Hotsy 555 HE Service manual

9.808-140.0
SERIAL NUMBER:
DATE PURCHASED:
FOR SALES AND SERVICE, PLEASE CONTACT:
OPERATING INSTRUCTIONS
AND PARTS MANUAL
1.109-137.0 555 HE SPECIFICATIONS
Pump Volume At Pump Head: 2.2 GPM/ 132 GPH
Burner Type: Fuel Oil Fired, 185,000 BTU/Hr.
Burner Fuel Pressure: 200 PSI Max.
Pump Pressure At Pump Head: 1300 PSI
Motor HP: 2.0
Machine Voltage: 120 VAC/60 Hz/1 Ph
Total Machine Amperage: 20 Amps
Machine Weight: 282 Lbs.
Shipping Weight: 385 Lbs.
Exhaust Stack Size: 8"
Machine Dimensions: Length = 42", Width = 29", Height = 42"
MODEL 555 HE
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 MODEL RELEASE ONLY: 555 HE

3
CONTENTS
HOTSY 555HE • 9.808-140.0 • Rev. 10/19
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.
Important Safety Information 4-6
Component Identification 6
Assembly Instructions 7
Operation Instructions 8
General Cleaning Techniques 9
Storage 9
Maintenance 10
Troubleshooting 11-12
Main Assembly Exploded Views 13-14
Main Assembly Parts List 15
Blower Assembly & Parts List 16
Fuel Tank Assembly & Parts List 17
Control Panel Assembly & Parts List 18
Accessories Assembly & Parts List 19
Pump Assembly & Parts List 20
HFP Series Pump & Parts List 21-22
Unloader & Parts List 23
Wiring Diagram 24-25

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
OPERATOR’S MANUAL
PRESSURE WASHER
4
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.
SAVE THESE 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 operators.
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
malfunction of the machine
and result in death, serious
bodily injury and/or prop-
erty damage.
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.
4. All installations must comply with local codes.
Contact your electrician, plumber, utility company
or the selling distributor for specific details. If your
machine is rated 250 volts or less, single phase will
be provided with a ground fault circuit interrupter
(GFCI). If rated more than 250 volts, or more than
single phase this product should only be connected
to a power supply receptacle protected by a GFCI.
DANGER: Improper connection of the equipment-
grounding conductor can result in a risk of elec-
trocution. Check with a qualied electrician or
service personnel if you are in doubt as to whether
the outlet is properly grounded. Do not modify the
plug provided with the product - if it will not t the
outlet, have a proper outlet installed by a qualied
electrician. Do not use any type of adaptor with
this product
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.
5. 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 dis-
connect power before servicing.
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 ame
or torch is permitted.
6. Use only home heating oil, or diesel. It is recom-
mended to use a red devil soot remover with every
tank to reduce soot build up on the heating coil.
RISK OF FIRE.
DO NOT ADD FUEL
WHEN OPERATING
MACHINE.
WARNING
WARNING: Risk of re — 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
re and/or explosion.
7. 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.
8. Do not allow acids, caustic or abrasive fluids to pass
through the pump.
9. Never run pump dry or leave spray gun closed
longer than 1-2 minutes.
10. Keep operating area clear of all persons.

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
5
PRESSURE WASHER
OPERATOR’S MANUAL
14. Be certain all quick coupler fit-
tings 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.
15. To keep machine in best
operating conditions, it is
important you protect machine
from freezing.Failure to protect
machine from freezing
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.
16. Inlet water must be cool clean water.
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.
17. Avoid installing machines in
small areas or near exhaust
fans. Adequate oxygen is
needed for combustion or
dangerous carbon monoxide
will result.
18. Manufacturer will not be liable for any changes
made to our standard machines or any components
not purchased from us.
19. 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.
20. Do not overreach or stand on unstable support.
Keep good footing and balance at all times.
21. Do not operate this machine when fatigued or under
the influence of alcohol, prescription medications,
or drugs.
IMPORTANT SAFETY INFORMATION
WARNING
USE PROTECTIVE
EYE WEAR
AND CLOTHING
WHEN OPERATING
THIS EQUIPMENT.
WARNING: High pressure spray
can cause paint chips or other
particles to become airborne
and y at high speeds. To avoid
personal injury, eye, hand and
foot safety devices must be
worn.
11. Eye, hand, and foot protection
must be worn when using this
equipment.
Always wear properly rated eye protection such as
safety goggles or face shield while operating. (Safety
glasses do not provide full protection.)
WARNING
EAR PROTECTION
MUST BE WORN
WARNING: This machine ex-
ceeds 85 db appropriate ear
protection must be worn.
WARNING
HOT DISCHARGE FLUID:
DO NOT TOUCH OR
DIRECT DISCHARGE
STREAM AT PERSONS.
WARNING: Hot discharge uid.
Do not touch or direct discharge
stream at persons.
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-
insulated areas of the pressure
washer.
12. 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.
13. Never make adjustments
on machine while in opera-
tion.
WARNING
RISK OF INJURY:
HOT SURFACES
CAN CAUSE BURNS

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
OPERATOR’S MANUAL
PRESSURE WASHER
6
COMPONENT IDENTIFICATION
Pump — Delivers a specific gpm to the high pressure
nozzle which develops pressure.
Spray Gun — Controls the application of water and
detergent onto cleaning surface with trigger device.
Includes safety latch.
Detergent Valve — Allows you to siphon and mix
detergents.
Wand — Must be connected to the spray gun.
High Pressure Hose — Connect one end to water
pump high pressure discharge nipple and the other
end to spray gun.
Relief valve — Secondary pressure release in the
unlikely event the unloader valve fails.
Unloader Valve — Safety device which, when the spray
gun closes, prevents over pressurization.
Garden Hose
(Not Included)
Wand
High Pressure
Hose
Oil Burner
Assembly
Backow
Preventer
Fuel Tank
Power Cord
w/GFCI
Spray Gun
Burner
Switch
Pump
Switch
Thermostat
Unloader
Valve High
Pressure
Nozzle
Hose Reel
Mount
Burner
Exhaust
Detergent
Valve
IMPORTANT SAFETY INFORMATION
Follow the maintenance instructions
specied in the manual.
Brake
WARNING: To prevent damage or injury.
Keep brake engaged during machine
operation and storage.

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
7
PRESSURE WASHER
OPERATOR’S MANUAL
Figure 1.
3. Assemble pressure hose onto trigger gun/wand
assembly as shown in Figure 2.
4. Make sure that all plumbing connections are tight.
ASSEMBLY & INSTALLATION INSTRUCTIONS
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
•High Pressure Hose
•Spray Gun
•Wand
•Operating Instructions and Parts Manual
Tools Required
•10" Adjustable Crescent Wrench (2 ea.)
Pressure Hose
1. When assembling use sealant in all plumbing connec-
tions to prevent leakage.
2. Install high pressure hose on machine as shown in
Figure 2 - Pressure Hose Installation
Trigger Gun
Wand Assembly
Pressure Hose
INSTALLATION
Getting Started
IMPORTANT: Proper initial installation of equipment
will assure more satisfactory performance, longer
service life and lower maintenance cost.
WARNING: If connection is made to a potable wa-
ter system, the system shall be protected against
backow.
The pressure washer should be run on a level surface
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.
Venting
CAUTION: All venting must be in accordance with ap-
plicable federal and state laws, and local ordinances.
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 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 lid. 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.
Note: This product is labeled of outdoor use only and
should be operated outdoors. It is not recommended to
operate indoors. If under certain conditions that make
it impossible to operate outdoors you can operate
indoor using a hood vent or venting. Venting can
cause restriction of air ow through the combustion
chamber causing excessive soot. Use a larger vent
size then the exhaust stack to prevent restriction and
contact the local servicing dealer to adjust the air
mixture after installation of vent.
Figure 1 - Pressure Hose Installation
Pressure
Hose

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
OPERATOR’S MANUAL
PRESSURE WASHER
8
Pressure Nozzle/Trigger Lock Installation
IMPORTANT: If the pressure washer has not been used
for an extended period of time, remove the nozzle from
the end of the wand and turn on water supply. Allow
water to run from the end of the wand until clear.
1. Install quick connector nozzle on end of the wand.See
Figure 4.
IMPORTANT: The trigger gun provided with this pres-
sure washer is equipped with a manual trigger lock to
prevent accidental operation of the trigger gun. The
trigger lock should be used whenever the trigger gun
is not in use.
To Start
IMPORTANT: The water must be turned on before
starting. Running the pump dry will cause damage to
pump seals and void warranty.
IMPORTANT: DO NOT allow the machine to run in
bypass for more than 10 minutes at any one time or
damage 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 burner
will fire immediately with a small puff of smoke. If smoke
continues refer to the Troubleshooting Guide in this
manual. When the trigger gun is closed the burner
will turn off.
To Stop
1. 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 machine
is plugged in. Always test GFCI before each use. See
instructions in the Electrical Connections section of
this manual.
OPERATION INSTRUCTIONS
OPERATION
Before Starting
WARNING: Check hoses, trigger guns, ttings, and
fuel connections daily for signs of wear, cracks and
looseness, and replace as required.
1. Read all manuals provided with this pressure washer.
Become familiar with location and function of all
operating and safety controls.
2. Connect water supply hose to the standard garden
hose connector. The water faucet and supply hose
must be capable of providing 3.0 GPM.
3. Fill fuel tank. Use home heating oil or diesel fuel. DO
NOT USE GASOLINE, CRANKCASE OIL RESIDU-
ALS OR WASTE OIL.
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.
Electrical Connections
WARNING: Make sure all switches and controls are in
the OFF position prior to plugging in.
CAUTION: This pressure washer is equipped with a
UL approved ground fault circuit interrupter (GFCI)
power cord. Use UL grounded type receptacles
of proper voltage and amperage ratings. Where a
properly grounded receptacle is not available, it is
the personal responsibility of the owner to have one
installed. Always disconnect power before servicing
your pressure washer.
Connect electrical cord and test the GFCI using the reset
and test procedures provided on the GFCI device. The
GFCI must be reset and tested with every use. Do not use
machine if the GFCI device fails test.
WARNING: Use copper conductors only.
Figure 4 - Nozzle Installation/Manual Trigger Lock
Manual Trigger
Lock
Pressure Nozzle
Garden
Hose
Water Inlet
Fuel tan
k

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
9
PRESSURE WASHER
OPERATOR’S MANUAL
OPERATION INSTRUCTIONS & CLEANING TECHNIQUES
GENERAL CLEANING
TECHNIQUES
Warning: Pressure washers produce a kickback. To
prevent personal injuries due to falls use auxiliary
safety equipment.
The detergent injector valve operates by reducing the
volume of water, thus a vacuum is achieved and detergent
is drawn into the system. DO NOT reduce the water inlet
flow so much as the pump cavitates because of water
starvation. Operating a pump with insufficient water will
damage the pump seals.
1. Insert detergent line and screen into container of
detergent.
2. Completely open detergent control knob located on
the side of the detergent injector valve.
3. Start the detergent suction by rotating the water
adjustment knob of the detergent injector valve. See
Figure 5. Turning the knob counterclockwise will pull
detergent into the system.The flow may be observed
4. The side control knob can now be adjusted to meter
the desired amount of detergent.
Figure 5 - Detergent Injector Valve
Water Adjustment Knob
Water
Increase Water
Decrease
Detergent
Off
Detergent
On
Detergent
Control Knob
5. Do not wash at a 90oangle to the work (straight at
it). This will allow water to splash back at you and
reduces your cleaning power. Wash at a 30oto 60o
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 cover-
age washing 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 pres-
sure does not push them away. Larger, lightweight
parts should be clamped down so the pressure does
not push them away.
9. 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 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.
STORAGE & MAINTENANCE
STORAGE
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 with antifreeze, attach
a short length of hose to the garden hose connector
located on the pump. Place the other end of the hose into
a container of antifreeze. Start machine and allow to run
until antifreeze flows from the end of the wand. Squeeze
and release the trigger of the trigger gun several times
to antifreeze the unloader system. Also draw antifreeze
through the detergent inlet line to antifreeze the detergent
system.For added protection after anti-freezing, disconnect
the pressure hose from machine and remove the coil drain
plug (refer to Exploded View 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.

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
OPERATOR’S MANUAL
PRESSURE WASHER
10
STORAGE & MAINTENANCE
MAINTENANCE
WARNING: Unauthorized machine modication or
use of non-approved replacement parts may cause
personal injury and/or property damage and will void
the manufacturer warranty.
Pump
Lubrication: To lubricate pump, use 10W-40 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 side of the pump, refer to Figure 7.
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, whichever comes first.
Figure 7 - Pump Lubrication
Oil Fill/
Dipstick
Oil
Drain
Unloader Valve
WARNING: The unloader valve on this pressure
washer has been factory set and sealed and is a
eld 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 Pump Assembly.
Burner Fuel Filter
Drain any water which has accumulated in fuel filter and
clean or replace element as needed. For replacement
parts, refer to Burner Assembly.
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.
Relief Valve
WARNING: The relief valve on this pressure washer
has been factory set and sealed and is a eld non-
adjustable part. Tampering with the factory setting
may cause personal injury and/or property damage,
and will void the manufacturer warranty. For replace-
ment parts refer to Coil Outlet Assembly.
If pressure from pump or thermal expansion should
exceed safe limits, the relief valve will open, allowing
high pressure to be discharged through hose to ground.
Caution: Inspect relief valve annually for any
obstruction.
Proper Pump Care
•DO NOT pump acids.
•DO NOT allow pump to run dry.
•Winterize if storing in freezing temperatures, refer
to Storage & Maintenance 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 manu-
facturer’s mix recommendations.
•Flush the system with clear water immediately after
using detergent solutions.
•Clean filter screen on detergent inlet line periodi-
cally.
•Flush the pressure washer system with antifreeze
if storing for an extended period of time, refer to
Storage & Maintenance 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.

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
11
PRESSURE WASHER Troubleshooting Guide
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION
PUMP MOTOR WILL
NOT RUN GFCI tripped Reset and test GFCI with every use. Follow
instructions on GFCI device.
No voltage to machine Test power supply and correct.
Pump motor reset switch (thermal
overload protector) tripped
Push reset switch on control box, thermal
overload protector. If tripped, check for proper
voltage or clogged pressure nozzle.
Excessive pressure due to clogged
pressure nozzle Clean pressure nozzle.
PRESSURE WASHER
RUNS BUT WON’T
SPRAY
Trigger of trigger gun released Squeeze trigger.
Water supply not turned on Open water supply valve.
Clogged pressure nozzle Clean pressure nozzle opening.
LOW SPRAY PRES-
SURE AT PRESSURE
NOZZLE
Inlet water screen clogged Check screen and clean if necessary.
Inadequate water supply Fully open faucet. Check for kinked or dam-
aged hose. Use 5/8 inch minimum hose.
Check for debris clogging inlet screen.
Partially clogged or damaged pres-
sure nozzle
Clear or replace.
Air being drawn through detergent
inlet line
Refill detergent container. Ensure that pick-
up screen is fully immersed.
POOR OR NO
DETERGENT FLOW
Inadequate detergent supply Refill detergent container. Ensure that pick-
up screen is fully immersed.
Detergent screen or hose clogged Clean. Always start with a clean detergent
container.
Clogged detergent injector check
valve
Clean check valve at detergent injector inlet.
Detergent injector not set correctly Refer To Clean for settings.
UNEVEN SPRAY
PATTERN
Partially clogged or damaged pres-
sure nozzle
Clean or replace.
PRESSURE WASHER
WILL NOT PRODUCE
HOT WATER
Burner switch in OFF position Place switch in ON position
Inadequate fuel supply Refill fuel tank. Use only recommended fuels.
Refer to Before Starting under Operation.
Pump switch turned off Pump motor must be running before burner
will light.
Inadequate water supply Fully open faucet. Check for kinked or dam-
aged hose. Use 5/8 inch minimum hose.
Check for debris clogging inlet screen.

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
PRESSURE WASHER Troubleshooting Guide
12
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 visiting www.hotsy.com
PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION
PRESSURE WASHER
WILL NOT PRODUCE
HOT WATER
Water must be spraying for burner
to light
Squeeze trigger. Water must be spraying for
burner to light.
Defective pressure switch Replace pressure switch.
Fuel valve closed Check that fuel valve on fuel tank is open.
Clogged fuel filter Replace fuel filter.
Thermostat set too low Adjust thermostat to desired temperature.
BURNER SMOKES Air bands need to be adjusted Adjust air by opening or closing the air flap
until smoke spot value is 1 or lower.
A) SMOKES WHILE
UNIT IS RUNNING
Improper fuel User proper fuel.
Low fuel pressure ˂140 PSI Adjust fuel pump pressure to specifications.
B) SMOKE AT
COLD-START WHEN
BURNER IS OFF
Weak fuel pump Check fuel pump pressure. Replace pump if
needed.
Fuel filter partially clogged Replace as needed.
Soot build up on coils Clean coils with soot remover.
Lime build up in coils Clean inside of coils using Hotsy’s coils
cleaner.
Improper burner nozzle See combustion assembly breakdown.
Electrode is misaligned Realign electrodes to specs.
Fuel pressure is to high for clean
burn (fuel PSI above 140 but less
that 200)
Reduce fuel PSI/increase air and band set
for cleaner burn without max water heat loss.
POOR CLEANING Improper detergent concentration
or mixing
Mix detergent per manufacturer’s instruc-
tions. Ensure that powdered detergents are
fully dissolved.
Wrong detergent for the application Select appropriate detergent.
Rinsing with hot water A final rinse with cold water will reduce water
spotting.
TROUBLESHOOTING

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
13
PRESSURE WASHER
OPERATOR’S MANUAL
MAIN ASSEMBLY EXPLODED VIEW
18
42
31
37
40
39
36
53
38 47
48
34
35
54
49
43
8
5
10
33
44
4
7
7
45
46
1
34
55
3
2
6
52 51
50
For
Detail See
Burner
Assy
For
Detail See
Tank Assy
For
Detail
See Panel
Assy

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
OPERATOR’S MANUAL
PRESSURE WASHER
14
MAIN ASSEMBLY EXPLODED VIEW
19
17
15
18
16
14
13
8
12
11
22
23 24
29
9
10
25
61 62
62
62
62
63
64
66
65
60
62
58
28
26
30
20
21
56
57
32
59
41
27
Coil Assembly Detail
For
Detail See
Coil Assy

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
15
PRESSURE WASHER
OPERATOR’S MANUAL
MAIN ASSEMBLY PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.925-840.0 Frame 1
2 8.754-435.0 Wheel & pu tire 4
assy, 12" steel rim
3 8.751-374.0 Spacer 5/8 x 1,25 Black 8
4 9.802-782.0 Collar, 5/8" Bore 4
Shaft 3010
5 8.757-786.0 Rivet nut M8 x 1.25 13
6 Please See Burner Assembly Page
7 9.802-778.0 Nut, 5/16" Whiz 6
LOC Flange
8 8.758-159.0 Screw M6-1 X 16 Torx
PHSTZNPLT 3
9 5.044-420.0 Holder 3
10 8.758-142.0 Screw M8x20 11
11 5.195-251.0 Seal air circulation 1
12 5.263-094.0 Tensioning part air 1
circulation
13 5.664-256.0 Flame tube 1
14 4.663-088.0 Baffle plate complete 1
15 2.638-974.0 Conversion Kit Ignition 1
Electrode
16 8.700-856.0 Fuel Nozzle 1.10 X 1
60 A Hollow
17 4.654-288.0 Cover pressure coil 1
18 7.303-038.0 Screw M5x12 -St-P2R 5
(In6Rd)
19 8.755-757.0 Ignition Transformer 1
Heat Exchanger 120V
20 8.601-297.0 Washer, M5 FNDR 1
SS ISO7039
21 8.627-409.0 Screw, 10-32 X 1.5 1
PHPNHMS STL ZNPLT
22 8.757-799.0 Fuel line copper 1
23 6.389-262.0 Union nut A 4-LL 2
24 6.389-263.0 Cutting ring d.4 2
25 9.803-600.0 Swivel,M22X3/8 2
Hex Male Pipe
26 8.757-712.0 Manifold Block High 1
Pressure Side HDS
27 8.757-729.0 Label Warning Symbol 1
Hot Surface
28 9.196-012.0 Plug Allen 10-24 x 1/4" 1
29 9.802-042.0 Elbow, 1/2 JIC X 1
3/8 Fem, 90DGR, ST
30 8.704-198.0 Valve, safety 1
relief 6000 PSI
31 Please See Control Panel Assembly Page
32 9.802-431.0 GFCI, 125V 20A, 36' 1
12-3 CORD (981000)
33 8.757-784.0 Motor 2hp 115V 1
1725rpm 56C TEFC
ITEM PART NO. DESCRIPTION QTY
34 9.802-741.0 Bolt, 8MM X 16MM 8
Hex Head
35 8.718-980.0 Washer, 5/16" Flat, 12
SAE (780452)
36 Please See Pump Assembly Page
37 8.755-187.0 Grommet, Rubber, 4
Nozzle Holder Base 3/16
38 Please See Fuel Tank Assembly Page
39 8.925-828.0 Handle Assembly 1
Painted 555HE
40 8.925-842.0 Base Cover Plate 555HE 1
41 8.929-154.0 Top part Hat Heat 1
Exchanger Black
42 8.757-730.0 Label Warning Symbol 1
Disconnect
43 8.757-733.0 Label Caution Hot Fluid 1
44 9.802-712.0 Bolt, 5/16-18 X 1-3/4", 4
NC Carriage zinc
45 8.928-977.0 Assembly Brake 1
46 8.757-736.0 Label Logo White Hotsy 2
47 8.757-735.0 Label Detergen Use Hotsy 1
48 8.901-125.0 Label, Detergent 1
Metering
49 9.803-545.0 Grommet, 2-5/16" 2
Rubber,Cab Washer,P/N80
50 8.757-691.0 Elbow Blower plastic 1
PP Black
51 8.929-143.0 Hose 3/8 X 34.5 1 Wire 3/8
Mpt X 3/8 Np 1
52 8.755-033.0 Bulkhead,3/8"FXF 1
NPT X1-14UNS M,ST,6KPSI
53 8.929-142.0 Hose 3/8 x 37 3/8 90 1
Deg Npt x 1/2 Ji
54 8.707-152.0 Nipple, 3/8", Male, Ssteel 1
55 8.757-732.0 Label Caution Diesel Type 1
56 8.704-654.0 Label, Hotsy Logo Red 1
57 8.757-731.0 Label Warning 1
Symbol Injuries
58 5.363-360.0 Seal 2
59 8.757-734.0 Label Danger Electrocution 1
60 4.655-044.0 Bottom pressure coil 1
61 6.303-258.0 Self-tapping screw 3
62 4.652-009.0 Complete coil cover 1
63 5.652-002.0 Outer covering
(only coil wrap) 1
64 4.680-126.0 Heating coil 1
65 7.311-155.0 Hexagon nut M22x1,5
-Cu2 DIN 936 2
66 6.366-009.0 Seal string 1

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
OPERATOR’S MANUAL
PRESSURE WASHER
16
BLOWER ASSEMBLY EXPLODED VIEW
BLOWER ASSEMBLY PARTS LIST
10
9
22
2
7
4
12
14 13
11
ITEM PART NO. DESCRIPTION QTY
1 5.064-341.0 Cover blower 1
2 8.757-700.0 Spacer Blower 6x25x 4
10mm PP
3 5.111-369.0 Sleeve 4
4 4.605-139.0 Housing blower complete 1
5 5.600-100.0 Blower wheel 1
6 5.606-009.0 Air flap 1
7 8.757-692.0 Adapter Blower Wheel 1
Motor PP Black 1/2"
8 8.928-998.0 Support Bracket Fan 1
Painted
9 8.757-781.0 Electric Motor Simel 1
120V with plug
10 8.757-722. 0 Fuel Pump Oil Burner 1
OL35BK
8.929-360.0 Solenoid Kit 1
for fuel pump (Only Kit)
11 6.389-261.0 Screw union 1
12 8.757-366.0 Nipple, 1/4" X 3", W/SLNT 1
13 8.757-205.0 Hose barb, 1/4" 2
Barb x 1/4" M-NPTF, 90˂
ITEM PART NO. DESCRIPTION QTY
14 8.757-652.0 Filter Fuel Hotsy 1/4"
female 1
15 9.802-778.0 Nut, 5/16" Whiz 2
Loc Flange
16 7.303-084.0 Screw 4x25 - 2
10.9-R2R (K-In6Rd)
17 7.303-107.0 Screw 5x16 -10.9-P2R 1
(K-In6Rd)
18 7.306-181.0 Screw M 5x 1
12-A2-70 (In6Rd)
19 8.601-297.0 Washer M5 2
Flat SS
20 9.802-802.0 Washer, 1/4" 4
Flat Sae Zinc
21 8.757-818.0 Screw Hex M6 x 4
40 STZNPLT
22 8.757-788.0 Rivet Nut M6 x 1.0 4
23 8.757-832.0 Cap Plastic 1 1/4" 1
24 8.617-286.0 Screw, M4 X 12 4
PHMS SS ISO7045
1
19
16
23
17
18
19
5
21
3
15
8
24
20
6

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
17
PRESSURE WASHER
OPERATOR’S MANUAL
FUEL TANK ASSEMBLY EXPLODED VIEW
FUEL TANK ASSEMBLY PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.757-693.0 Fuel Tank PE-Crosslink Hotsy 8 Gal Black 1
2 8.757-205.0 Hose Barb, 1/4" Barb x 1/4" M-NPTF, 90˂ 1
3 8.707-352.0 Valve, Ball 1/4 NPT X 1/4 H 1
4 9.802-254.0 Hose, 1/4" Push-On, /FT 1.6'
5 6.390-126.0 Clamp Hose 4
6 9.803-535.0 Cap with fuel display 14" 1
7 9.802-254.0 Hose, 1/4" Push-On, /FT 2.7'
2
6
5
1
7
3
4

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
OPERATOR’S MANUAL
PRESSURE WASHER
18
CONTROL PANEL ASSEMBLY EXPLODED VIEW
CONTROL PANEL PARTS LIST
T
H
E
RM
OST
AT
ITEM PART NO. DESCRIPTION QTY
1 8.929-171.0 Control Tower Electrical Bracket Painted 1
2 8.929-172.0 Tower Body EVO Painted 2
3 8.716-054.0 Switch, Rocker, 20A/230V 2
4 9.802-283.0 Hour Meter, 24-240VAC 50/60HZ 1
5 8.724-272.0 Contactor, DP C25DNY153AL, 30 AMP 1
6 8.724-304.0 Overload, XTOB024CC1DP, 16.0 - 24.0 1
7 9.802-695.0 Nut, 10/32" KEPS 4
8 8.750-095.0 Thermostat, 120C/240F, 2 Meter Capillary 1
9 8.750-254.0 Socket, Receptacle, Panel-9 PIN, Fem 1
10 9.802-514.0 Strain Relief, LT, Str, 1/2 NPT,.23-.45D 2
11 9.802-518.0 Strain Relief, LT, Str, 3/4 NPT .49-_.71D 1
12 8.749-976.0 Terminal Block, Feed-Through, Phoenix 5
13 9.804-595.0 End Bracket, Entrelec, 103-002-26 2
14 8.749-977.0 Bar, Jumper, Phoenix FBS 2-5GY 3
15 8.749-980.0 Terminal Block, End Cap, Phoenix 2
16 8.929-168.0 Components Panel Painted 1
17 8.757-999.0 Gasket Control Panel 555HE 1
18 9.763-194.0 Screw M6x20 -A2-70 Scotchgrip 2
19 8.750-097.0 Knob, Thermostat 120C/248F 1
20 8.712-190.0 Bezel, Plastic, Thermostat (915390) 1
21 8.718-779.0 Screw, 4MM X 6 MM, Pan Head 2
22 8.925-831.0 Control Panel SS 555HE 1
23 8.752-969.0 Strain Relief,LT,STR,1/2NPT 0.39-0.75ID 1
24 8.750-255.0 Socket, Plug, Panel-9 PIN, Male 1
25 9.802-065.0 Grommet 1-5/16'Rubber,Drum Cleanr,MB28 1
26 8.757-773.0 Label control box 1
19
416
26
17
22
2
1
7
5
12,13,14,15
10
23
11
24
25
25
9
6
8
21
20
18
3

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
19
PRESSURE WASHER
OPERATOR’S MANUAL
ACCESSORIES ASSEMBLY
ACCESSORIES ASSEMBLY PARTS LIST
1
2
3
4
5
6
ITEM PART NO. DESCRIPTION QTY
1 9.804-624.0 Nozzle, Sacqmeg,
150375, Yellow. 1
9.804-625.0 Nozzle, Sacqmeg,
250375, Green. 1
9.804-626.0 Nozzle, Sacqmeg,
400375, White. 1
2 8.725-389.0 Wand, Single, 36" Insulated 1
W/ Side Grip
3 9.802-164.0 Coupler, 1/4" Socket, Fem 1
Brass
4 8.707-140.0 Nipple, 1/4", Male, 1
Ssteel
5 8.751-235.0 Gun, Hotsy, H1050 1
5000 Psi, 10.4 Gpm
6 8.925-130.0 Hose, 3/8" X 50' 1W 1
4000PSI SW/SO/CPL
REPLACEMENT PARTS
8.717-661.0 Insulator Grip Assembly 1
8.706-670.0 Side Handle Grip 1
8.751-119.0 Kit, Gun Repair 1

HOTSY 555HE • 9.808-140.0 • Rev. 10/19
OPERATOR’S MANUAL
PRESSURE WASHER
20
11
15
2
10
17
9
13
14
5
7
14
12
16
8
4
1
6
3
PUMP ASSEMBLY EXPLODED VIEW
PUMP ASSEMBLY PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.757-784.0 Motor 2hp 115V 1725rpm 56C TEFC 1
2 8.754- 696.0 Unloader, VBT Banjo 1/2M 3/8M, 3000PSI 1
3 8.757-740.0 Piston pump Hotsy HFP2230SR 1
4 9.803-275.0 Injector,Adjustable,Inlet,Hotsy (873596) 1
5 8.707-057.0 Strainer,˂Plastic,˂1/4",˂Hose˂Barb 1
6 8.757-511.0 Elbow, 3/8", Steel 1
7 8.757-513.0 Bushing, 1/2"NPTF(M) X 3/8"NPTF(F),Steel 1
8 8.757-800.0 Swivel Brass 3/8 NPTF (M) x 3/4 GHF 1
9 9.802-720.0 Bolt, 3/8" x 1", NC HH 4
10 9.802-814.0 Washer, 3/8" Split Ring Lock, Zinc 4
11 8.757-192.0 Plug, 1/4" NPTF Countersunk Brass 1
12 8.705-039.0 Back Flow Preventor 3/4' F X M 1
13 9.802-252.0 Hose, 1/4 x 1/2 Braided Vinyl 8'
14 6.390-126.0 Clamp Hose 2
15 8.707-256.0 Pump Protector,1/2" PTP,140DEG,P/N 100 1
16 9.804-016.0 Filter Screen Washer, Garden Hose/30MESH 1
17 8.716-125.0 Switch,Pressure,3/8" BSP Brass, 65" 1
18 9.803-834.0 Washer, Reducing 3/4" x 1/2" 1
19 8.752-969.0 Strain relief, LT, STR, 1/2 NPT 0.39-0.75ID 1
19
18