permitted. WARNING: Keep water spray away from electrical wiring or fatal electrical shock may result. 6. To protect the operator from electrical shock, the machine must be electrically grounded. It is the responsibility of the owner to connect this machine to a UL grounded receptacle of proper voltage and amperage ratings. Do not spray water on or near electrical components. Do not touch machine with wet hands or while standing in water. Always disconnect power before servicing. 7. Grip cleaning wand securely with both hands before starting the cleaner. Failure to do this could result in injury from a whipping wand. WARNING: High pressure stream of WARNING fluid that this equipment can produce can pierce skin and its underlying tissues, leading to serious injury and possible amputation. 8. High pressure developed by these machines can cause personal injury or equipment damage. Use caution when operating. Do not direct discharge stream at people, or severe injury and/or death may result. HIGH PRESSURE SPRAY CAN PIERCE SKIN AND TISSUES. Page 7

8 9. Never make adjustments on machine while in operation. WARNING: High pressure spray WARNING can cause paint chips or other particles to become airborne and fly at high speeds. PROTECTIVE EYEWEAR AND CLOTHING MUST BE WORN. 10. Eye safety devices and foot protection must be worn when using this equipment. 11. When the machine is working, do not cover or place in a closed space where ventilation is insufficient. 12. Machines with shut-off trigger gun should not be operated with the trigger in the off position for extensive periods of time as this may cause damage to the pump. 13. Protect from freezing. 14. Be certain all quick coupler fittings are secured before using pressure washer. 15. Do not allow acids, caustic, or abrasive fluids to pass through the pump. 16. Inlet water must be from a cold, fresh city water supply. 17. To reduce 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. 18. The best insurance against an accident is precaution and knowledge of the machine. 19. Do not operate this product when fatigued or under the influence of alcohol or drugs. Keep operating area clear of all persons. 24. Hotsy will not be liable for any changes made to our standard machines, or any components not purchased from Hotsy. 25. Do not overreach or stand on unstable support. Keep good footing and balance at all times. 26. Follow maintenance instructions specified in manual. 27. When making repairs disconnect from electrical source and shut off gas valve. 28. Turn burner off and cool to 100 F before turning machine off. 29. On natural gas and propane machines, if you smell gas extinguish any open flame, and test all joints with a soap solution. If the odor persists, call your gas supplier immediately. 30. Use extreme caution when moving pressure washer over rough or uneven surfaces. 31. When applying detergents follow the safety rules on the detergent label. Use detergent from a covered D.O.T. approved container. 32. This machine has been provided with Warning and Instruction decals for the safety of the operator. If these decals are removed or become damaged they should be replaced. Contact your dealer for replacement decals. Venting CAUTION - RISK OF ASPHYXIATION: Do not run machine indoors or in an enclosed area without the required venting, as exhaust fumes may be hazardous to your health. CAUTION: All venting must be in accordance with applicable federal and state laws, and local ordinances. Consult local heating contractors. IMPORTANT: A draft regulator shall be installed. INSTALLER UNE HOTTE DE TIRAGE. If the pressure washer is to be used in an enclosed area, a flue must be installed to vent burner exhaust to the outside atmosphere. Exhaust gases should not be vented into a wall, a ceiling, or a concealed space of a building. Be sure the flue is the same size as the burner exhaust vent on the pressure washer. Poor draft will cause the pressure washer to soot and not operate properly. When selecting the location for installation, beware of poorly ventilated locations or areas where exhaust fans may cause an insufficient supply of oxygen. Proper combustion can only be obtained when there is a sufficient supply of oxygen available for the amount of fuel being burned. If it is necessary to install the machine in a poorly ventilated area, outside fresh air may have to be piped to the burner and a fan installed to bring sufficient air into the machine. Locate the pressure washer so that the flue will be as straight as possible and protrude through the roof at a proper height and location to provide adequate draft. This oil fired pressure washer must have a draft regulator installed in the flue (available from most heating contractors). A draft regulator will permit proper upward flow of exhaust flue gases. Page 8 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

9 Oil Burner Burner Air Adjustment: The oil burner is preset for operation at altitudes below 3000 feet. If operated at higher altitudes, it may be necessary to adjust the air band setting. Adjust the air band for a #1 or #2 smoke spot on the Bacharach scale. To adjust, start machine and turn burner ON (refer to Operation for details). Loosen two locking screws found in the air shutter openings (refer to Figure 8) 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. AIR SHUTTER LOCKING SCREW AIR SHUTTER AIR BAND WARNING: DO NOT stand in water while connecting and disconnecting electrical supply. WARNING: Always disconnect power before servicing your pressure washer. IMPORTANT: Consult local building codes for exact electrical requirements. Licensed contractors may be required. IMPORTANT: This machine must be electrically grounded. LA MACHINE DOIT ÊTRE MISE À LA TERRE. Grounding Instructions: This product must be electrically grounded. If it should malfunction or break down, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This product is equipped with a cord having an equipment grounding conductor and a grounding plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances. DANGER: Improper connection of the equipment grounding conductor can result in a risk of electrocution. Check with a qualified electrician or service personnel if you are in doubt as to whether the outlet is properly grounded. AIR SHUTTER LOCKING SCREW If the desired position cannot be obtained using only the air shutter, lock the air shutter in as close a position as can be obtained, then repeat the above procedure on the air band setting. CAUTION: If white smoke appears from burner exhaust vent during start-up or operation, discontinue use and readjust air bands. NOTE: If a flue is installed, have a professional serviceman adjust your burner for a #1 or #2 smoke spot on the Bacharach scale. For additional burner component information, see Figure 21. It is recommended that the oil burner be serviced yearly or as needed. Contact your local service center. Water Supply Connect water supply hose to water inlet. See Figure 2 for location. The water faucet and supply hose must be capable of providing a minimum of 4.0 gallons per minute (GPM). Electrical AIR BAND LOCKING SCREW Figure 8 - Burner Air Band Adjustment DANGER: Do not modify the plug provided with the product - if it will not fit the outlet, have a proper outlet installed by a qualified electrician. DO NOT use any type of adaptor with this product. Extension Cords: The models 980SS and 1410SS should not be used with extension cords. All other models must be used only with UL listed extension cords that are rated for the voltage and amperage requirements of the machine. In no case should more than one cord be used and cord length should be kept to a minimum to reduce the risk of severe electrical shock and/or damage to the machine. WARNING: To reduce the risk of electrocution, keep all connections dry and off the ground. DO NOT touch plug with wet hands. OPERATION Before Starting 1. Read all manuals provided with this pressure washer. Become familiar with location and function of all operating and safety controls. DANGER: Improper wiring connections of the equipment can result in a risk of electrocution. Check with a qualified electrician or service personnel if you are in doubt as to whether the outlet is properly grounded. WARNING: Check hoses, fittings, wand, trigger gun and fuel connections daily for signs of wear, cracks WARNING: Make sure all switches and controls are and looseness, and replace as required. in the OFF position prior to connecting electrical supply. 2. Connect water supply hose to the standard garden hose connector. The water faucet and supply hose must be capable of providing 4.0 GPM. Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 9

10 3. Fill oil burner fuel tank. Use kerosene, #1 grade home heating oil, #1 or #2 diesel fuel. IMPORTANT: Do not use gasoline, crankcase drainings, used oil or oil containing gasoline or solvents. NE PAS UTILISER D ESSENCE, DE PRODUITS DE VIDANGE NI D HUILE CONTENANT DE L ESSENCE OU DES SOLVENTS. 4. Check pump oil level. 5. If detergents are to be used, only use detergents intended for pressure washers. Follow instructions on the detergent container. IMPORTANT: Before installing pressure nozzle on initial start-up, turn on the water supply, start the pump by pressing the pump ON switch, and hold the trigger gun open until water appears at the end of the wand. Allow water to run from the end of the wand until clear to prevent the nozzle from clogging. IMPORTANT: If the pressure washer has not been used for an extended period of time, remove the pressure nozzle from the end of the wand and turn on water supply, and start the pump by pressing the pump ON switch. Hold the trigger gun open and allow water to run from the end of the wand until clear. 6. Install the pressure nozzle on end of wand, refer to Figure 9. MANUAL TRIGGER LOCK IMPORTANT: The trigger gun provided with this pressure washer is equipped with a manual trigger lock to prevent accidental operation of the trigger gun, refer to Figure 9. The trigger lock should be used whenever the trigger gun is not in use. To Start PRESSURE NOZZLE Figure 9 - Nozzle Installation/Manual Trigger Lock WARNING: Risk of injection or severe injury - Keep clear of nozzle - DO NOT direct discharge stream at persons - This machine is to be used only by qualified operators. AVERTISSEMENT: RISQUE D INJECTION ET DE BLESSURES GRAVES. SE TENIR À L ÉCART DU JET. NE PAS DIRIGER LE JET DE SORTIE VERS D AUTRES PERSONNES. CONFIER L UTILISATION DE CE MATÉRIEL À UN OPÉRATEUR QUALIFIÉ. WARNING: Wear eye, ear, hand, foot and skin protection at all times while operating pressure washer. WARNING: Before changing pressure nozzle, engage manual trigger gun lock. IMPORTANT: The water must be turned on before starting. Running the pump dry will cause damage and void warranty. IMPORTANT: Do not allow the machine to run with trigger of the trigger gun released for more than 10 minutes at any one time or damage to pump may occur. 1. If equipped with a GFCI, test the GFCI using the reset and test procedures provided on the GFCI device. The GFCI must be tested with every use. 2. Turn ON water supply. 3. Hold wand firmly, release trigger of trigger gun and turn pump switch ON. Squeeze trigger of trigger gun and allow air to purge from system. 4. If HOT water is desired, adjust the thermostat to the proper temperature and turn burner switch ON. The burner will light immediately with a small puff of smoke. You may need to initially adjust your burner for peak performance. See Oil Burner section under Installation. If smoke continues, refer to the Troubleshooting Guide in this manual. When the trigger of the trigger gun is released or when the thermostat temperature setting is reached, the burner will automatically turn off. IMPORTANT: If ignition or flame failure is experienced, discontinue use of pressure washer at once. Turn off burner and shut off fuel supply. Have cause of failure corrected by an authorized service technician before use of pressure washer is continued. To Clean 1. Refer to the chart in Figure 10. This machine has been equipped with three (3) detergent metering orifice plugs. A red plug has been installed in the detergent screen. This plug has been factory drilled with a #60 drill bit. The chart indicates that a #60 hole will allow a 1% detergent concentration, (or a 1/100 de- DETERGENT/WATER RATIO % DETERGENT CONCENTRATION 1/8 12% 1/10 10% 1/12 8% 1/16 6% 1/25 4% 1/50 2% 1/100 1% 1/200.05% 1/400.02% DRILL NO DRILL SIZE Figure 10 - Detergent Metering System Page 10 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

11 tergent-to-water ratio). The other two (2) plastic plugs have not been drilled. Use the chart to determine the hole size needed to achieve a desired detergent concentration. Install the plug which will provide the correct concentration for the detergent to be used before proceeding. 2. Insert detergent inlet line into container of mixed detergent. Open detergent ON/OFF valve. The detergent will be pulled automatically into the system. Allow detergent to reach end of wand before proceeding to step Select pressure nozzle with spray pattern that matches your cleaning needs. Engage manual trigger lock (refer to Figure 9) and install selected nozzle. 4. Wash from the bottom to the top, using side to side motions. This washes away heavy dirt and allows the detergent to soak as you work toward the top. 5. Do not wash at a 90 angle to the work (straight at it). This will allow water to splash back at you and reduces your cleaning power. Wash at a 30 to 60 angle to the work. This will allow the water to splash away from you and the water will wash the dirt away faster and easier. 6. Use the width of the spray pattern to wash in a wide path. Overlap spray paths for complete coverage. Wash from side to side, using slow, steady motions. 7. The nozzle should be 12" to 24" from work, closer for tough areas. Be careful on painted or delicate surfaces, the pressure may damage surface if nozzle is too close. 8. Small parts should be washed in a basket so the pressure does not push them away. Larger, light weight parts should be clamped down so the pressure does not push them away. 9. Close the detergent ON/OFF valve to permit rinse. Always rinse with cold water after using detergents. Rinse from the top to the bottom to prevent detergent from dripping onto a rinsed area. For the best results, contact your Hotsy dealer to help you select the best detergent for your application. To Stop 1. If detergents were used, draw clear water through the detergent line to purge detergent. Failure to do so may clog detergent injector valve. 2. If burner was used, turn OFF burner switch and allow pump to run cold water through coil for several minutes. 3. Turn pump switch OFF. 4. Turn water supply OFF. 5. Squeeze trigger gun open to relieve system pressure. STORAGE IMPORTANT: Machine must be stored indoors. 1. Protect from freezing by storing in a heated area, or by flushing the system with antifreeze (use an automotive engine antifreeze or windshield washer solvent to antifreeze). To flush the system fill the float tank with antifreeze and remove pressure nozzle from wand. Start the machine and allow it to run until antifreeze runs from the end of the wand. Place wand into float tank and circulate the solution through system for several minutes. Open and close the trigger gun several times to circulate antifreeze through the unloader valve system. Also draw antifreeze through the detergent inlet line to antifreeze the detergent system. For added protection after antifreezing, disconnect the pressure hose from machine and remove the coil drain plug (refer to Figure 14, item 26 for location). After coil has drained, replace pressure hose and coil drain plug. If the pressure washer is not to be used for an extended length of time, it is recommended that the system be flushed with antifreeze for rust protection. MAINTENANCE WARNING: Unauthorized machine modification or use of non-approved replacement parts may cause personal injury and/or property damage and will void the manufacturer warranty. IMPORTANT: Machine must be stored indoors. Pump Use Hotsy Pump Oil P/N or equivalent 30W non-detergent oil for pump crankcase. Crankcase must be filled to the full mark on the dipstick or to center of sight glass window found on the rear of the pump (refer to Figure 11). During the break-in-period, make sure the oil is changed after the first 25 hours of operation. After that, replace oil every 3 months or 300 hours of operation, whichever comes first. SIGHT GLASS OIL DRAIN Figure 11 - Pump Lubrication OIL FILL/DIPSTICK DANGER: Do not store flammable liquids (gasoline, fuel oil, petroleum, solvents, etc.) near pressure washer, or in non-ventilated areas. Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 11

12 Proper Pump Care: DO NOT pump acids. DO NOT allow pump to run dry. Winterize if storing in freezing temperatures, refer to Storage for details. Use a water softener on the water system if known to be high in mineral content. Use only high quality detergents and follow manufacturer s mix recommendations. Flush the system with clear water immediately after using detergent solutions. Clean filter screen on detergent inlet line periodically. Flush the pressure washer system with antifreeze if storing for an extended period of time, refer to Storage for details. Pump Motor On a yearly basis, oil pump motor per instructions on motor nameplate. NOTE: Some motors may be equipped with permanently lubricated bearings and will not require additional lubrication. Relief Valve Unloader Valve WARNING: The unloader valve on this pressure washer has been factory set and sealed and is a field nonadjustable part. Tampering with the factory setting may cause personal injury and/or property damage, and will void the manufacturer warranty. For replacement refer to Figure 22. Burner Fuel Filter Drain any water which has accumulated in fuel filter and clean or replace filter element as needed. Refer to Figure 21. Heating Coil Coil Descaling: In hard water areas, scale buildup within the heating coil will occur. Scale deposits will decrease the water temperature rise and may eventually clog the heating coil. Contact your local service center when descaling is needed. Coil Desooting: Poor grades of fuel oil or inadequate combustion air will cause heavy soot buildup on the outside surface of the heating coil. These deposits will insulate the coil. This will restrict the air flow through the coil, further aggravating the soot buildup. Contact your local service center when desooting is needed. WARNING: The relief valve on this pressure washer has been factory set and sealed and is a field nonadjustable part. Tampering with the factory setting may cause personal injury and/or property damage, and will void the manufacturer warranty. For replacement parts refer to Figure 17. Page 12 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

13 TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Pressure washer will not run. Pressure runs but won't spray. Low spray pressure at pressure nozzle. Uneven spray pattern. Pressure washer will not produce hot water. Poor or no detergent flow. Pump switch in OFF position. Power supply disconnected. Fuse blown or circuit breaker tripped in electrical supply line. Motor circuit overload tripped. Trigger of trigger gun released. Water supply not turned on. Clogged pressure nozzle. Inadequate water supply. Partially clogged or damaged pressure nozzle. Air being drawn through detergent inlet line. Partially clogged or damaged nozzle. Burner switch in OFF position. Inadequate fuel supply. Pump switch turned off. Inadequate water supply. Trigger of trigger gun released. Inadequate detergent supply. Detergent screen or hose clogged. Clogged detergent valve. Place switch in ON position. Connect power supply. Replace fuse or reset circuit breaker. Use only fuses of adequate capacity. Reset pump switch. Squeeze trigger. Open water supply valve. Clean pressure nozzle opening. Fully open faucet. Check for kinked or damaged hose. Use 5/8 inch minimum hose. Check for debris clogging inlet screen. Clean or replace. Refill detergent container. Ensure that pick-up screen is fully immersed. Clean or replace. Place switch in ON position. Refill fuel tank. Use only recommended fuels. Refer to Before Starting under Operation. Pump must be running before burner will light. Fully open faucet. Check for kinked or damaged hose. Use 5/8 inch minimum hose. Check for debris clogging inlet screen. Squeeze trigger. Water must be spraying for burner to light. Refill detergent container. Ensure that pick-up screen is full immersed. Open metering valve. Clean. Always start with a clean detergent container. Clean. Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 13

14 TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Poor cleaning. Improper detergent concentration or mixing. Wrong detergent for the application. Rinsing with hot water. Mix detergent per manufacturer's instructions. Ensure that powdered detergents are fully dissolved. Select appropriate detergent. A final rinse with cold water will reduce water spotting. IMPORTANT If the pressure washer demonstrates other symptoms or the corrective actions listed do not correct the problem, contact the local authorized Hotsy Service Center. The Hotsy Service Center can be identified by contacting: Customer Service Department The Hotsy Corporation 21 Inverness Way East Englewood, Colorado (303) When ordering from your dealer, please provide the following: Model Number: Release: Machine Serial Number: Component Part Number: Description: FOR HELP OR ADDITIONAL INFORMATION, CONTACT: Customer Service Department The Hotsy Corporation 21 Inverness Way East Englewood, CO (303) /1400 OIL-FIRED SERIES OPTIONAL EQUIPMENT " Draft Regulator Page 14 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

15 ,6, , ,16,17,18 17,18,19,20 CAUTION 28 17,18,19,27 17,18,26 24, ,22 Figure 12 - Machine Assembly, Front View Ref. No. Part No. Description Qty. 1 Fig. 15 Trigger Gun/ Wand Assembly Hose Hanger Pressure Hose Vent Clip Burner Exhaust Vent Vent Insulation Insulation Retaining Ring Nipple 1/2" x 2" 1 9 Fig. 17 Coil Outlet Assembly Hose 3/8" Shrink Tubing Decal Hotsy Detergent 1 13 Fig. 18,19 Control Panel Assembly Decal Beltguard Warning Hose Reel Mount 1 16 Bolt 5/16" - 18 x 2" 2 Ref. No. Part No. Description Qty. 17 Flat Washer 5/16" 9 18 Locknut 5/16" Bolt 5/16" - 18 x 3/4" 4 20 Lock Washer 5/16" External Tooth 2 21 Fig. 20 Fuel Tank Assembly Fuel Tank Strap Chassis Strain Relief Strain Relief Nut 1 26 Fig. 21 Burner Assembly Wand Holder Decal Inst/Warnings 1 Order amount needed in feet. Standard hardware item available locally. Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 15

16 1,2, , Figure 13 - Machine Assembly, Side View Ref. No. Part No. Description Qty Red Coil Tank Stainless Steel Coil Tank 1 2 Fender Washer 5/16" 4 3 Locknut 5/16" Fig. 22 Pump Assembly 1 5 Bolt 1/2" - 13 x 3-1/2" 1 6 Flat Washer 1/2" Decal Water Inlet 1 Ref. No. Part No. Description Qty Decal Fuel Type Grommet (980,990, , 1410,1420, ) Grommet (993,1423) Edge Trim Electrical Box Cover (900 Series) Electrical Box Cover (1400 Series) 1 Order amount needed in feet. Standard hardware item available locally. Page 16 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

17 11,12 1,2,3,4 5, ,10 13,14,15, , ,3 20, ,25,26 Figure 14 - Machine Assembly, Rear View Ref. No. Part No. Description Qty Pump/Motor Cover 1 2 Bolt 1/4" - 20 x 3/4" 5 3 Flat Washer 1/4" 5 4 Flange Nut 1/4" Pump Pulley Pump Pulley Bushing Belt Strain Relief Motor Pulley Motor Bushing (900 Series) Hotsy Logo Plate Rivet Motor (980) Motor (990,993) Motor ( ) Motor (1410) Motor (1420,1423) Motor ( ) 1 Ref. No. Part No. Description Qty. 14 Bolt 3/8" - 16 x 1" 4 15 Flat Washer 3/8" 8 16 Flange Nut 3/8" Coil Coil Insulation Coil Insulation 1 20 Fig. 24 Float Tank Assembly Float Tank Strap Snap Bushing 1 23 Fig. 25 Transformer Assy (993,1423) Nipple 1/2" x 2" Coil Inlet Manifold Coil Drain Plug 1 Standard hardware item available locally. Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 17

18 ,6,7 Figure 15 - Trigger Gun/Wand Assembly Ref. No. Part No. Description Qty Trigger Gun Fig Quick Disconnect Plug Quick Disconnect Wand Pressure Nozzle - Red (900) Pressure Nozzle - Red (1400) Pressure Nozzle - Yellow (900) Pressure Nozzle - Yellow (1400) 1 Ref. No. Part No. Description Qty Pressure Nozzle - White (900) Pressure Nozzle - White (1400) 1 Replacement Parts Insulator Grip Assembly Side Handle Grip Page 18 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

19 Figure 16 - Trigger Gun, Exploded View Ref. No Part No. Description Qty 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 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 Ref. No Part No. Description Qty. 14 Plunger Seat Trigger Pin Left Gun Shell Phillips Screw Trigger Lock Pin Trigger Trigger Lock Lever Inlet Pipe Seat Inlet Pipe Inlet Fitting Right Gun Shell 1 Replacement Parts Trigger Gun Repair Kit Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 19

20 Figure 17 - Coil Outlet Assembly Ref. No. Part No. Description Qty Manifold Thermostat Well 1 3 Screw #6-32 x 1/2" Relief Valve (900 Series) Relief Valve (1400 Series) 1 Ref. No. Part No. Description Qty Hose Clamp Vinyl Tubing 3/8" Order amount needed in feet. Standard hardware item available locally. Page 20 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

21 2 3,4,5, CAUTION , Figure 18 - Control Panel Assembly, Front View Ref. No. Part No. Description Qty Control Panel Control Panel Decal Thermostat Thermostat Mounting Plate Thermostat Dial 1 6 Screw 4 mm x 6 mm Rocker Switch V Green Lamp /4" Ball Valve 1 Ref. No. Part No. Description Qty Grommet Winterize Decal Caution Decal Cleaning Fluid Decal /4" Ball Valve 1 Standard hardware item available locally. Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 21

22 1,8 6,10 11,12 6,13,14,15 16,17 7 5,6 1,2,3,4 18,19,20, 21,22 13,14 15, ,25 23 Figure 19 - Control Panel Assembly, Rear View Ref. No. Part No. Description Qty 1 Flange Nut 1/4" Ground Lug 2 3 Bolt 1/4" - 20 x 3/4" 2 4 Screw, #8-32 x 1/2" Tapping Transformer, 100KVA, 208/230/460-24/115 (208V Models) Transformer, 100VA, 230/ (All Models Except 208V) 2 NS Fuse, KTK-R2 600V 2 NS Fuse, FNM Electrical Equipment Panel 1 8 Bolt 1/4" - 20 x 1/2" Strain Relief DIN Rail Contactor - 980SS Contactor - 990SS-208, 990SS Contactor - 993SS Contactor SS Contactor SS-208, 1420SS Contactor SS Overload - 980SS Overload - 990SS-208, 990SS Overload - 993SS Overload SS Overload SS-208, 1420SS Overload SS Terminal Block Marker Terminal Block 14 Pole Spade Jumper Grommet Hose 3/8" Suction Screen 1 Ref. No. Part No. Description Qty Nipple Hose x 1/4" NPT Tubing 1/4" Pipe Plug Red #60 Drill Hose Clamp Plastic Plug Tubing 1/4" Clear Hose Clamp Relay DPST 24 Volt Strain Relief GFCI Cord (980) GFCI Cord (1410) Cord 10/4 SO (1420, ) Cord 12/4 SO (990, , 993, 1423) Cord 10/3 (980) Cord 8/3 (1420) Cord 10/4 SO (1420, ) Cord 12/4 SO (990, , 993, 1423) Strain Relief Strain Relief (980, 1410) Strain Relief Nut (980, 1410) 1 NS Plug 1/8" (Orange) 1 NS Plug 1/8" (Blue) 1 NS Plug Electrical Male (990, ) 1 NS Plug Electrical Fem. ( ) 1 NS Plug Electrical Male (1420, ) 1 NS Plug Electrical Fem. (1420, ) 1 NS Plug Electrical Male (993, 1423) 1 NS Plug Electrical Fem. (993, 1423) 1 Standard hardware item available locally. NS Not Shown Order amount needed in feet. Page 22 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

23 Figure 20 - Fuel Tank Assembly Ref. No. Part No. Description Qty Fuel Tank Cap Fuel Tank 1 Ref. No. Part No. Description Qty Nipple 1/4" x 1/4" Hose Fuel Valve 1 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 23

24 5/32" 7/16" /16" Figure 21 - Burner Assembly Ref. No. Part No. Description Qty Burner Nipple, 1/4" NPT x 1/4" H Elbow, 1/4" Street Nipple, 1/4" x 2-1/2" Bushing, 3/8" - 1/4" Fuel Filter Assembly Nipple, 3/8" NPT x 1/4" Hose Fuel Pump W/230V Solenoid Fuel Solenoid Transformer Electrode Assembly 1 Ref. No. Part No. Description Qty Air Cone, F Nozzle, 2.00 A Motor 1 NS Filter Screen Replacement 1 NS Blower Fan 1 NS Coupling 1 NS Fuel Pump Stem 1 NS Screen Fuel Pump 1 NS Strain Relief 1 NS Strain Relif Nut 1 Page 24 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

25 ,17 Figure 22 - Pump Assembly Ref. No. Part No. Description Qty Nipple 3/8" x 1/2" Hose Screen Filter Hose 3/8" x 34" Elbow 3/8" x 3/8" Hose Elbow 3/8" Nipple 3/8" x 1-1/2" Tee 3/8" Hose 3/8" Pressure Switch Pump Fig Hose 1/2" Nipple 1/2" x 1/2" Hose Check Valve 1/2" Nipple 1/2" x 3/8" Pump Base 1 16 Flat Washer 10 mm 4 Ref. No. Part No. Description Qty. 17 Bolt 10 mm x 20 mm Unloader Valve (900 Series) Unloader Valve (1400 Series) Nipple 3/8" x 1-1/2" Street Elbow 3/8" Hose Clamp Check Valve 1/4" x 1/4" Hose Street Elbow 1/4" Bushing 3/8" x 1/4" 1 Order amount needed in feet. Standard hardware item available locally. Replacement Parts Micro Switch O-Ring Kit 1 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 25

26 Figure 23 - Pump, Exploded View Page 26 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

27 Ref. No. Part No. Description Qty. 1 Valve Seat O-Ring 6 2 Valve Seat 6 3 Valve Plate 6 4 Valve Spring 6 5 Valve Cage Manifold Plug O-Ring Manifold Plug Washer Manifold Stud Bolt Drain Plug 3/8" Copper Washer Manifold Housing 1 13 Support Ring 20 mm 6 14 V-Sleeve 20 mm 6 15 Intermediate Ring 20 mm 3 16 Pressure Ring 20 mm 3 17 Pressure Ring O-Ring 3 18 Plunger Seal Plunger Guide Oil Dipstick Gasket 3/8" Crankcase Bearing Housing O-Ring Closed-end Bearing Housing Bearing Housing Plunger Rod Crankshaft Crank Shaft Key 8 x 25 mm 1 Ref. No. Part No. Description Qty Roller Bearing Crankshaft Seal Crankcase Cover Gasket Crankcase Cover Crankcase Cover Allen Screw Sight Glass 3/8" Allen Screw Spring Washer Connecting Rod Assembly Connecting Rod Pin Connecting Rod Pin Snap Ring 6 40 Copper Spacer 3 41 Ceramic Plunger Sleeve 20 mm 3 42 Copper Spacer 3 43 Teflon Ring 3 44 Plunger Bolt O-Ring 3 45 Plunger Assembly Bolt Shim Washer Hex Screw 8 Replacement Parts Qty/Pump Complete Seal Packing Kit Ceramic Sleeve Kit Complete Valve Assembly Kit Plunger Seal Kit Seal Packing Kit 1 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 27

28 ,12, Figure 24 - Float Tank Assembly Ref. No. Part No. Description Qty Garden Hose Gasket Garden Hose Connector Spring Locknut 3/8" 2 5 Flat Washer 5/8" Adapter 3/8" x 3/8" Float Valve Float Tank Rod Threaded Float Ball 1 Ref. No. Part No. Description Qty. 11 Bolt 1/4" - 20 x 3/4" 1 12 Flat Washer 1/4" 1 13 Flange Nut 1/4" Hose Clip 1 Standard hardware item available locally. Replacement Parts Rubber Cup Rubber Disk 1 Page 28 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

29 1 3,4,5 5,6, ,4,5 Figure 25 - Transformer Assembly (993,1423) Ref. No. Part No. Description Qty Transformer Strain Relief 2 3 Bolt 1/4" -20 x 3/4" 3 4 Flat Washer 1/4" 3 5 Locknut 1/4" Bolt 1/4" - 20 x 1/2" 1 7 Lock Washer 1/4" External Tooth Rubber Bumper 1 Ref. No. Part No. Description Qty Mounting Bracket 1 10 Screw #12-14 x 3/4" Self Drill 1 NS Cord 16/3 SO NS Cord 16/3 SJO NS = Not Shown Order amount needed in feet. Standard hardware item available locally. Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 29

30 Figure 26 - Wiring Diagram (Models 980SS, 987, 1410SS) Page 30 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

31 Figure 27 - Wiring Diagram (Models 993, 1423) Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03 Page 31

32 Figure 28 - Wiring Diagram (Models , ) Page 32 Hotsy 900/1400 OIL-FIRED SERIES REV. 9/03

33

34 WARRANTY HOTSY LIMITED WARRANTY: Hotsy products are warranted by the Hotsy Corporation (Hotsy) to be free of defects in material and workmanship 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 warranty. Hotsy will at its option repair or replace any part covered by this warranty which is defective under normal use for one year at no charge for parts or labor. All defects must be verified by an authorized Hotsy service location. This warranty is not transferable. EXCEPTIONS TO THE ONE YEAR WARRANTY FOR PARTS ONLY ARE: LIMITATION OF LIABILITY: Hawk Pumps: SEVEN YEAR Warranty (LIFETIME Brass Manifold Warranty- Even Against Freezing) General Pumps: FIVE YEAR Warranty Heating Coils: FOUR YEAR Warranty To the extent allowable under applicable law, Hotsy liability for consequential and incidental damages is expressly disclaimed. Hotsy liability in all events is limited to, and shall not exceed, the purchase price paid for the equipment. Hotsy liability is limited to repair or replacement of defective parts only, at the option 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 not express or imply a warranty that the product is merchantable or fits a particular purpose, or that the product 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. While attempts to assure that its products comply with such codes, it cannot guarantee compliance and cannot 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 that the 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 any product which proves to be defective within limited warranty. For any product believed to be defective within limited warranty, contact dealer from whom product was purchased. Dealer will give additional directions. 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 product was damaged in transit to you, file claim with freight carrier. The Hotsy Corporation 21 Inverness Way East Englewood, Colorado (303)