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 Pressure Washer. This manual covers the operation and mainte-
nance of your pressure washer. All information in this manual is based on the latest product infor-
mation 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 Power Rating: 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 Power Rating: 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 Power Rating: 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 Power Rating: 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. 5/06
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 4-5
Component Identification 6
Assembly Instructions 7-8
Installation Instructions 8-9
Operation Instructions 10-11
General Cleaning Techniques & Storage 12
Maintenance 13
Troubleshooting 14-15
Exploded Views & Parts List 16-19
Control Panel Assembly & Parts List 20
Burner Assembly & Parts List 21
Fuel Tank Assembly & Parts List 22
Pump Assembly & Parts List - 965SS 23
Pump Assembly & Parts List, 1065SS, 1065SSE, 1075SSE 24-25
Coil Outlet Assembly & Parts List, 965SS 26
Coil Inlet Assembly & Parts List, 1065SS, 1065SSE 27
Coil Inlet Assembly & Parts List, 1075SSE 28
Coil Inlet Parts Exploded View and Parts List 29
Hose, Spray Gun & Wand Assembly & Parts List 30
Unloader Exploded View and Parts List 31
HS Pump Exploded View and Parts List 32-33
HG-1 Pump Exploded View and Parts List 34-35
Wiring Diagrams 36-37
Warranty

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
OPERATOR’S MANUAL PRESSURE WASHER
4
CAUTION:To reduce the risk of
injury, read operating instruc-
tions carefully before using.
1.Read owner's manual thor-
oughly. Failure to follow instruc-
tions could cause malfunction of
the machine and result in death,
serious bodily injury and/or prop-
erty 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. All installations must comply with local codes.
Contact your electrician, plumber, utility company
or the selling distributor for specific details.
WARNING: Risk of asphyxiation.
Use this product only in a well
ventilated area.
5. When the machine is work-
ing, do not cover or place in
a closed space where venti-
lation is not sufficient.
WARNING: Risk of fire. Do not
add fuel when the machine in
operating.
6. Risk of explosion — do not
spray flammable liquids or
operate in an explosive lo-
cation. Operate only where
open flame or torch is per-
mitted.
WARNING: Keep water spray
away from electrical wiring
or fatal electrical shock may
result.
7. 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 wa-
ter on or near electrical components. Do not touch
machine 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.
IMPORTANT SAFETY INFORMATION
WARNING
RISK OF
ASPHYXIATION.
USE ONLY IN A WELL
VENTILATED AREA.
WARNING
READ OPERATOR’S
MANUAL
THOROUGHLY
PRIOR TO USE.
WARNING
HIGH PRESSURE
SPRAY CAN PIERCE
SKIN AND TISSUES.
WARNING
KEEP WATER SPRAY
AWAY FROM
ELECTRICAL WIRING.
WARNING: High pressure
stream of fluid that this equip-
ment can produce can pierce
skin and its underlying tissues,
leading to serious injury and
possible amputation.
9. High pressure developed by
these machines can cause
personal injury or equipment
damage. Use caution when
operating. Do not direct discharge stream at
people, or severe injury and/or death may result.
10. Never make adjustments on machine while
in operation; 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
protection must be worn
when 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-
tensive periods of time as this may cause damage
to the pump.
13. Protect from freezing.
14. Be certain all quick coupler fittings are secured
before using pressure washer.
15. Do not allow acids, caustic, or abrasive fluids to
pass through the pump.
16. Inlet water must be from a cold, fresh city water
supply.
17. To reduce 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 pre-
caution and knowledge of the machine.
19. Do not operate this product when fatigued or under
the influence of alcohol or drugs. Keep operating
area clear of all persons.
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. 5/06
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PRESSURE WASHER 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. Follow maintenance instructions specified in man-
ual.
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. Use extreme caution when moving pressure
washer over rough or uneven surfaces.
26. When applying detergents follow the safety rules
on the detergent label. Use detergent from a cov-
ered D.O.T. approved container.
27. This machine has been provided with Warning and
Instruction decals for the safety of the operator. If
these decals are removed or become damaged
they should be replaced. Contact your dealer for
replacement decals.

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
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 Injector — 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.
UnloaderValve — Safety device which, when the spray
gun closes, redirects flow of water. (Not Shown.)
Note:If trigger on spray gun is released for more
than 2 minutes, water may leak from the pump
protector. Warm water will discharge from pump
protector onto floor.This system prevents internal
pump damage.
Pump
Unloader
Valve
Detergent
Injector
Spray
Gun
High
Pressure Hose
Wand
Burner
Exhaust
Coil Outlet Hose
Hanger
Engine
High
Pressure
Nozzle
Burner
Fuel Oil
Tank

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
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PRESSURE WASHER 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 pal-
let.
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 during
normal battery operation.
WARNING: DO NOT expose the battery to flame or
sparks as these gases may ignite.
WARNING: Battery fluid is highly acidic. If battery fluid
contacts skin or clothing, wash immediately with soap
and water. If battery fluid enters eye, 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
Coil Outlet

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
OPERATOR’S MANUAL PRESSURE WASHER
8
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 & INSTALLATION INSTRUCTIONS
INSTALLATION
Responsibility
The owner and/or user must have an understanding of
the manufacturer’s operating instructions and warnings
before using this Hotsy pressure washer.Warning infor-
mation should be emphasized and understood. If the
operator is not fluent in English, the manufacturer’s in-
structions and warnings shall be read to and discussed
with the operator in the operator’s native language by
the purchaser/owner, making sure that the operator
comprehends its contents.
Owner and/or user must study and maintain for future
reference the manufacturers’ instructions.
This manual should be considered a permanent part
of the machine and should remain with it if machine
is resold.
When ordering parts, please specify model and 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
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.
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 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 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.
In addition, the pressure washer should never be operated
in an enclosed area where high ambient temperatures
exist. High ambient temperatures (above 100oF) can
cause engine oil failure and will greatly reduce the
engine’s performance.
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, attach the black wire
from the voltage regulator and the black wire from the
control box to the negative “-” terminal of the battery.
To disconnect the battery remove the wires in the
opposite order as installed. Install battery box cover
and fasten in place.

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
9
PRESSURE WASHER OPERATOR’S MANUAL
INSTALLATION INSTRUCTIONS
Figure 5 - Burner Adjustment
Air Band
Pressure
Adjustment Screw
Fuel
Filter
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 10W30)
 Burner fuel (No. 1 or No. 2 home heating fuel or die-
sel)
Oil Burner
Burner Air Adjustment: The oil burner on this machine
is preset for operation at altitudes below 3000 feet. If
operated at higher altitudes, it may 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.
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 air shutter until black smoke appears from burner
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
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.

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
OPERATOR’S MANUAL PRESSURE WASHER
10
OPERATION INSTRUCTIONS
Before Starting
1. Read all manuals provided with this pressure wash-
er. 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. Fill oil burner fuel tank. Use kerosene, #1 grade home
heating oil, #1 or #2 diesel fuel. DO NOT USE GAS-
OLINE, CRANKCASE OIL DRAININGS, OR WASTE
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
bottom of filler neck only. Use lead free gasoline min-
imum 86 octane. DO NOT use gasoline containing
more than 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
intended for pressure washers. Follow instructions on
the detergent container.
IMPORTANT: Before installing pressure nozzle on
initial 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
pressure 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: The water must be turned on before
starting. Running the pump dry will cause damage
and void warranty.
IMPORTANT: DO NOT allow the machine to run with
trigger of the trigger gun released for more than
2 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
needed on warm engine). Move throttle lever to HALF
THROTTLE position.
5. Pull the rope starter slowly until resistance is felt, then
pull briskly. Do not allow the rope starter to snap back
against the engine.Return it gently to prevent damage
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 FULL THROTTLE position.
IMPORTANT: To allow for proper battery charging,
the throttle control must be kept in the full throttle
position 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 with a small puff of smoke.
You may need to initially adjust your burner for peak
performance. See Oil Burner section under Instal-
lation. When the trigger of the trigger gun is released
or when the thermostat temperature setting is reached,
the burner will automatically turn off.
To Clean
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 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. 5/06
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PRESSURE WASHER OPERATOR’S MANUAL
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.
Refer to Figure 7. Turning the knob counterclockwise
will pull detergent into the system. The flow may be
observed through the clear detergent line. Secure the
knob position with the knurled nut.
4. The side 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 cover-
age 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
surfaces, the pressure may damage surface if nozzle
is too close.
9. Small parts should be washed in a basket so the
pressure 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. If detergents were used, draw clear water through the
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.
OPERATION INSTRUCTIONS
Figure 7 - Detergent Injector Valve
Water
Adjustment
Knob
Detergent On
(Counterclockwise)
Detergent
Control Knob
Detergent
Injector

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
OPERATOR’S MANUAL PRESSURE WASHER
12
CLEANING TECHNIQUES
Pre-rinse cleaning surface with fresh water. Place deter-
gent 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 washing.
CAUTION - Never use:
• Bleach, chlorine products and other corrosive
chemicals
• Liquids containing solvents (i.e., paint thinner,
gasoline, oils)
• Tri-sodium phosphate products
• Ammonia products
• Acid-based products
These chemicals will harm the machine and will damage
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 desired 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 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
GENERAL CLEANING TECHNIQUES & STORAGE
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 system
pressure.
For added protection, after antifreezing, disconnect the
pressure hose from the machine and remove the coil drain
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
system be flushed with antifreeze for rust protection.
Refer to the Gasoline Engine Manual for engine storage
information.
Funnel
Garden Hose Connector
Figure 8 - Winterizing

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
13
PRESSURE WASHER OPERATOR’S MANUAL
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
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 manu-
facturer'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.
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.
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.
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. 5/06
PRESSURE WASHER Troubleshooting Guide
14
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 Opera-
tion.
Fuel valve closed (if so equipped). Open valve.
Loose 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.
Low engine oil level. Replenish supply. Engine will not start or run
if oil is low (on engines equipped with low oil
protection).
Refer to provided 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.
If water spray doesn’t show with in
10-15 seconds
Discontinue running the machine and trou-
bleshoot as damage to the pump will occur if
allowed to run
LOW SPRAY
PRESSURE AT
PRESSURE
NOZZLE.
Inadequate water supply. Fully open faucet. Check for kinked or dam-
aged hose. Use 3/4 inch minimum hose.Check
for debris clogging inlet screen.
Partially clogged or damaged pres-
sure 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 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 recommend-ed fuels.
Refer to Before Starting under Operation.
Inadequate water supply. Fully open faucet. Check for kinked or dam-
aged hose. Use 3/4 inch minimum hose.Check
for debris clogging inlet screen.
Trigger of trigger gun released. Squeeze trigger. Water must be spraying for
burner to light.
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.

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
15
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: __________________________________________
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.
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
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 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.

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
OPERATOR’S MANUAL PRESSURE WASHER
16
EXPLODED VIEW - LEFT SIDE
View A-A
Foot Brake Assy.
(Reversed View)
39 51
53
54
52
55
18
19
For
Detail See
Fuel Tank
Assy.
23
24
21
48
46
22
45
56
57
For
Detail See
Pump
Assy.
59
61
60
62
61
63
64 38
1065SS
1065SSE
1075SSE

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
17
PRESSURE WASHER OPERATOR’S MANUAL
EXPLODED VIEW - RIGHT SIDE
28
117 31
27
26
32
3
4
30
5
14
15
12
39
25
7
16
6
44
47
35
34
12
39
37
For
Foot Brake
Detail See
View
A-A
43
41
42
43
13
36
50
49
8
10,11
9
40
For
Detail See
Burner
Assy.
49
20
For
Detail See
Control
Box Illus.
2
58
29
29
For
Detail See
Coil Outlet
Assy.
For
Detail See
Coil Inlet
Assy.
68

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
OPERATOR’S MANUAL PRESSURE WASHER
18
EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 961532 Tubing 3/8" 38”
2 9.800-049.0 Label, Cleaning Solution 1
3 213044 Burner Exhaust Vent 1
4 268004 Insulation 1
5 860102 Retaining Ring 1
6 780452 Flat Washer 5/16" 6
7 703155 Locknut 5/16" - 18 4
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 860285 Reducer, M12 to 1/4” Female 1
39 780451 Washer Flat 1/4" 10
40 983013 Wheel 4

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
19
PRESSURE WASHER OPERATOR’S MANUAL
EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
41 817322 Hubcap 4
42 848616 Push Nut 4
43 980254 Flat Washer 5/8" 8
44 815329 Snap Bushing 3
45 661282 Engine 11 HP (1065SS) 1
661254 Engine 9 HP (965SS) 1
661364 Engine, E-Start 11 HP (1065SSE) 1
677375 Engine, E-Start 13 HP (1075SSE) 1
46 890783 Tag Gasoline Engine 1
47 2-010532 Mount , Vibration, 3/8” Rubber 70 Dura 4
48 612985 Bolt, 3/8” x 1-1/2” NC HH 4
49 703107 Flange Nut 5/16" - 18 8
50 780460 Fender Washer 5/16" 4
51 95-07104827 Lever, Brake 1
52 95-07104829 Linkage, Brake, Red 1
53 95-07101828 Bracket, Brake Pad, red 1
54 90-100472 Bolt, 1/4-20 x 1.0 Plt, Carriage, Zinc 4
55 703185 Nut, 1/4" ESNA, NC 4
56 780562 Washer, 3/8" SAE Flat 4
57 780480 Washer, 3/8" Lock, Split Ring 4
58 9.800-018.0 Label, Tip-Over Hazard 1
59 630980 Cap, Pipe, 1/8" NPT, Brass 1
60 698019 Hose Barb, 1/4" Barb x 1/8" ML Pipe 1
61 823988 Clamp, Hose 2
62 867368 Hose, 1/4" Push-On 3”
63 698020 Hose Barb, 1/4" Barb x 1/4" ML 1
64 921584 Valve, Mini Oil Drain 1
65 823987 Hose Clamp 1

97-6554 • HOTSY 965SS-1075SS • REV. 5/06
OPERATOR’S MANUAL PRESSURE WASHER
20
CONTROL PANEL ASSEMBLY EXPLODED VIEW & PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 983516 Box, Front 1
2 11-0511 Label, Control Box 1
3 4-050823 Hour Meter, 12-28 V DC 1
4 875465 Switch, Rocker, 15A/12V 1
5 835150 Knob, Thermostat 1
6 735321 Screw, 4mm x 6mm, Pan Head 2
7 915390 Plate, Thermostat Cover 1
8 955940 Thermostat 1
9 707147 Capacitor (965SS, 1065SS) 1
10 612937 Bolt, 1/4" x 3/4" 4
11 2-011681 Cap, Capacitor (965SS,1065SS) 1
12 703127 Locknut, 1/2" 3
13 615414 Box, Back 1
14 703185 Nut, 1/4" 4
15 876032 Strain Relief 3
16 358026 Clamp (965SS,1065SS) 1
17 612945 Bolt, 1/4-20 x 1/2" (965SS, 1065SS) 1
18 703106 Nut, 1/4" (965SS,1065SS) 1
676638 Fuse, ATC 30 Amp 1
707146 Holder, Fuse 1
829620 Plug 1
19 70-180503 Screw, M4 x 10 4
20 70-030207 Nut, M4 4
Not Shown
2
7
6
5
3
4
1
11
17
9
18
16
10
14
13
8
12
15
19
20