Hotsy 790SS, Operating Instructions And Parts Manual

Page 1: ...ACT 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 MODELS 790SS 795SS 795SS 208 895SS ...

Page 2: ......

Page 3: ...9 Lbs Shipping Weight 459 Lbs Exhaust Stack Size 8 Machine Dimensions Length 51 Width 29 Height 42 795SS 208 Pump Volume At Pump Head 3 5 gpm 210 gph Pump Pressure At Pump Head 2000 psi Burner Type Fuel Oil Fired 289 900 BTU Hr Burner Fuel Pressure 200 PSI Max Machine Voltage 208Vac 60Hz 1Ph Total Machine Amperage 27 Amps Machine Weight 409 Lbs Shipping Weight 459 Lbs Exhaust Stack Size 8 Machine ...

Page 4: ...ructions 11 General Cleaning Techniques Storage 12 Maintenance 13 Troubleshooting 14 15 Exploded Views Parts List 16 19 Control Panel Assembly Parts List 790SS 795SS 20 Control Panel Assembly Parts List 895SS 21 Burner Assembly Parts List 22 Fuel Tank Assembly Parts List 23 Float Tank Assembly Parts List 23 Pump Assembly Parts List 790SS 795SS 24 Pump Assembly Parts List 895SS 25 Coil Outlet Assem...

Page 5: ...round 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 groun...

Page 6: ...f 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 IMPORTANT SAFETY INFORMATION WARNING USE PROTECTIVE EYE WEAR AND CLOTHING WHEN OPERATING THIS EQUIPMENT WARNING High pressure spray can cause paint chips or oth...

Page 7: ...o 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 Unloader Valve Safety device which when the spray gun closes prevents over pressurization Not Shown Note If trigger on spray gun ...

Page 8: ...2 5 ea Flange Nut 5 16 18 7 ea Flat Washer 5 16 5 ea Operating Instructions Parts Manual Tools Required 10 Adjustable Crescent Wrench 2 ea Teflon Tape Pressure Hose Trigger Gun and Wand 1 Use teflon tape on plumbing connections to prevent leakage 2 Install pressure hose on machine as shown in Figure 1 3 Attach the wand assembly to the pressure hose trigger gun assembly as shown in Figure 2 Handle ...

Page 9: ...ctors If the pressure washer is to be used in an enclosed area a flue must be installed to vent burner exhaust to the outside atmosphere Exhaust gases should not be vented into a wall a ceiling or a concealed space of a building Be sure the flue is the same size as the burner exhaust vent on the pressure washer See Component Identification for location Poor draft will cause the pressure washer to ...

Page 10: ...r 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...

Page 11: ...efore installing 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 nozzle from clogging IMPORTANT If the pressure washer has not been used for an extended period of time remove the nozzle from the end of the wand and turn on water supply Allow water to run from the end of the wand until clear 1 Install the proper pressure...

Page 12: ...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 fl...

Page 13: ...ealed 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 ex ceed safe limits the relief valve will open allowing high pressure to be discharged through hose to ground Cau tion Inspect relie...

Page 14: ...place 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 Exc...

Page 15: ...OKES Improper fuel or water in fuel Drain tank and replace contaminated fuel Improper air adjustment Readjust air bands on burner assembly Low fuel pressure 140 PSI Adjust fuel pump pressure to specifica tions Weak fuel pump Check fuel pump pressure Replace pump if needed Fuel filter partially cogged Replace as needed Soot build up on coils Clean coils with soot remover Lime build up in coils Clea...

Page 16: ... OFF WA RN ING EXPLODED VIEW LEFT SIDE Brake Assembly 16 57 59 56 58 55 27 29 1 47 28 30 2 For Detail See Control Box Assy 25 3 4 46 45 54 21 76 70 39 22 20 16 31 24 23 23 23 60 61 19 18 17 6 11 68 68 69 For Detail See Coil Outlet Assy Only for 895SS To Float Tank To Detergent Injector Foot Brake Detail Reversed View 51 66 895SS Only 42 ...

Page 17: ...For Detail See Float Tank Assy For Detail See Detergent Valve Assy 34 35 13 14 15 36 12 33 44 37 40 43 16 41 10 38 For Detail See Fuel Tank Assy 9 14 For Detail See Burner Assy 6 15 12 53 52 44 40 16 73 75 74 43 6 5 7 8 For Detail See Brake Assy 50 49 62 63 16 63 16 65 64 6 32 26 72 71 ...

Page 18: ...x Head 24 9 802 813 0 Washer 5 16 Split Ring 4 Lock Zinc 25 8 900 896 0 Label Operating Oil Fired 1 Electric ITEM PART NO DESCRIPTION QTY 26 9 802 514 0 Strain Relief Lt Str 1 1 2 Npt 23 45D 27 8 719 913 0 Top Hat Weld Assy 1 16 Hotsy Coils 28 9 803 108 0 Ring Insul Retainer 16 1 Top Hat 29 9 802 904 0 Insulation Top Head 1 16 Od x 8 Id Fiberglass 30 9 802 825 0 Clip Retaining U Type 4 31 8 917 88...

Page 19: ... 1 66 8 752 969 0 Strain Relief 1 2 NPT 790SS Only 1 9 802 518 0 Strain Relief 3 4 Npt 49 71D 1 895SS 795SS 795SS 208 68 9 802 767 0 Screw 3 8 x 3 4 Nc 4 Whiz Loc Flange 895SS 9 803 277 0 Screw 5 16 x 1 2 Whiz 4 Loc Flange 795SS 795SS 208 69 8 719 047 0 Washer Nylon 4 281 Id x 1 Od x 25 Thk 895SS Only 70 8 901 144 0 Label Hotsy Logo 1 71 9 802 819 0 WASHER 7 16 x 2 1 2 ZINC PG FOOT 3 72 9 802 710 ...

Page 20: ...Plastic Front 1 1 Square Hole 10 8 905 888 0 Ground Wire W Bolt 1 11 8 750 095 0 Thermostat 120C 240F 1 2 Meter Capillary 12 8 718 779 0 Screw 4mm x 6mm 2 Pan Head 13 9 802 480 0 Back Box 1 14 9 802 700 0 Bolt 1 4 20 x 3 4 Nc Hh 4 15 9 802 775 0 Nut 1 4 Flange Zn 4 ITEM PART NO DESCRIPTION QTY 16 9 802 514 0 Strain Relief 1 2 Npt 795SS 795SS 208 790SS 2 18 9 802 427 0 Cord Serv 12 3 795SS 208 795S...

Page 21: ...at 120C 240F 1 2 Meter Capillary 12 8 718 779 0 Screw 4mm x 6mm 2 Pan Head 13 8 929 004 0 Electric Box 895SS 1 14 9 802 073 0 Weatherstrip 2 3 ft 1 8 x 1 2 x 75 15 9 802 764 0 Screw 10 32 x 3 4 Hex 4 16 9 802 775 0 Nut 1 4 Flange Zn 4 17 9 802 518 0 Strain Relief Lt Str 3 4 Npt 2 ITEM PART NO DESCRIPTION QTY 19 9 802 521 0 Strain Relief Cg75 850 3 4 1 20 9 802 523 0 Locknut 3 4 Conduit 1 21 9 802 ...

Page 22: ...50 778 0 Electrode Crossfire 1 12 8 750 781 0 Air Cone F 22 Crossfire 1 13 8 755 610 0 Fuel Nozzle 1 75 x 80 AZ ITEM PART NO DESCRIPTION QTY 14 8 750 518 0 Motor 1 7 HP 230V 1 60Hz Crossfire 15 9 802 254 0 Hose 1 4 Push On 18 16 9 802 254 0 Hose 1 4 Push On 21 17 6 390 126 0 Clamp Hose 46 54 St 1 18 8 750 933 0 Band Hose Clamp Hose id 1 8 5 16 1 19 8 754 911 0 Check Valve 1 way 1 4 BARB 1 20 8 717...

Page 23: ...amp Hose 46 54 St 1 7 9 802 177 0 Valve 1 4 Shut Off 1 180 Deg 8 9 802 254 0 Hose 1 4 x 20 Push On 25 Fuel Line 9 8 901 134 0 Label Fuel Type 1 10 8 901 119 0 Tag Oil Burner 1 11 8 750 933 0 Band hose clamp hose id 1 8 5 16 1 ITEM PART NO DESCRIPTION QTY 1 9 802 259 0 Hose 1 2 Push On 12 2 8 706 947 0 Hose Barb 1 2 Barb x 1 2 1 Mnpt Brass 3 8 707 310 0 Valve Float Brass Hotsy 1 4 8 707 311 0 Adapt...

Page 24: ... FPT x 1 2 1 MPT Brass 4 8 707 232 0 Valve 1 2 FNWTSC12 1 Brass Swing CHE 5 9 802 042 0 Elbow 1 2 JIC X 3 8 Fem 1 90DGR 6 8 706 958 0 Hose Barb 1 4 Barb x 1 4 1 MPT 90 DGR ITEM PART NO DESCRIPTION QTY 7 8 705 173 0 Elbow MPT BR 1 1 2 M x 1 2M 8 8 706 947 0 Hose Barb 1 TO Male Pipe 9 9 804 022 0 Cap Valve 22MM W 1 4 1 Gauge Port LG LD 10 9 802 259 0 Hose 1 2x22 867372CTL 1 11 8 918 425 0 Hose 3 8 x...

Page 25: ... Steel 6 8 706 214 0 Tee 3 8 Female Pipe 1 7 8 706 965 0 Hose Barb 1 4 Barb x 3 8 1 ML Pipe 8 8 706 880 0 Nipple 1 2 Mpt x 3 8 Mpt 1 Brass 9 8 707 232 0 Valve 1 2 FNWYSC12 1 Brass Swing Check 10 9 802 151 0 Swivel 1 2 Barb x 1 2 Jic 1 Fem Brass 11 8 706 294 0 Bushing 1 2 x 3 8 Steel 1 12 8 706 865 0 Plug 1 4 NPT Counter Sunk 1 13 8 918 424 0 Hose 3 8 x 25 2 Wire 1 Pressure Loop 14 9 802 259 0 Hose...

Page 26: ... 0 Screw 10 24 x 1 4 Hex Set 1 4 9 802 041 0 Elbow 3 8 Street 45 Dgr 1 Steel 5 9 802 171 0 Coupler 3 8 Plug Male 1 Steel Zinc 6 8 902 433 0 Valve Safety Relief Vsa 1 7 8 711 785 0 Hose 3 8 Push On 33 5 Per Ft 8 9 800 021 0 Label Hot Water Outlet 1 ITEM PART NO DESCRIPTION QTY 1 9 802 188 0 Valve Metering 1 4 Hose 1 2 6 390 126 0 Clamp Hose 46 54 St 4 3 9 802 252 0 Hose 1 4 x 1 2 Braided 72 Vinyl F...

Page 27: ...795SS 208 3 8 712 348 0 Nozzle 4004 White 1 790SS 895SS 8 712 356 0 Nozzle 4005 white 1 795SS 795SS 208 4 9 802 164 0 Coupler 1 4 Socket 2 Female Brass 5 8 725 389 0 Wand Single 36 Insulated 1 W Side Grip 6 8 707 139 0 Coupler 1 4 Plug Male 1 Steel Zinc 7 8 751 235 0 Gun Hotsy H1050 1 5000 PSI 10 4 GPM ITEM PART NO DESCRIPTION QTY 8 8 916 740 0 Hose 3 8 x 50 1W Ts 1 So x Sw All Except 895SS 8 739 ...

Page 28: ...ow Washer Pressure Ring 16 mm 3 6 See Kits Below U Seal 16 mm 3 7 See Kits Below Pressure Ring 16 mm 3 8 9 803 199 0 U Seal 16 mm 3 9 9 803 199 0 Washer Copper G1 2 1 10 9 802 926 0 Plug Brass G1 2 1 11 8 754 852 0 Manifold 1 12 8 717 233 0 O ring Ø1 78 X 15 6 6 13 See Kits Below Valve Assembly 6 14 9 803 948 0 O ring Ø1 78 X 18 77 6 15 9 803 949 0 Valve Plug 6 16 8 754 851 0 Plug Brass G1 4 1 17 ...

Page 29: ...0 Seal Spacer Crankshaft 2 30 9 802 914 0 Snap Ring 25 mm 1 31 9 803 955 0 Bearing Ball 2 32 8 754 830 0 Shaft 24 mm 4025 1 33 9 803 167 0 Key Crankshaft 1 34 8 754 219 0 Oil Dipstick 1 35 8 933 010 0 Seal Crankshaft 1 36 8 754 855 0 Bolt Plunger 3 37 8 754 092 0 Spacer Copper 3 38 8 754 848 0 Plunger 16 mm 3 39 9 803 962 0 Spacer Copper 3 40 8 754 827 0 Plunger Rod 3 41 9 803 965 0 Connecting Rod...

Page 30: ... 803 198 0 Copper Washer 3 8 1 18 9 802 925 0 Brass Plug 3 8 2 23 9 802 944 0 Hexagonal Screw 8 24 8 717 210 0 Closed Bearing Housing 1 25 9 803 192 0 O Ring Ø1 78 x 60 05 2 26 8 933 011 0 Tapered Roller Bearing 2 27 8 751 222 0 Crankshaft 1 28 9 803 167 0 Crankshaft Key 1 29 9 802 921 0 Oil Dip Stick 1 30 9 803 140 0 Crankshaft Seal 1 31 9 803 178 0 Shim 2 32 8 717 209 0 Bearing Housing 1 33 See ...

Page 31: ...TION Plunger Seal 4035 18mm Plunger Seal 4030 4031 20mm Plunger Seal 3540 15mm Complete Seal Packing 4035 18mm Complete Seal Packing 4030 4031 20mm Complete Seal Packing 3540 15mm Plunger 4035 18mm Plunger 4030 4031 20mm Plunger 3540 15mm Complete Valve Plunger Oil Seals ITEM NUMBERS INCLUDED 3 5 7 3 5 7 3 5 7 3 4 5 6 7 3 4 5 6 7 3 4 5 6 7 33 34 35 36 37 38 33 34 35 36 37 38 33 34 35 36 37 38 11 1...

Page 32: ...ment Parts For best performance specify genuine replacement parts WAYNE BURNER EXPLODED VIEW EXPLODED VIEW 32 12 REF NOZZLE 12 ELECTRODE SETTINGS 10 39 10 25 13 20 2 21 22 31 34 24 8 10 25 26 1 9 3 3 2 25 1 25 7 8 34 31 22 24 10 1 1 34 31 24 7 8 21 2 23 4 27 30 30 23 ...

Page 33: ...ner Mod M 1 8 20602 002 Band Air Outer 8 Hole Mod M 1 9 13392 Plate Slot Cover 1 10 30537 028 Gun RG CST 1 1 4 BB 21 31954 001 Strain Relief Low Profile 1 22 14222 Connector Male 3 16 x 1 8 IPT 1 23 14451 Oil Line ASM 6 1 24 101128 010 Pump S A2VA3006 N753 220V Combo 1 25 24001 001 Motor 1 7 220 230 50 60 PSC 1 26 13424 Coupling EG1 M A Pumps 1 27 21427 Fan 3 44 W x 4 25 D M 1 2 BOR 1 30 550053 Fi...

Page 34: ...41 0 Connector Female 1 13A 9 702 892 0 Connector Male 14 O Ring A B 1 15 Spring B 1 ITEM PART NO DESCRIPTION KIT QTY 16 Poppet B 1 17 9 802 893 0 Seal Washer 3 8 2 18 9 803 915 0 Banjo Bolt 3 8 w 1 8 Pilot 1 9 803 919 0 Banjo Bolt 3 8 Solid Cap 1 19 9 803 920 0 Banjo Bolt 1 2 w 1 4 Pilot 1 8 750 105 0 Banjo Bolt 1 2 Solid Cap 9 803 919 0 Banjo Bolt 3 8 Solid Cap 20 9 803 921 0 Seal Washer 1 2 2 2...

Page 35: ...9 802 893 0 Seal Washer 3 8 1 14 9 803 919 0 Banjo Bolt 3 8 1 15 8 754 936 0 O ring Ø2 62 x 10 78 A 1 16 9 803 920 0 Banjo Bolt 1 2 w 1 4 Port 1 ITEM PART DESCRIPTION KIT QTY 17 9 803 914 0 Seal Washer 1 2 1 18 8 754 937 0 Bypass Manifold 1 19 9 802 892 0 Outlet Connector 3 8 MPT 1 20 9 803 191 0 O ring Ø2 62 X 17 13 A B 1 21 8 933 017 0 Poppet Spring B 1 22 8 754 939 0 Poppet B 1 23 8 754 940 0 O...

Page 36: ...8 914 355 0 Rev 07 17 PRESSURE WASHER Wiring Diagram 36 FUEL SOLENOID 230V WAYNE BURNER IGNITOR 230V MOTOR 230W WIRING DIAGRAM 790SS 795SS ...

Page 37: ...8 914 355 0 Rev 07 17 PRESSURE WASHER WARRANTY Wiring Diagram 37 FUEL SOLENOID 230V WAYNE BURNER IGNITOR 230V MOTOR 230W WIRING DIAGRAM 895SS ...

Page 38: ......

Page 39: ...contact your local Hotsy dealer or visit www Hotsy com Smart phone users scan the code below to link directly to the Service Request page To REGISTER your pressure washer please visit our Warranty Registra tion page at www hotsy com WarrantyRegistration aspx or scan the code below with your smart phone ...