Hotsy pressure washer troubleshooting

In the work of the Hotsy pressure washer, various minor problems may occur, since no equipment is immune from breakdowns. Hotsy pressure washer is not turning on, is not supplying water under sufficient pressure, is not working or is not heating the water – breakage can be any. A full manual could help you not only to identify the problem, but also to repair the problem yourself. 2 tables below can be just such a manual.

Hotsy HC-232439 pressure washer troubleshooting

LOW OPERATING PRESSUREFaulty pressure gaugeInstall new gauge.
Insufficient water supplyUse larger supply hose; clean filter at water inlet.
Old, worn or incorrect spray nozzleMatch nozzle number to machine and/or replace with new nozzle.
Belt slippageTighten or replace; use correct belt.
Plumbing or hose leakCheck plumbing system for leaks. Retape leaks with teflon tape.
Faulty or mis-adjusted unloader valveAdjust unloader for proper pressure. Install repair kit when needed.
Worn packing in pumpInstall new packing kit.
Fouled or dirty inlet or discharge valves in pumpClean inlet and discharge valves.
Worn inlet or discharge valvesReplace with valve kit.
Obstruction in spray nozzleRemove obstruction.
Leaking pressure control valveRebuild or replace as needed.
Slow engine RPMSet engine speed at proper specifications.
Pump sucking airCheck water supply and possibility of air seepage.
Valves stickingCheck and clean or replace if necessary.
Unloader valve seat faultyCheck and replace if necessary.
BURNER WILL NOT LIGHTLittle or no fuelFill tank with fuel.
Improper fuel or water in fuelDrain fuel tank and fill with proper fuel.
Clogged fuel lineClean or replace.
Plugged fuel filterReplace as needed.
Mis-adjusted burner air bandsReadjust air bands for clean burn.
Little or no fuel pressure from fuel pumpIncrease fuel pressure to specification and/ or replace fuel pump. Test with pressure gauge.
Faulty burner transformerTest transformer for proper arc between contacts. Replace as needed.
Disconnected or short in electrical wiringAll wire contacts should be clean and tight. No breaks in wire
BURNER WILL NOT LIGHTFlex coupling slipping on fuel pump shaft or burner motor shaftReplace if needed.
On-Off switch defectiveCheck for electrical current reaching burner assembly with burner switch on.
Heavy sooting on coil and burner can cause interruption of air flow and shorting of electrodesClean as required.
Improper electrode settingCheck and reset according to diagram in Operator’s Manual.
Fuel not reaching combustion chamberCheck fuel pump for proper flow. Check solenoid flow switch on machines with spray gun control, for proper on-off fuel flow control.
Clogged burner nozzleClean as required.
Thermostat faulty or slow engine speedIncrease engine RPM to increase voltage.
Flow switch malfunctionRemove, test for continuity and replace as needed.
Flow solenoid malfunctionReplace if needed.
Blockage in valveCheck and replace if necessary.
Pump sucking airCheck water supply and air seepage at joints in suction line.
Worn piston packingCheck and replace if necessary.
MACHINE SMOKESImproper fuel or water in fuelDrain tank and replace contaminated fuel.
Improper air adjustmentReadjust air bands on burner assembly.
Low fuel pressureAdjust fuel pump pressure to specifications.
Plugged or dirty burner nozzleReplace nozzle.
Faulty burner nozzle spray patternReplace nozzle.
Heavy accumulation of soot on coils and burner assemblyRemove coils and burner assembly, clean thoroughly.
Misaligned electrode settingRealign electrodes to specifications.
Obstruction in smoke stackCheck for insulation blockage or other foreign objects.
Low engine RPMIncrease RPM
LOW WATER TEMPERATUREImproper fuel or water in fuelReplace with clean and proper fuel.
Low fuel pressureIncrease fuel pressure.
Weak fuel pumpCheck fuel pump pressure. Replace pump if needed.
Fuel filter partially cloggedReplace as needed.
Soot build-up on coils not allowing heat transferClean coils.
Improper burner nozzle
WATER TEMPERATURE TOO HOTIncoming water to machine warm or hotLower incoming water temperature.
Fuel pump pressure too highSee specifications for proper fuel pressure.
Fuel pump defectiveReplace fuel pump.
Detergent line sucking airTighten all clamps. Check detergent lines for holes.
Defective temperature switchReplace.
Incorrect fuel nozzle sizeSee specifications for proper fuel nozzle
Insufficient water suppliedCheck water G.P.M. to machine.
Restricted water flowCheck nozzle for obstruction, proper size.
PUMP NOISYAir in suction lineCheck water supply and connections on suction line.
Broken or weak inlet or discharge valve springs
Excessive matter in valves
Worn bearings
PRESENCE OF WATER IN OILOil seal wornCheck and replace if necessary.
High humidity in airCheck and change oil twice as often.
O-Ring plunger retainer worn
Cracked pistonCheck and replace if necessary.
Pump protectorLower water supply pressure. Do not run with spray gun closed longer than 2 minutes
OIL DRIPPINGOil seal worn
EXCESSIVE VIBRATION IN DELIVERY LINEIrregular functioning of the valvesCheck and replace if necessary.
DETERGENT NOT DRAWINGAir leakTighten all clamps. Check detergent lines for holes.
Restrictor in float tank is missingReplace restrictor. Check for proper orifice in restrictor.
Filter screen on detergent suction hose pluggedClean or replace.
Dried up detergent plugging metering valveDisassemble and clean thoroughly.
High viscosity of detergentDilute detergent to specifications.
Hole in detergent line(s)Repair hole.
Low detergent levelAdd detergent, if needed.
PUMP RUNNING NORMALLY BUT PRESSURE LOW ON INSTALLATIONPump sucking airCheck water supply and possibility of air seepage.
Valves stickingCheck and clean or replace if necessary.
Nozzle incorrectly sized
Unloader valve seat faulty
Worn piston packingCheck and replace if necessary.
BURNER MOTOR WILL NOT RUNFuel pump seizedReplace fuel pump.
Burner fan loose or misalignedPosition correctly, tighten set screw.
Defective control switchReplace switch.
Loose wireCheck and replace or tighten wiring.
Defective burner motorReplace motor.
RELIEF VALVE LEAKS WATERRelief valve defectiveReplace or repair


Hotsy 965B pressure washer troubleshooting

ENGINE WILL NOT RUNNo fuelReplenish supply.
Low batteryCharge battery.
Poor battery cable connectionClean battery terminals and check cables.
NO WATER FROM PRESSURE NOZZLEPressure nozzle cloggedClean pressure nozzle.
Inlet water screen cloggedClean.
Pump sucking airFill the detergent container.
Check for loose hose clamps or fittings.
POOR OR NO DETERGENT FLOWLow detergent levelReplenish supply.
Detergent screen cloggedClean.
Detergent metering valve not openingCheck that handle or knob is not slipping on shaft.
Pressure nozzle cloggedClean.
Spray nozzle worn or incorrect sizeReplace.
Inadequate water supplyIncrease water supply.
Pump sucking airFill the detergent container. Check for loose hose clamps or fittings.
UNLOADER VALVE CYCLES WHEN TRIGGER GUN IS OPEN OR CLOSEDAir in systemOpen and close trigger gun several times.
Defective unloader valveRepair or replace.
Water leak between unloader valve and trigger gunCheck fittings, hose and trigger gun for leaks. Repair or replace.
Adjustable thermostat set too lowRaise temperature setting.
Defective pressure switchRepair or replace.
Electrodes are dirty or out of adjustmentRefer to Oil Burner Manual provided with machine.
No AC generator outputCheck AC generator.
BURNER SMOKES OR HAS OBNOXIOUS ODORAir bands need to be adjustedReadjust. Refer to Oil Burner Section under Installation.
Improper fuelUse kerosene. DO NOT USE GASOLINE.