Hotsy 680SS Service manual

8.914-368.0
SERIAL NUMBER:
DATE PURCHASED:
FOR SALES AND SERVICE, PLEASE CONTACT:
SPECIFICATIONS
●Pump Volume At Pump Head: 3.0 GPM/180 GPH
●Pump Pressure At Pump Head: 1000 PSI
●Burner Type: Fuel Oil Fired, 289,900 BTU/Hr.
●Burner Fuel Pressure: 200 PSI Max.
●Machine Voltage: 120VAC/60Hz/1Ph
●Total Machine Amperage: 20 Amps
●Machine Weight: 332 Lbs.
●Shipping Weight: 367 Lbs.
●Exhaust Stack Size: 8"
●Machine Dimensions: Length = 44", Width = 26", Height = 41"
Output specifications are based on engine power curves at 100 meters
above sea level and 25oC ambient temperature in accordance with
SAE J1349.
MODEL 680SS
OPERATING INSTRUCTIONS
AND PARTS MANUAL
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!

3
CONTENTS
HOTSY 680SS • 8.914-368.0 • Rev. 02/15
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 7
Assembly Instructions 8
Installation Instructions 9
Operation Instructions 10
General Washing Techniques & Storage 11
Maintenance 12
Troubleshooting 13-14
Exploded Views 15-16
Exploded View Parts List 17
Burner Assembly Exploded View & Parts List 18
Crossfire Burner Exploded View & Parts List 19-20
Fuel Tank Assembly & Parts List 21
Control Panel Assembly & Parts List 22
Coil Outlet Assembly & Parts List 23
Hose, Gun & Wand Assembly & Parts List 24
Pump Assembly & Parts List 25
Pump, Exploded View & Parts List 25-26
VBA Unloader Exploded View & Parts List 27
Wiring Diagram 28

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
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 fol-
low 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 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 qualified 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 fit the
outlet, have a proper outlet installed by a qualified
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 elec-
tric 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 amper-
age 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.
RISK OF EXPLOSION:
OPERATE ONLY WHERE
OPEN FLAME OR TORCH
IS PERMITTED
WARNING
WARNING: Flammable liquids
can create fumes which can ig-
nite, causing property damage
or severe injury.
WARNING: Risk of explosion —
Operate only where open flame
or torch is permitted.
6. In oil burning models, use only kerosene, No. 1
home heating fuel, or diesel. If diesel is used, add
a soot remover to every tankful.
RISK OF FIRE.
DO NOT ADD FUEL
WHEN OPERATING
MACHINE.
WARNING
WARNING: Risk of fire — Do not
add fuel when the product is
operating or still hot.
WARNING: Do not use gasoline
crankcase draining or oil con-
taining gasoline, solvents or
alcohol. Doing so will result in
fire and/or explosion.
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 680SS • 8.914-368.0 • Rev. 02/15
5
PRESSURE WASHER OPERATOR’S MANUAL
13. Never make adjustments on machine while in
operation.
14. Be certain all quick coupler fittings are secured
before using pressure washer.
RISK OF INJECTION
OR SEVERE INJURY
TO PERSONS. KEEP
CLEAR OF NOZZLE.
WARNING
WARNING: High pressure de-
veloped 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 clean fresh water and no hotter
then 90°F.
WARNING
RISK OF
ASPHYXIATION: USE
THIS PRODUCT ONLY
IN A WELL
VENTILATED AREA.
WARNING: Risk of asphyxiation.
Use this product only in a well
ventilated area.
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 compo-
nents 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
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 fly 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.
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 fluid.
Do not touch or direct discharge
stream at persons.
WARNING: This machine pro-
duces hot water and must have
insulated components attached
to protect the operator.
WARNING
RISK OF INJURY:
HOT SURFACES
CAN CAUSE BURNS
WARNING: Risk of injury. Hot
surfaces can cause burns. Use
only designated gripping areas
of spray gun and wand. Do not
place hands or feet on non-in-
sulated 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.

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
OPERATOR’S MANUAL PRESSURE WASHER
6
IMPORTANT SAFETY INFORMATION
and drainage to reduce the possibility 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 medi-
cations, or drugs.
Follow the maintenance instructions
specified in the manual.

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
7
PRESSURE WASHER OPERATOR’S MANUAL
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.
Note:If trigger on spray gun is released for more
than 2 minutes, water will leak from the pump
protector. Warm water will discharge from pump
protector onto floor. This system prevents internal
pump damage.
Relief Valve
Unloader
Valve
Wand
Pump
Detergent
Valve
High
Pressure
Hose
Spray
Gun

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
OPERATOR’S MANUAL PRESSURE WASHER
8
Figure 2 - Pressure Hose Installation
Relief
Valve
Pressure
Hose
ASSEMBLY INSTRUCTIONS
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 pal-
let.
2. Remove pressure washer from pallet.
Parts Included
• Pressure Washer
• Pressure Hose
• Hose Hanger
• Wand
• Wheels (4 Ea.)
• Axles (2 Ea.)
• Handle
• Parts Bag Containing:
■ Bolts 5/16" x 1-1/2" (5 Ea.)
■ Vinyl Cap
■Nuts 5/16" (5 Ea.)
■Washers 5/8" (10 Ea.)
■Pressure Nozzle
■Hubcaps (4 Ea.)
■Spring Washers (4 Ea.)
■Quick Disconnect
■Quick Disconnect Plug
■Trigger Gun
■GFCI Cord Hanger
• Operating Instructions and Parts Manual
Tools Required
• 10" Adjustable Crescent Wrenches (2 Ea.)
• 11/16" Socket
• Hammer
• 7/16" Open End Wrench
• Teflon Tape
Pressure Hose and Wand
1. When assembling, use teflon tape on all plumbing
connections to prevent leakage.
2. Install pressure hose on machine as shown in
Figure 2.
IMPORTANT: Before installing pressure hose onto the
trigger gun/wand assembly, turn on the water supply
and allow water to run from the end of the hose until
clear to prevent the nozzle from clogging.
3. Assemble wand components as shown in Figure 3.
Connect pressure hose to trigger gun.
4. Make sure that all plumbing connections are tight.
Figure 3 - Wand Components
Quick Disconnect
Plug
Quick Disconnect
Wand
Nozzle
Trigger
Gun
Pressure Hose
INSTALLATION
INSTRUCTIONS
Getting Started
IMPORTANT: Proper initial installation of equipment
will assure more satisfactory performance, longer
service life, and lower maintenance cost.
IMPORTANT: The use of a backflow preventer on the
water supply hose is recommended and may be re-
quired by local code.
The pressure washer should be run on a level surface
and in a protected area where it is not readily influenced
by outside forces 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 from coming in
contact with the pressure washer. Moisture reaching the
equipment will reduce the pressure washer’s service life.
All installations must comply with the local codes covering
such installations.

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
9
PRESSURE WASHER OPERATOR’S MANUAL
INSTALLATION INSTRUCTIONS
Figure 4 - Burner Air Band Adjustment
10
8
6
4
2
Air Shutter Locking Screw
Air Shutter
Air Band
Air Band Locking Screw
Air Shutter Locking Screw
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. 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. 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.
Beckett Oil Burner
Burner Air Adjustment: The oil burner is preset for
operation at altitudes below 1000 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 4) and
close air shutter until black smoke appears from burner
exhaust vent. Note air band position. Next, slowly open
the air shutter until white smoke just starts to appear.
Turn air shutter halfway back to the black smoke position
previously noted. Tighten locking screws.
If the desired position cannot be obtained using only the
air shutter, lock the air shutter in as close a position 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 ser-
viceman adjust your burner for a #1 or #2 smoke spot
on the Bacharach scale.
For additional burner component information, see
Burner Assembly. It is recommended that the oil burner
be serviced yearly or as needed. Contact your local
service center.
Crossfire Oil Burner
Burner Air Adjustment:The oil burner on this machine
is preset for operation at altitudes below 1000 feet. If
operated at higher altitudes, it may be necessary to
adjust the air band for a #1 or #2 smoke spot on the
Bacharach scale.
To adjust, start machine and turn burner ON. Loosen
two locking screws found on the air band and close air
band until black smoke appears from burner exhaust
vent. Note air band position. Next, slowly open the air
band until white smoke just starts to appear. Turn air
band halfway back to the previously noted position.
Tighten locking screws.
Burner Air Adjustment
Reference Numbers
Air Band Locking Screws
Air Band
CAUTION: If white smoke appears from burner ex-
haust vent during start-up or operation, discontinue
use and readjust air bands.
NOTE: If a flue is installed, have a professional service-
man adjust your burner for a #1 or #2 smoke spot on
the Bacharach scale.

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
OPERATOR’S MANUAL PRESSURE WASHER
10
OPERATION INSTRUCTIONS
Before Starting
WARNING: Check hoses, trigger guns, fittings, and
fuel connections daily for signs of wear, cracks and
looseness, and replace as required.
1. Connect water supply hose to the standard garden
hose connector. The water faucet and supply hose
must be capable of providing 3.0 GPM at 20 to 80
PSI.
2. Fill fuel tank. Use kerosene, #1 grade home heating
oil, #1 or #2 diesel fuel. DO NOT USE GASOLINE.
3. Check pump oil level.
4. 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 cleaner is equipped with a UL
approved ground fault circuit interrupter (GFCI) power
cord. Use UL grounded type receptacles of proper volt-
age and amperage ratings. Where a properly grounded
receptacle is not available, it is the personal respon-
sibility of the owner to have one installed. Always
disconnect power before servicing your cleaner.
Connect electrical cord and test the GFCI using the reset
and test procedures conveniently located on the GFCI
device.The GFCI must be reset and tested with every use.
Do not use machine if the GFCI device fails test.
To Start
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 in
bypass for more than 10 minutes at any one time or
damage to pump may occur.
1. Turn water on.
2. Hold trigger gun firmly, squeeze trigger 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
or temperature setting is reached, the burner will
automatically 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. Turn OFF pump switch.
4. Turn OFF water supply.
5. Squeeze trigger gun open to relieve system pres-
sure.
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.

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
11
PRESSURE WASHER OPERATOR’S MANUAL
Pre-rinse cleaning surface with fresh water. Place de-
tergent suction tube directly into cleaning solution and
apply to surface at low pressure (for best results, limit
your work area to sections approximately 6 feet square
and always apply detergent from bottom to top). Allow
detergent to remain on surface 1-3 minutes. Do not
allow detergent to dry on surface. If surface appears
to be drying, simply wet down surface with fresh water.
If needed, use brush to remove stubborn dirt. Rinse at
high pressure from top to bottom in an even sweeping
motion keeping the spray nozzle approximately 1 foot
from cleaning surface. Use overlapping strokes as you
clean and rinse any surface. For best surface cleaning
action spray at a slight angle.
Recommendations:
• Before cleaning any surface, an inconspicuous
area should be cleaned to test spray pattern and
distance for maximum cleaning results.
• If painted surfaces are peeling or chipping,
use extreme caution as pressure washer may
remove the loose paint from the surface.
• Keep the spray nozzle a safe distance from the
surface you plan to clean. High pressure wash a
small area, then check the surface for damage. If
no damage is found, continue to pressure wash-
ing.
CAUTION - Never use:
• Bleach, chlorine products and other corrosive
chemicals
• Liquids containing solvents (i.e., paint thinners,
gasoline, oils)
• Tri-sodium phosphate products
• Ammonia products
• Acid-based products
These chemicals will harm the machine and will dam-
age the surface being cleaned.
GENERAL CLEANING TECHNIQUES & STORAGE
RINSING
It will take a few seconds for the detergent to clear.
Apply safety latch to spray gun. Select and install de-
sired high pressure nozzle. NOTE: You can also stop
detergent from flowing by removing detergent siphon
tube from bottle.
STORAGE
DANGER: DO NOT store flammable liquids (gasoline,
diesel fuel, solvents, etc.) near pressure washer, or in
non-ventilated areas.
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 flows from
the end of the wand. Place end of wand into float tank
and circulate the antifreeze through system for several
minutes. 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 Figure
12 Item 15 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 680SS • 8.914-368.0 • Rev. 02/15
OPERATOR’S MANUAL PRESSURE WASHER
12
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.
Pump
Lubrication: To lubricate pump, use 30W non-detergent
oil for pump crankcase. Crankcase must be filled to center
of sight glass window found on the rear of the pump, refer
to Figure 5. 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.
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 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 to details.
Pump Motor
On a yearly basis, oil pump motor per instructions on
motor nameplate.
NOTE: Some motors may be equipped with perma-
nently lubricated bearings and will not require ad-
ditional lubrication.
Relief Valve
WARNING: The relief valve on this pressure washer
has been factory set and sealed and is a field non-
adjustable part. Tampering with the factory setting
may cause personal injury and/or property 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.
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 Pump Assembly, Item 4.
Burner Fuel Filter
Drain any water which has accumulated in fuel filter
and clean or replace filter element as needed. 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.
Figure 5 - Pump Lubrication
Oil Sight
Glass
Oil Fill/
Dipstick
Oil Drain Plug

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
13
PRESSURE WASHER Troubleshooting Guide
TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
PUMP MOTOR WILL
NOT RUN
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 (thermal
overload protector) tripped
Push reset button on control box. If
tripped, check for proper voltage or
clogged water nozzle.
Excessive pressure due to clogged
water nozzle
Clean water nozzle.
NO WATER SPRAYS
FROM WATER
NOZZLE
Water nozzle completely clogged Clean water nozzle.
Inlet water screen clogged Check screen and clean if necessary.
Pump sucking air Fill the detergent container and check for
loose hose clamps or fittings.
LOW PRESSURE
FROM WATER
NOZZLE
Inlet water screen clogged Check screen and clean if necessary.
Water nozzle worn or incorrect size Replace nozzle with proper size.
Water supply low Correct water supply.
Pump sucking air Fill the detergent container and check for
loose hose clamps or fittings.
POOR OR NO
DETERGENT FLOW
Low detergent level Fill the detergent container.
Detergent screen clogged Clean if necessary.
Detergent valve not opening Check that handle or knob is not slip-
ping on shaft.
Water nozzle clogged Clean water nozzle.
Excessive inlet pressure
(more than 80 PSI)
Install pressure regulator on the inlet
line.
BURNER WILL NOT
IGNITE WHEN
TRIGGER GUN IS OPEN
Defective pressure switch Replace pressure switch.
No fuel Fill fuel tank with proper fuel.
Fuel valve closed Check that fuel valve on fuel tank is
open.
Thermostat set too low Raise thermostat setting.
Burner motor reset button (thermal
overload protector) tripped
Push reset button on burner motor. If
tripped, check for proper voltage.
Clogged fuel filter Clean fuel filter.
BURNER SMOKES
OR HAS
OBNOXIOUS ODOR
Air intake adjustment needs to be
adjusted
Readjust air intake per the oil burner
section of this manual.
Improper fuel Use proper fuel.

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
PRESSURE WASHER Troubleshooting Guide
14
TROUBLESHOOTING
When ordering from your dealer, please provide the following:
Model Number: 680SS
Machine Serial Number: ________________________________
Component Part Number: _______________________________
Description: __________________________________________
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.

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
15
PRESSURE WASHER OPERATOR’S MANUAL
EXPLODED VIEW - LEFT
36
2
29
31
49
2
48
17 16
51
55
22
21
23
52
57
54
18
52
2
51
2
19
16
17
20
13
1
34 24
25
27
12
25
33
26
2
See
View
A-A
58
59
56
55
47
61
60
26
27
2
56
2
50
50

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
OPERATOR’S MANUAL PRESSURE WASHER
16
EXPLODED VIEW - RIGHT
A-A
46
43
30
41
44
45
42
47 5
6
7
4
9
3
32
8
14
10
11
40
39
37
38
See Control
Panel Assy.
For Detail
51
17
16
15
62 63
35 53
For
Detail See
Coil Outlet
Assy.

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
17
PRESSURE WASHER OPERATOR’S MANUAL
EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.901-106.0 Label, Hotsy Logo Stripe 2
2 9.802-778.0 Nut, 5/16" Whiz Loc Flange 16
3 8.704-654.0 Label, Hotsy logo Red 2
4 9.802-825.0 Clip, Retaining U-Type 4
5 8.719-913.0 Top Hat, Weld Assy, 16" 1
6 9.802-904.0 Insulation, Top Head, 1
16 Od x 8.0 Id, Fiberglass
7 9.803-108.0 Insulation Retaining Ring 1
8 8.717-438.0 Insulation Blanket 22.5 x 52 1
9 8.719-946.0 Hanger, Hose 1
10 8.900-894.0 Label, Operating/Warning 1
11 9.802-903.0 Insulation, Bottom, 16 Od x 4.5 1
12 8.911-832.0 Frame, Welded Assy Hotsy 1
13 9.802-716.0 Bolt, 5/16 x 2", Nc Hh 4
14 8.911-804.0 Outer Wrap Assy 1
15 9.802-274.0 Wheel & Tire Hard Rubber 4
16 8.718-870.0 Nut, .61 Id, Push Flat 4
17 9.182-506.0 Cap Blk Plastic 5/8" Fastener 4
18 9.802-754.0 Screw, 1/4" x 1/2" Nc, 2
Whiz Loc Flange
19 8.719-000.0 Washer, 5/16" x 1-1/4", 3
Fender, Sae
20 8.901-136.0 Label, Use Hotsy Detergent 1
21 8.901-124.0 Label, Water Metering 1
22 8.901-125.0 Label, Detergent Metering 1
23 8.901-135.0 Label, Caution Winterize 1
24 8.706-744.0 Plug, Plastic 1" 1
25 8.709-090.0 Clamp, Wire/Tube, 0.750D 2
26 8.718-588.0 Screw, 10-24" x 1/2", Ph, Ms 2
27 8.718-863.0 Nut, 10-24, Esna, Nf 2
29 8.706-698.0 Cap, 0.812 Od x 1", Vinyl Black 1
30 9.802-431.0 CFCI, 120V 20A, 36' 12-3 Cord 1
31 8.920-274.0 Handle, Hotsy 1
32 8.919-134.0 Coil Assy 1
33 9.803-098.0 Holder 1
34 8.706-731.0 Bushing, 3/4" Snap 1
35 8.932-969.0 Label, Warning Service Cord 1
36 9.804-517.0 Motor, 2Hp 1Ph 120V, 1
1725 Rpm 56C Odp
37 8.706-216.0 Tee, 1/2" Fpt Steel 1
38 8.705-975.0 Nipple, 1/2" Hex Steel 1
39 8.706-243.0 Plug, 1/2" Square Head, Galv 1
40 9.802-038.0 Nipple, 1/2" Jic x 1/2" Mpt 1
Steel
ITEM PART NO. DESCRIPTION QTY
41 8.918-425.0 Hose, 3/8” x 29”, 2 Wire, 1
Pressure Loop
42 8.912-017.0 Lever, Brake, Red 1
43 8.912-020.0 Linkage, Brake, Red 1
44 8.912-019.0 Bracket, Brake Pad, Red 1
45 9.802-705.0 Bolt, 1/4"-20 x 1" Carriage Zinc 4
46 9.802-773.0 Nut, 1/4-20 Esna Nc 4
47 9.802-802.0 Washer, 1/4" Flat Sae Zinc 14
48 9.802-720.0 Bolt, 3/8" x 1", Nc Hh 4
49 8.752-969.0 Strain Relief, Lt, Str, 1/2 Npt 1
50 6.390-126.0 Clamp, Hose, .46-.54 St 2
51 9.802-810.0 Washer, 5/8", Flat, Sae Zinc 4
52 8.718-625.0 Bolt, 5/16"-18 x 3/4", Nc 5
Carriage Zinc
53 9.800-021.0 Label, Hot Water Outlet 1
54 8.911-807.0 Bracket, Hose Reel Mount 1
55 8.718-980.0 Washer, 5/16" Flat, Sae 5
56 9.802-104.0 Bushing, 1" Snap 1
57 8.718-618.0 Bolt, 5/16-18 x 3/4", 1
Hh Gr Cs Zinc
58 9.800-032.0 Label, Motor Overload Reset 1
59 9.800-049.0 Label, Manufacturers Cleaning 1
Solution
60 9.802-807.0 Washer, 3/8" Sae, Flat, Zinc 4
61 9.802-814.0 Washer, 3/8" Split Lock Zinc 4
62 8.932-968.0 Label, Intended for Outdoor Use1
63 9.800-034.0 Label, Clear Lexan 1

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
OPERATOR’S MANUAL PRESSURE WASHER
18
ITEM PART NO. DESCRIPTION QTY
1 8.717-091.0 Burner, Beckett Afg, 120V 1
1.75 Noz
8.918-908.0 Burner, 120V Crossfire
2 8.706-941.0 Hose Barb, 1/4" Barb x 1/4" 1
Mpt, Brass
3 8.706-161.0 Elbow, 1/4" Street, 90 Deg 1
Galv
4 9.803-043.0 Nipple, Pipe 1/4" x 2" Zinc 1
Sch 80 Mpt
5 8.706-297.0 Bushing, 3/8" x 1/4" Steel 1
Yellow Chrom
6 8.709-153.0 Filter, Fuel Hotsy, 3/8" Female 1
7 8.706-965.0 Hose Barb, 1/4" Barb x 3/8" 1
ML Pipe
8 9.802-645.0 Fuel Pump Cleancut 110V 1
8.700-759.0 Fuel Pump, 120V Crossfire 1
9 8.700-779.0 Oil Solenoid Valve, 110V 1
10 9.802-647.0 Burner Ignitor, Afg/LoAmp 1
Mount, 120V
8.919-114.0 Igniter, 120V Crossfire 1
11 9.802-670.0 Electrode kit 1
8.750-778.0 Electrode, Crossfire 1
12 825676 Air Cone, 5-16 1
8.750-781.0 Air Cone F22 Crossfire 1
13 8.717-346.0 Fuel Nozzle 1.75 x 90 A 1
BURNER ASSEMBLY
1
2
3
4
5
8
97
10 11
6
12
13
14
21
13
BURNER ASSEMBLY PARTS LIST
ITEM PART NO. DESCRIPTION QTY
14 9.802-642.0 Burner Motor, 120V, 1
3450 Rpm 1/7 Hp
8.750-517.0 Motor, 115V Crossfire 1
15 8.717-711.0 ▲Filter Screen Replacement 1
16 9.802-649.0 ▲Blower Wheel 4.25 x 2.5 1
Afg/Turb
8.750-520.0 ▲ Fan, Crossfire 1
17 8.717-853.0 ▲Coupling 1
8.751-543.0 ▲ Coupling, Crossfire 1
18 9.802-646.0 ▲ Valve Stem kit Cleancut 1
Pump
19 9.802-666.0 ▲ Screen, Fuel Pump 1
20 9.802-519.0 ▲ Strain Relief, 1/2" Metal 1
21 9.801-264.0 Label, Hotsy Crossfire 1
▲ Not Shown
1/8" AC
3/16" DC Nozzle-to-tip
spacing
1/8"min
5/32" max Gap
1/4" Above
nozzle center

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
19
PRESSURE WASHER OPERATOR’S MANUAL
Replacement Parts
For best performance specify genuine KNA replacement parts
BURNER HOTSY CROSSFIRE EXPLODED VIEW
5
4
50
51

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
OPERATOR’S MANUAL PRESSURE WASHER
20
Replacement Parts
For best performance specify genuine KNA replacement parts
Item # Part # Description Qty Item # Part # Description Qty
1 8.919-050.0 BURNER HOUSING ASSEMBLY 1 23 8.919-116.0 IGNITOR, BURNER 12VDC 1 2 8.751-160.0 AIR GUIDE 24 8.751-165.0 PLUG, HOLE 0.875 PLASTIC 1 3 8.700-758.0 FUEL PUMP, SUNTEC A2VA-3106 12-24V SOL 1 25 8.750-830.0 PLUG, HOLE 0.285 PLASTIC 1 3 8.700-759.0 FUEL PUMP, SUNTEC A2VA-3106 120V SOL 1 26 8.751-134.0 PLUG, 1/8" NPT x HEX SHOULDER 1 3 8.700-760.0 FUEL PUMP, SUNTEC A2VA-3106 230V SOL 1 27 8.918-454.0 GASKET, JUNCTION BOX 1 3 8.753-000.0 FUEL PUMP, DANFOSS 071N1298 1 28 8.750-542.0 COVER, JUNCTION BOX 1 4 8.750-762.0 COIL, SOLENOID DANFOSS 230V 1 29 8.750-116.0 BLOCK, TERMINAL, 5 POLE 1 4 8.750-763.0 COIL, SOLENOID DANFOSS 120V 1 30 8.750-817.0 LIGHT, INDICATOR, GREEN 14V 2 4 8.750-764.0 COIL, SOLENOID DANFOSS 12-24V 1 30 8.750-818.0 LIGHT, INDICATOR, GREEN 28V 1 5 8.750-765.0 CABLE, SOLENOID COIL, DANFOSS 1 30 8.750-819.0 LIGHT, INDICATOR, GREEN 125V 1
5a 8.750-783.0 MOUNTING KIT, FLANGE/HUB, DANFOSS 1 30 8.750-820.0 LIGHT, INDICATOR, GREEN 250V 1
6 8.750-541.0 AIR BAND 1 31 8.750-784.0 SITE GLASS 1 7 8.750-517.0 MOTOR, 1/6 HP 120V 60Hz 1 32 8.750-785.0 RING, PUSH ON INTERNAL, 1305-112 1 7 8.750-518.0 MOTOR, 1/6 HP 230V 60Hz 1 33 8.733-001.0 SCREW, 8 x 1/4" HI LOW THREAD CUT, PPH 2 7 8.751-074.0 MOTOR, 1/7 HP 12VDC AMETEK 1 34 8.718-762.0 SCREW, 8-32 X 1/2", M PH RDH PL 2 8 8.750-543.0 COUPLING, FLEX, 1/2" x 5/16" 1 35 8.750-769.0 SCREW, 8/32 X 3/8" PH 1 8 8.751-073.0 COUPLING, FLEX, 5/16" x 5/16" 1 36 8.718-810.0 SCREW, 10/32 x 1/2", WHIZ LOC FLANGE 6 9 8.750-520.0 FAN, 4.53" X 2.42", 1/2" BORE, F115-62S 1 37 8.750-770.0 SCREW, 10/32 x 5/8", WHIZ LOC FLANGE 3 9 8.751-072.0 FAN, 4.53" x 2.42" x .313 BORE, F115-625 1 38 8.750-816.0 SCREW, 10/32 X 1/4" GROUNDING 1
11 8.750-547.0 CONNECTOR, 37 DEG FLARE X 1/8" NP LONG 1 39 8.750-768.0 SCREW, 1/4-20 x 1", WHIZ LOC FLANGE 4 12 8.750-545.0 CONNECTOR, 37 DEG FLARE X 1/8" NPT 1 40 8.750-771.0 SCREW, 1/4-20 X 1/2", PHIL FHMS 4 13 8.749-000.0 FUEL LINE ASSEMBLY 1 42 — LABEL, BRAND NAME 1 14 8.918-864.0 FLANGE 1" TUBE ASSY, BURNER 1 43 9.801-268.0 LABEL, DISCONNECT POWER SUPPLY 1 15 8.918-866.0 FLANGE 3" TUBE ASSY, BURNER 1 44 — LABEL, SERIAL PLATE 1 16 8.750-539.0 GASKET, FLANGE 1 46 9.807-339.0 LABEL, WIRING DIAGRAM, BURNER 120V-120V 1 17 8.750-528.0 DISK, STATIC 2.00 1 46 9.807-340.0 LABEL, WIRING DIAGRAM, BURNER 230V-230V 4 17 8.918-868.0 DISK, STATIC 2.75 1 46 9.807-341.0 LABEL, WIRING DIAGRAM, BURNER 230V-115V 1 17 8.918-869.0 DISK, STATIC 2.50 1 46 9.807-342.0 LABEL, WIRING DIAGRAM, BURNER 120V-24V 1 17 8.918-870.0 DISK, STATIC 2.25 1 46 9.807-343.0 LABEL, WIRING DIAGRAM, BURNER 230V-24V 1 18 8.750-526.0 GUN, ELECTRODE / NOZZLE, 3" 1 46 9.807-344.0 LABEL, WIRING DIAGRAM, BURNER 12VDC 1 19 8.750-525.0 GUN, ELECTRODE / NOZZLE, 1" 1 48 9.801-274.0 LABEL, BURNER LIGHTS 1 20 Varies NOZZLE, FUEL 1 49 8.919-105.0 PLATE, TERMINAL BLOCK NUMBERS 1 21 8.750-778.0 ELECTRODE, IGNITION 1 50 8.716-451.0 TERMINAL, JUMPER SPADE 1 22 8.750-779.0 CONE, AIR F4 1 51 9.802-510.0 CABLE, TIE, 4" BLACK 2 22 8.750-782.0 CONE, AIR F6 1 52 9.807-348.0 LABEL, CLEAR MYLAR 1 22 8.750-780.0 CONE, AIR F12 1 53 9.807-345.0 LABEL, IGNITER 120V 1 22 8.750-781.0 CONE, AIR F22 1 53 9.807-346.0 LABEL, IGNITER 230V 1 23 8.919-114.0 IGNITOR, BURNER 120V 1 53 9.807-347.0 LABEL, IGNITOR 12VDC 1 23 8.919-115.0 IGNITOR, BURNER 230V 1
BURNER HOTSY CROSSFIRE PARTS LIST

HOTSY 680SS • 8.914-368.0 • Rev. 02/15
21
PRESSURE WASHER OPERATOR’S MANUAL
FUEL TANK ASSEMBLY
FUEL TANK ASSEMBLY PARTS LIST
6
7
5
9
4
8
1
3
2
ITEM PART NO. DESCRIPTION QTY
1 8.706-614.0 Tank, Fuel, 8 Gal Hotsy 1
2 8.901-134.0 Label, Fuel Type 1
3 9.803-535.0 Cap With Fuel Display 14" 1
4 9.802-053.0 Bushing, Fuel Line, Rubber 2
5 9.802-141.0 Hose Barb, 1/4" Barb x 3/8", Barb, Dou 1
6 9.802-254.0 Hose, 1/4" Push-On, Ft 18"
7 6.390-126.0 Clamp, Hose, .46-.54 St 4
8 9.802-177.0 Valve, 1/4" Shut Off, 180 Deg 1
9 9.802-254.0 Hose 1/4" x 20" Push-On, Fuel Line 20"