Hotsy 555 HE - Service Manual

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9.808-216.0 English Rev B (01/21) 1

555 HE

Service Manual

Main Page

Table of Contents2
Preface5
Safety Instructions5
Hazard Levels5
Description in this Service Manual6
Service Groups6
Technical Features6
Intended Use6
Field of Application6
Safety Installations6
Connection Performance of Appliance6
Pump6
Safety Catch7
Unloader / Bypass Valve7
Thermal Relief Valve7
Symbols on the Machine7
Type Plate7
Flow Pattern8
Overview of the Appliance9
Callouts 555 HE9
Pump Overview11
Pump Head Overview11
Pump Head Cross Section Overview11
Pump Breakdown Overview12
Unloader / Bypass Valve Overview13
Thermal Relief Valve Overview13
Fuel Pump14
High-Efficiency Burner14
Fuel Nozzle15
Burn Head Assembly15
Measure Fuel Consumption (Only for California)15
Service Group16
Scheduled Maintenance Chart16
Trouble Shooting Chart17
Trouble Shooting Process18
Understanding the Difference between Low, Cavitation and Pulsating Pressure18
Pulsation18
Cavitation19
Low Pressure19
Replacing Leaking Thermal Relief Valve19
Vibration20
Water Leaking from under Pump20
Oil Is Leaking from under Pump20
Oil Is Milky20
Pressure Washer Unloader Cycles When Trigger or Spray Bar Trigger Is Released21
Motor will Not Turn on21
Machine Shuts off after Running a While22
No Burner22
Burner Motor Turns on but There Is no Flame-Fuel23
Raw Fuel out of Burner Exhaust24
Burner Flame Turns on but Low Water Temperature24
Water Temperature Is too Hot24
Scheduled Maintenance Activities25
Inspecting Pump Oil25
Changing Pump Oil25
Changing Quick Connects / O-Rings25
Burner Fuel Filter-Drain Water / Clean / Replace26
Cleaning Hard Water Deposits from Heating Coils26
Cleaning Soot Deposits from Heating Coils27
Fuel Nozzle Replacement29
Trouble Shooting Activities30
Check Valve Inspection / Replacement30
Inspect Packings, Ceramic Pistons and Connecting Rod Connection31
Inspect Inlet Screen32
Bypass Thermal Protector32
Test Pressure at Trigger Gun33
Test Pressure off the Machine33
Test Pressure off the Coil Outlet33
Test Pressure before the Coil Inlet34
Test Pressure off the Unloader34
Test Pressure off the Pump (Bypassing the Unloader)35
Changing and Setting the Unloader35
Inspecting Side of Pump for Oil Leak36
Inspecting Crankshaft Cap Side of Pump for Oil Leak36
Inspecting Piston Guide Oil Seals for Oil Leak37
Inspecting Trigger Gun for Leak37
Testing Power Supply38
Reset GFCI38
Check to See if Voltage Is into the Machine from Power Supply38
Check Voltage into the Pump Switch38
Check Voltage out of the Pump Switch39
Check Voltage into the Overload39
Check Voltage out of the Overload to the Contactor Coil39
Check Voltage into the Contactor Coil39
Check Voltage out of the Contactor40
Check Voltage out of the Overload to the Motor40
Check Voltage at the Motor40
Check Voltage into the Burner Switch40
Check Voltage out of the Burner Switch41
Check to See if the Burner Motor Is Spinning41
Check Fuel Pressure41
Adjusting Fuel Pressure41
Check Voltage at Fuel Solenoid42
Determining if the Fuel Solenoid Needs Replacing42
Checking Power out of the Thermostat42
Checking Power into the Thermostat42
Check Voltage into the Pressure Switch43
Checking for Spark43
Adjusting Air43
Technical Documentation44
Technical Specifications 555 HE44
Tools Required45
Torque Specifications49

Hotsy 555 HE - Service Manual

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