Hotsy 965SS Service manual

97-6554
SERIAL NUMBER:
DATE PURCHASED:
FOR SALES AND SERVICE, PLEASE CONTACT:
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OPERATING INSTRUCTIONS AND PARTS MANUAL
Thank you for purchasing a Hotsy PressureWasher.This manual covers the operation and mainte-
nance of your pressure washer. All information in this manual is based on the latest product informa-
tion 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!
MODELS 965SS, 1065SS,
1065SSE, 1075SSE

965SS SPECIFICATIONS
●Pump Volume At Pump Head: 3.0 GPM/180 GPH
●Pump Pressure At Pump Head: 3000 PSI
●Burner Type: Fuel Oil Fired, 248,000 BTU/Hr.
●Burner Fuel Pressure: 140 PSI
●Machine Voltage: 9 HP Honda
●Machine Weight: 385 Lbs.
●Shipping Weight: 415 Lbs.
●Exhaust Stack Size: 8"
●Machine Dimensions: Length=47", Width=31", Height=49"
1065SS SPECIFICATIONS
●Pump Volume At Pump Head: 3.5 GPM/210 GPH
●Pump Pressure At Pump Head: 3000 PSI
●Burner Type: Fuel Oil Fired, 310,000 BTU/Hr.
●Burner Fuel Pressure: 160 PSI
●Machine Voltage: 11 HP Honda
●Machine Weight: 450 Lbs.
●Shipping Weight: 480 Lbs.
●Exhaust Stack Size: 8"
●Machine Dimensions: Length=47", Width=31", Height=49"
1065SSE SPECIFICATIONS
●Pump Volume At Pump Head:3.5 GPM/210 GPH
●Pump Pressure At Pump Head: 3000 PSI
●Burner Type: Fuel Oil Fired, 310,000 BTU/Hr.
●Burner Fuel Pressure: 160 PSI
●Machine Voltage: 11 HP Honda Electric Start
●Machine Weight: 450 Lbs.
●Shipping Weight: 480 Lbs.
●Exhaust Stack Size: 8"
●Machine Dimensions: Length=47", Width=31", Height=49"
1075SSE SPECIFICATIONS
●Pump Volume At Pump Head:3.8 GPM/228 GPH
●Pump Pressure At Pump Head: 3500 PSI
●Burner Type: Fuel Oil Fired, 310,000 BTU/Hr.
●Burner Fuel Pressure: 160 PSI
●Machine Voltage: 13 HP Honda Electric Start
●Machine Weight: 450 Lbs.
●Shipping Weight: 480 Lbs.
●Exhaust Stack Size: 8"
●Machine Dimensions: Length=47", Width=31", Height=49"

3
CONTENTS
97-6554 • HOTSY 965SS-1075SS • REV. 7/05
ModelNumber ______________________________
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 4-5
ComponentIdentification 6
Assembly Instructions 7-8
InstallationInstructions 9-10
Operation Instructions 11-12
General CleaningTechniques & Storage 13-14
Maintenance 15
Troubleshooting 16-17
ExplodedViews & Parts List 18-21
Control Panel Assembly & Parts List 22-23
Burner Assembly & Parts List 24-25
FuelTank Assembly & Parts List 26
Pump Assembly & Parts List 27-28
Pump - ExplodedView & Parts List 29-30
Coil Outlet Assembly & Parts List 31-32
Coil Inlet Assembly & Parts List 33
Hose, Spray Gun & Wand Assembly & Parts List 34
Wiring Diagrams 35-36
Warranty

97-6554 • HOTSY 965SS-1075SS • REV. 7/05
OPERATOR’S MANUAL PRESSURE WASHER
4
IMPORTANT SAFETY INFORMATION
WARNING
RISK OF
ASPHYXIATION.
USE ONLY IN A WELL
VENTILATED AREA.
WARNING
READ OPERATOR’S
MANUAL
THOROUGHLY
PRIORTO USE.
WARNING
HIGH PRESSURE
SPRAY CAN PIERCE
SKIN AND TISSUES.
WARNING
KEEPWATER SPRAY
AWAY FROM
ELECTRICAL WIRING.
CAUTION:To reduce the risk of
injury, read operating instruc-
tions carefully before using.
1.Read owner's manual thor-
oughly.Failuretofollowinstruc-
tions could cause malfunction
of the machine and result in
death, serious bodily injury
and/or property damage.
2. Know how to stop machine and bleed pressures
quickly. Be thoroughly familiar with the controls.
3. Stay alert — watch what you are doing.
4. Allinstallationsmustcomply with local codes.Con-
tact your electrician, plumber, utility company or
the selling distributor for specific details.
WARNING:Riskof asphyxiation.
Use this product only in a well
ventilated area.
5. Whenthemachineisworking,
do not cover or place in a
closed space where ventila-
tion is not sufficient.
WARNING: Risk of fire. Do not
add fuel when the machine in
operating.
6. Risk of explosion — do not
sprayflammableliquidsorop-
erateinanexplosivelocation.
Operate only where open
flame or torch is permitted.
WARNING: Keep water spray
away fromelectrical wiring or fa-
tal electrical shock may result.
7. To protect the operator from
electricalshock,themachine
mustbeelectricallygrounded.
It is the responsibility of the
owner to connect this ma-
chine to a UL grounded re-
ceptacle of proper voltage
and amperage ratings. Do not spray water on or
nearelectrical components.Donottouchmachine
with wet hands or while standing in water.Always
disconnect power before servicing.
8. Grip cleaning wand securely with both hands be-
fore starting the cleaner. Failure to do this could
result in injury from a whipping wand.
WARNING:High pressure stream
of fluid that this equipment can
producecanpierceskinanditsun-
derlyingtissues,leadingtoserious
injury and possible amputation.
9. High pressure developed by
these machines can cause
personal injury or equipment
damage.Use caution when
operating.Donotdirectdischargestreamatpeople,
or severe injury and/or death may result.
10. Never make adjustments on machine while in op-
eration; disconnect from electrical source or shut
off gas valve. WARNING: High pressure spray
can cause paint chips or other
particles to become airborne
and fly at high speeds.
11. Eye safety devices and foot
protectionmustbewornwhen
using this equipment.
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 when starting gasoline
engine.
12. Machines with shut-off trigger gun should not be
operated with the trigger in the off position for ex-
tensiveperiods of time as this maycause damage
to the pump.
13. Protect from freezing.
14. Becertain allquickcoupler fittingsare secured be-
fore using pressure washer.
15. Do not allow acids, caustic, or abrasive fluids to
pass through the pump.
16. Inletwatermustbefromacold,freshcitywater supply.
17. 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.
18. The best insurance against an accident is precau-
tion and knowledge of the machine.
19. Do not operate this product when fatigued or un-
derthe influence ofalcohol or drugs. Keep operat-
ing area clear of all persons.
WARNING
RISK OF INJURY.
HOT SURFACES
CAN CAUSE BURNS
WARNING
RISK OF FIRE.
DO NOT ADD FUEL
WHEN OPERATING
MACHINE.
WARNING
PROTECTIVE
EYEWEAR AND
CLOTHING MUST
BE WORN.

97-6554 • HOTSY 965SS-1075SS • REV. 7/05 5
PRESSUREWASHER OPERATOR’S MANUAL
IMPORTANT SAFETY INFORMATION
20. Hotsy will not be liable for any changes made to
our standard machines, or any components not
purchased from Hotsy.
21. Do not overreach or stand on unstable support.
Keep good footing and balance at all times.
22. Followmaintenanceinstructionsspecifiedinmanual.
23. Cleaning area should be provided with adequate
slopes and drainage to reduce possibility of falls
because of slippery surfaces.
24. Turn burner off and cool to 100°F before turning
machine off.
25. Ifagas odor ispresent,extinguishanyopen flame,
and test all joints with a soap solution. If the odor
persists, call your gas supplier immediately.
26. Use extreme caution when moving pressure
washer over rough or uneven surfaces.
27. When applying detergents follow the safety rules
on the detergent label.Use detergent from a cov-
ered D.O.T.approved container.
28.Thismachine has been providedwithWarning 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.

97-6554 • HOTSY 965SS-1075SS • REV. 7/05
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
detergentonto cleaning surfacewithtriggerdevice.In-
cludes safety latch.
Detergent Injector — Allows you to siphon and mix
detergents.
Wand — Must be connected to the spray gun.
High Pressure Hose — Connect one end to water
pumphighpressuredischargenippleandtheother end
to spray gun.
UnloaderValve—Safetydevicewhich, when the spray
guncloses,preventsover pressurization (NotShown.)
Note:If trigger on spray gun is released for more
than 2 minutes,water will leak from the pump pro-
tector.Warm water will discharge from pump pro-
tector onto floor. This system prevents internal
pump damage.
Pump
Unloader
Valve
Detergent
Injector
Spray
Gun
High
Pressure
Hose
Wand
Burner
Exhaust
Relief
Valve Hose
Hanger
Engine
High
Pressure
Nozzle
Burner
Fuel Oil
Tank

97-6554 • HOTSY 965SS-1075SS • REV. 7/05 7
PRESSUREWASHER OPERATOR’S MANUAL
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 carrier concerning discrepancies.
1. Cut strapping band from pressure washer and pallet.
2. Remove pressure washer from pallet.
Parts Included
•Pressure Washer
•Pressure Hose
•Wand
•Operating Instructions and Parts Manual
•Gasoline Engine Manual
•Parts Bag Containing:
■Pressure Nozzles (3 Ea.)
■Trigger Gun
■Battery Terminals (2 Ea.)
Tools Required
•8" Adjustable Wrench
•Teflon Tape
•Flat Blade Screwdriver
Pressure Hose,Trigger Gun and Wand
1. When assembling, use teflon tape on all threaded
plumbing connections to prevent leakage.
2. Install the pressure hose on the pressure washer as
shown in Figure 1.
Figure 1 - Pressure Hose Installation
Relief Valve
Pressure Hose
3. Assemble wand components as shown in Figure 2.
NOTE: The pressure nozzle is not to be installed at
this time.
4. Make sure all plumbing connections are tight.
Battery
WARNING:Wear eye, hand and skin protection when
handling or connecting battery.
WARNING: Batteries generate explosive gases dur-
ing normal battery operation.
WARNING: DO NOT expose the battery to flame or
sparks as these gases may ignite.
WARNING:Battery fluidis highly acidic.If battery fluid
contactsskin or clothing,washimmediatelywith soap
andwater.Ifbattery fluidenterseye,immediately flood
eye with running cold water for at least 15 minutes
and get immediate medical attention.
1. Electric Start Machines Only: Place battery in bat-
tery box (battery not included). Use a standard 12
volt automotive battery.Select a battery similar to the
one in Figure 3 for proper fit and installation.
Figure 2 - Wand Assembly
Trigger Gun
Quick
Disconnect
Quick Disconnect
Wand
Quick
Disconnect Plug
Pressure
Hose
Figure 3 - Battery Dimensions
6-3/4"
Max
10-1/2"
Max
8-3/4"
Max

97-6554 • HOTSY 965SS-1075SS • REV. 7/05
OPERATOR’S MANUAL PRESSURE WASHER
8
2. Install the provided battery terminals as shown in
Figure 4.
3. To reduce the possibility of sparking attach the wires
to the battery in the following order. Refer to Figure
4.First attach the red wire from the voltage regulator
and the red wire from the control box to the positive
“+”terminal of battery.Next,attachtheblackwirefrom
thevoltageregulator and the black wire from the con-
trol box to the negative “-” terminal of the battery.To
disconnect the battery remove the wires in the oppo-
site order as installed. Install battery box cover and
fasten in place.
Figure 4 - Battery Installations/Connections
Box Strap
Battery
Box Lid
Red Wire From
Control Box
Black Wire
From Voltage
Regulator
Red Wire From
Voltage Regulator
12 Volt
Battery
Battery
Terminal
Battery Box
Black Wire From
Control Box
ASSEMBLY INSTRUCTIONS

97-6554 • HOTSY 965SS-1075SS • REV. 7/05 9
PRESSUREWASHER OPERATOR’S MANUAL
INSTALLATION INSTRUCTIONS
Responsibility
Theownerand/oruser musthave an understanding of
themanufacturer’soperating instructionsandwarnings
before using this Hotsy pressure washer.Warning in-
formation shouldbeemphasizedandunderstood.Ifthe
operator is not fluent in English, the manufacturer’s in-
structionsand warnings shall be readtoand 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 se-
rial number.
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
required 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
fromcomingin contact withthepressurewasher.Moisture
reachingtheequipmentwill reduce the pressure washer’s
service life. All installations must comply with the local
codes covering such installations.
Venting
CAUTION: All venting must be in accordance with
applicable federal and state laws, and local ordi-
nances. Consult local heating contractors.
If the pressure washer is to be used in an enclosed area,
afluemustbe installed to ventburner and engine exhaust
to the outside atmosphere. Be sure the flue is the same
size as the burner exhaust vent on the pressure washer.
See Component Identification for location. 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
bepipedto the burnerandafaninstalledtobring sufficient
air into the machine.Locate the pressure washer so that
the flue will be as straight as possible and protrude
throughtheroofataproperheightandlocationtoprovide
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.
Inaddition,the pressurewashershould neverbe operated
in an enclosed area where high ambient temperatures
exist. High ambient temperatures (above 100oF) can
causeengine oilfailureandwillgreatlyreduce theengine’s
performance.
Gasoline Engine
The gasoline engine is preset for operation at altitudes
below 3000 feet above sea level. If operated at higher
altitudes, it may be necessary to install a high altitude
main jet in the carburetor. Contact an authorized engine
sales and service center for details.
Pre-Operation Check
❑Pump Oil (SAE 30W non-detergent oil)
❑Cold Water Supply (6 gpm • 5/8" • 20 psi)
❑Hose, wand, nozzle (nozzle size per serial plate)
❑Water filter (intact, nonrestrictive)
❑Engine fuel (unleaded 86 or higher)
❑Engine oil (SAE 10W40)
❑Burner fuel (No.1 or No.2 home heating fuel or diesel)
Oil Burner
Burner Air Adjustment: The oil burner on this machine
is preset for operation at altitudes below 3000 feet. If
operatedat higher altitudes,itmay be necessary to adjust
the air shutter and air band setting. Adjust the air shutter
for a #1 or #2 smoke spot on the Bacharach scale.
Figure 5 - Burner Adjustment
Air Band
Pressure
Adjustment Screw
Fuel
Filter

97-6554 • HOTSY 965SS-1075SS • REV. 7/05
OPERATOR’S MANUAL PRESSURE WASHER
10
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 5) and close
airshutteruntilblack smoke appearsfromburner exhaust
vent. Note air shutter 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
canbe obtained, then repeat the aboveprocedure on the
air band setting.
CAUTION: If white smoke appears from burner
exhaustvent duringstart-up oroperation,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.
INSTALLATION INSTRUCTIONS

97-6554 • HOTSY 965SS-1075SS • REV. 7/05 11
PRESSUREWASHER OPERATOR’S MANUAL
OPERATION INSTRUCTIONS
Before Starting
1. Readallmanualsprovided with this pressure washer.
Become familiar with location and function of all
operating and safety controls.
WARNING: Check hoses, fittings, wand, trigger gun
and fuel connections daily for signs of wear, cracks
and looseness, and replace as required.
2. Connect water supply hose to the garden hose con-
nector located on pump.The water faucet and supply
hose must be capable of providing a minimum of 3.5
gallons per minute (GPM).
3. Filloilburnerfueltank.Usekerosene,#1gradehome
heating oil, #1 or #2 diesel fuel.
DO NOT USE GASO-
LINE,CRANKCASE OIL DRAININGS,ORWASTE OIL.
WARNING: DO NOT fill engine fuel tank while engine
is running or hot. Let engine cool before refueling or
spontaneous fire may result. Fuel spillage or vapors
could ignite if engine is hot.
4. Fill the engine fuel tank.Do not overfill, fill to the bot-
tom of filler neck only. Use lead free gasoline mini-
mum 86 octane. DO NOT use gasoline containing
morethan 15% MTBE, 5% methanol or 10% ethanol.
Refer to the provided gasoline engine manual for
additional details.
5. Check pump and engine oil levels.
6. If detergents are to be used, only use detergents
intendedfor pressure washers.Follow instructions on
the detergent container.
IMPORTANT:Before installing pressure nozzle on ini-
tial start-up, turn on the water supply and allow water
to run from the end of the wand until clear to prevent
the pressure nozzle from clogging.
IMPORTANT: If the pressure washer has not been
used for an extended period of time, remove the pres-
sure nozzle from the end of the wand and turn on
water supply. Allow water to run from the end of the
wand until clear.
7. Install the proper pressure nozzle for your cleaning
needs on the end of wand, refer to Figure 6.
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.
(Refer to Figure 6.)The manual trigger lock should be
used whenever the trigger gun is not in use.
To Start
IMPORTANT:Thewater mustbe turned onbeforestart-
ing. 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. Turn ON water supply.
2. Hold wand firmly, release trigger of trigger gun.
3. Place engine ON/OFF switch in the ON position.
4. Open fuel shutoff valve (if so equipped).Move choke
lever to FULL CHOKE position, (choke may not be
neededonwarm engine).Movethrottleleverto HALF
THROTTLE position.
5. Pulltheropestarter slowlyuntil resistance is felt,then
pull briskly.Do not allow the rope starter to snap back
against the engine. Return it gently to prevent dam-
age to the starter.
6. When the engine starts, move choke lever until
engine runs smoothly. When engine warms, move
choke lever to NO CHOKE position. Move throttle
lever to FULLTHROTTLE position.
IMPORTANT:To allow for proper battery charging,the
throttle control must be kept in the full throttle posi-
tion during operation.
NOTE:If engine fails to start, refer toTroubleshooting
Guide in this manual.
7. Squeeze trigger of trigger gun and allow air to purge
from system.
8.
If hot water is desired, adjust the thermostat to the
proper temperature and turn burner switch ON. The
burner will light immediately withasmallpuffofsmoke.
You may need to initially adjust your burner for peak
performance. See Oil Burner section under Installa-
tion. If smoke continues, contact Customer Service
at 1-303-792-5200.When the trigger of the trigger gun
isreleasedorwhenthe thermostat temperaturesetting
is reached, the burner will automatically turn off.
To Clean
The detergent injector valve operates by reducing the
volumeofwater, thus avacuumisachievedand detergent
is drawn into the system.DO NOT reduce the water inlet
flow so the pump cavitates due to water starvation.
Operating a pump with insufficient water will damage
the pump seals.
1. Insert detergent inlet line into container of mixed
detergent.
Figure 6 - Nozzle Installation/Manual Trigger Lock
Manual
Trigger Lock
Pressure
Nozzle

97-6554 • HOTSY 965SS-1075SS • REV. 7/05
OPERATOR’S MANUAL PRESSURE WASHER
12
2. Completely open detergent control knob located on
the side of the detergent injector valve. Refer to
Figure 7.
3. Start the detergent suction by rotating the water
adjustment knob of the detergent injector valve.
Referto Figure 8.Turning the knob counterclockwise
will pull detergent into the system. The flow may be
observedthrough the clear detergent line.Securethe
knob position with the knurled nut.
4. Theside detergent control knob can now be adjusted
to meter the desired amount of detergent.
5. 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.
6. 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.
7. Use the width of the spray pattern to wash in a wide
path. Overlap spray paths for complete coverage
washing from side to side, using slow, steady
motions.
8. The nozzle should be 12" to 24" from work, closer for
tough areas. Be careful on painted or delicate sur-
faces, the pressure may damage surface if nozzle is
too close.
9. Smallparts should be washedinabasketsothepres-
sure does not push them away. Larger, lightweight
parts should be clamped down so the pressure does
not push them away.
10. 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.
To Stop
1. Ifdetergentswereused,draw clear waterthroughthe
detergent inlet 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. Move throttle lever to idle position.
4. Turn engine ON/OFF switch to the OFF position.
5. Close fuel shutoff valve (if so equipped).
6. Turn water supply OFF.
7. Squeeze trigger of trigger gun to relieve system
pressure.
Figure 7 - Detergent Injector Valve
Water
Adjustment Knob
Detergent
On
Detergent
Control Knob
Detergent
Injector
OPERATION INSTRUCTIONS

97-6554 • HOTSY 965SS-1075SS • REV. 7/05 13
PRESSUREWASHER OPERATOR’S MANUAL
CLEANINGTECHNIQUES
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
yourwork areato sections approximately 6feetsquare
and always apply detergent from bottom to top).Allow
detergent to remain on surface 1-3 minutes. Do not
allowdetergent to dryon surface.Ifsurfaceappearsto
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
fromcleaning surface.Use overlappingstrokesas you
clean and rinse any surface.For best surface cleaning
action spray at a slight angle.
Recommendations:
• Before cleaning any surface, an inconspicuous
areashould be cleanedto test spraypattern and
distance for maximum cleaning results.
• If painted surfaces are peeling or chipping, use
extremecautionaspressurewashermayremove
the loose paint from the surface.
• Keepthespraynozzleasafedistancefromthe sur-
faceyouplan to clean.Highpressurewashasmall
area,thencheckthesurfacefordamage.Ifnodam-
age is found, continue to pressure washing.
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.
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
GENERAL CLEANINGTECHNIQUES & STORAGE
antifreeze). To flush the system with antifreeze, the
following steps are to be followed:
1. Connect the water supply hose to the garden
hose connector located on the pump. Turn on water
supply.
2. Place the detergent inlet line into a container of
antifreeze.
3. Hold wand firmly, release trigger of trigger gun.
4. Start engine. Place throttle lever in Full Throttle
position.
5. Squeeze trigger of trigger gun and allow water to
flow from the end of the wand.Watch for antifreeze to
be drawn through the detergent inlet line. Allow the
antifreeze to be drawn into the system for 5 to 10
seconds.
6. Release the trigger of the trigger gun and stop
engine.
7. Turn off water supply and disconnect water supply
hose from the pump.
8. Attach a short length of hose (approximately 3 feet
long) to the garden hose connector located on the
pump. Install a funnel in the other end of the hose as
shown in Figure 8.
9. Hold wand firmly, release the trigger of the trigger
gun.
10. Start engine. Place throttle lever in the idle position.
11. Squeeze trigger on trigger gun.
12. Slowly pour antifreeze into the funnel. Continue to
add antifreeze until antifreeze flows from the end of
the wand.
13. Squeeze and release the trigger of the trigger gun
several times to antifreeze the unloader system.
14. Release the trigger of the trigger gun. Stop engine.
15. Squeeze the trigger of the trigger gun to relieve sys-
tem pressure.
For added protection, after antifreezing, disconnect the
Funnel
Garden Hose Connector
Figure 8 - Winterizing

97-6554 • HOTSY 965SS-1075SS • REV. 7/05
OPERATOR’S MANUAL PRESSURE WASHER
14
pressurehosefrom the machineandremove the coildrain
plug (refer to Component Identification 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
systembeflushed with antifreezeforrust protection.Refer
to the Gasoline Engine Manual for engine storage
information.
STORAGE

97-6554 • HOTSY 965SS-1075SS • REV. 7/05 15
PRESSUREWASHER OPERATOR’S MANUAL
MAINTENANCE
WARNING:Unauthorized machinemodification or use
of non-approved replacement parts may cause per-
sonal injury and/or property damage and will void the
manufacturer warranty.
Pump
Lubrication: To lubricate pump, use 30W non-detergent
oilfor pump crankcase.Crankcasemustbe filled to center
of red dot on oil gauge found on the side of the pump,
refer to Figure 9.During the break-in-period, make sure
the oil is changed after the first 40 hours of operation.
After that, replace oil every 3 months or 500 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
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.
Gasoline Engine
Refer to the provided Gasoline Engine Manual for
recommended maintenance.
Oil Burner
Blower Motor:Inspect the motor brushes for wear every
250 hours of operation and replace when 1/8" to 1/4"
brush material remains. DO NOT allow the brushes to
wear out completely or motor damage will occur.Refer to
Burner Assembly.The motor bearings are permanently
lubricated and will not require any additional lubrication.
Relief Valve
WARNING: The relief valve on this pressure washer
has been factory set and sealed and is a field nonad-
justable 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 Coil Outlet Assembly.
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 set-
ting may cause personal injury and/or property dam-
age, and will void the manufacturer warranty. For
replacement refer to Pump Assembly.
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:Inhardwaterareas,scalebuildupwithin
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.
Hour Meter
This hour meter will monitor the total hours of operation
of the pressure washer to signal when routine
maintenance is required.
Battery
Refer to battery manufacturer’s literature for
recommended maintenance.
Oil Fill/Dipstick
Oil Drain
Plug
Oil Sight
Glass
Figure 9 - Pump Lubrication

97-6554 • HOTSY 965SS-1075SS • REV. 7/05
PRESSURE WASHER Troubleshooting Guide
16
TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
Gas engine will not run. Out of gas. Replenish supply. Use only recom-
mended fuels. Refer to Before Start-
ing under Operation.
Fuel valve closed (if so equipped). Open valve.
oose spark plug wire. Reconnect.
Choke or throttle set incorrectly. Refer to To Start under Operation.
Engine ON/OFF switch in OFF
position.
Place engine ON/OFF switch in ON
position.
ow engine oil level. Replenish supply. Engine will not start
or run if oil is low (on engines equipped
with low oil protection).
Refer to pro ided gasoline engine manual for additional troubleshooting.
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.
ow spray pressure at
pressure nozzle.
Inadequate water supply. Fully open faucet. Check for kinked or
damaged hose. Use 5/8 inch minimum
hose. Check for debris clogging inlet
screen.
Partially clogged or damaged
pressure nozzle.
Clean or replace.
Air being drawn through detergent
inlet line.
Refill detergent container. Ensure that
pick-up screen is fully immersed.
Detergent injector valve not set
correctly.
Refer to To Clean for settings.
Uneven spray pattern. Partially clogged or damaged
pressure 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 recommend-
ed fuels. Refer to Before Starting
under Operation.
Inadequate water supply. Fully open faucet. Check for kinked or
damaged hose. Use 5/8 inch minimum
hose. Check for debris clogging inlet
screen.
Trigger of trigger gun released. Squeeze trigger. Water must be spray-
ing for burner to light.

97-6554 • HOTSY 965SS-1075SS • REV. 7/05 17
PRESSURE WASHER Troubleshooting Guide
TROUBLESHOOTING
When ordering from your dealer, please provide the following:
Model Number: 965SS, 1060SS, 1065SS, 1065SSE, 1075SSE
Machine Serial Number: ________________________________
Component Part Number: ______________________________
Description: __________________________________________
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
Pressure washer will not
produce hot water.
...continued
Thermostat set too low. Adjust thermostat to desired temp-
erature.
Blown fuse. Replace. Fuse is located in Control
Box.
Engine is running too slow. Move throttle lever to full throttle
position.
Poor or no detergent
flow.
Inadequate detergent supply. Refill detergent container. Ensure that
pick-up screen is fully immersed. Open
detergent valve.
Detergent screen or hose clogged. Clean. Always start with a clean deter-
gent container.
Detergent injector valve not set
correctly.
Refer to To Clean for settings.
Clogged detergent injector check
valve.
Clean check valve at detergent injector
inlet.
Poor cleaning. Improper detergent concentration or
mixing.
Mix detergent per manufacturer's
instructions. 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.
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 or
by calling 1-800-525-1976.

97-6554 • HOTSY 965SS-1075SS • REV. 7/05
OPERATOR’S MANUAL PRESSURE WASHER
18
EXPLODED VIEW - LEFT SIDE
Brake Assy.
39 51
53 54
52
55
18 19
See
FuelTank
Assy. For
Detail
23 24
21 48
46
22
45
7
6
See
Pump
Assy. For
Detail

97-6554 • HOTSY 965SS-1075SS • REV. 7/05 19
PRESSUREWASHER OPERATOR’S MANUAL
EXPLODED VIEW - RIGHT SIDE
28
1
2
17 31
27
26 32 3
4
30
5
14
15
12
39
25
7
16
6
44
47
35
34
12
39
37
See Brake
Assy. on
Previous
Page
43
41
42
43
13
36
50
49
56
857
10,11
9
40
For
Detail See
Burner
Assy.
49
20
For
Detail See
Control
Box Assy.

97-6554 • HOTSY 965SS-1075SS • REV. 7/05
OPERATOR’S MANUAL PRESSURE WASHER
20
EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 961532 Tubing 3/8" 38”
2 823987 Hose Clamp 1
3 213044 Burner Exhaust Vent 1
4 268004 Insulation 1
5 860102 Retaining Ring 1
6 780452 Flat Washer 5/16" 8
7 703155 Locknut 5/16" - 18 6
8 646113 Decal Detergent Metering 1
9 834159 Decal Hotsy Detergents 1
10 826167 Strain Relief 2
11 703127 Strain Relief Nut 2
12 703185 Locknut 1/4" - 20 (Battery Models Only) 6
13 375292 Mounting Plate (Battery Models Only) 1
14 220119 Battery Box (Battery Models Only) 1
15 890904 Battery Terminal (Battery Models Only) 2
16 834154 Decal Winterize 1
17 10-07993 Decal Warnings 1
18 612984 Bolt 3/8" - 16 x 1" 4
19 780480 Lock Washer 3/8" 4
20 375578 Chassis (1065SS, 1065SSE, 1075SSE) 1
375575 Chassis (965SS) 1
21 232025 Decal Battery 1
22 444462 Decal Caution Gasoline 1
23 646115 Decal Hot Surface 1
24 646026 Decal Carbon Monoxide 1
25 834416 Decal Operating Instruction 1
26 240834 Coil (1065SS, 1065SSE, 1075SSE) 1
226222 Coil (965SS) 1
27 824115 Vent Clip 4
28 375449 Coil Tank (965SS) 1
375446 Coil Tank (1065SS,1065SSE,1075SSE) 1
29 926598 Rivet 8
30 829979 Hotsy Logo Plate 2
31 646095 Decal Troubleshooting 1
32 268013 Insulation (1065SS, 1065SSE, 1075SSE) 1
268006 Insulation (965SS Only) 1
33 213191 Pancake Insulation 1
34 859806 Grommet 1
35 859815 Grommet (Nozzle Holder) 3
36 815329 Snap Bushing 1
37 77-31620-2GS-003 Voltage Reg. (1065SSE,1075SSE) 1
860273 Voltage Reg. (965SS,1065SS) 1
38 218189 Harness, Regulator (Honda Only) 1
39 780451 Washer Flat 1/4" 10
40 983013 Wheel 4