Hotsy 555 HE User manual
9.808-216.0 English Rev B (01/21) 1
555 HE
Service Manual
9.808-216.0 English Rev B (01/21) 2
Preface
Safety instrucons
Hazard levels
Descripon in this service manual
Service groups
Technical Features
Intended use
Field of applicaon
Safety installaons
Connecon performance of appliance
Pump
Safety catch
Unloader / bypass valve
Thermal relief valve
Symbols on the machine
Type plate
Flow paern
Overview of the appliance
Callouts 555 HE
Pump overview
Pump head overview
Pump head cross secon overview
Pump breakdown overview
Unloader / Bypass valve overview
Thermal relief valve overview
Fuel pump
High-eciency burner
Fuel nozzle
Burn head assembly
Measure fuel consumpon (only for California)
Service group
Scheduled maintenance chart
Trouble shoong chart
Trouble shoong process
Understanding the dierence between low, cavitaon and pulsang pressure
Pulsaon
Contents
5
5
5
6
6
6
6
6
6
6
6
7
7
7
7
7
8
9
9-10
11
11
11
12
13
13
14
14
15
15
15
16
16
17
18
18
18
9.808-216.0 English Rev B (01/21) 3
Cavitaon
Low pressure
Replacing leaking thermal relief valve
Vibraon
Water leaking from under pump
Oil is leaking from under pump
Oil is milky
Pressure washer unloader cycles when trigger or spray bar trigger is released
Motor will not turn on
Machine shuts o aer running a while
No burner
Burner motor turns on but there is no ame—fuel
Raw fuel out of burner exhaust
Burner ame turns on but low water temperature
Water temperature is too hot
Scheduled maintenance acvies
Inspecng pump oil
Changing pump oil
Changing quick connects / O-rings
Burner fuel lter—drain water / clean / replace
Cleaning hard water deposits from heang coils
Cleaning soot deposits from heang coils
Fuel nozzle replacement
Trouble shoong acvies
Check valve inspecon / replacement
Inspect packings, ceramic pistons and connecng rod connecon
Inspect inlet screen
Bypass thermal protector
Test pressure at trigger gun
Test pressure o the machine
Test pressure o the coil outlet
Test pressure before the coil inlet
Test pressure o the unloader
Test pressure o the pump (bypassing the unloader)
Changing and seng the unloader
Contents
19
19
19
20
20
20
20
21
21 –22
22
22
23—24
24
24
24
25
25
25
25
26
26
27-28
29
30
30
31
32
32
33
33
33
34
34
35
35
9.808-216.0 English Rev B (01/21) 4
Inspecng side of pump for oil leak
Inspecng cranksha cap side of pump for oil leak
Inspecng piston guide oil seals for oil leak
Inspecng trigger gun for leak
Tesng power supply
Reset GFCI
Check to see if voltage is into the machine from power supply
Check voltage into the pump switch
Check voltage out of the pump switch
Check voltage into the overload
Check voltage out of the overload to the contactor coil
Check voltage into the contactor coil
Check voltage out of the contactor
Check voltage out of the overload to the motor
Check voltage at the motor
Check voltage into the burner switch
Check voltage out of the burner switch
Check to see if the burner motor is spinning
Check fuel pressure
Adjusng fuel pressure
Check voltage at fuel solenoid
Determining if the fuel solenoid needs replacing
Checking power out of the thermostat
Checking power into the thermostat
Check voltage into the pressure switch
Checking for spark
Adjusng air
Technical documentaon
Technical specicaons 555 HE
Tools required
Torque specicaons
Contents
36
36
37
37
38
38
38
38
39
39
39
39
40
40
40
40
41
41
41
41
42
42
42
42
43
43
43
44
44
45-48
49
9.808-216.0 English Rev B (01/21) 5
Good service work requires extensive and pracce-oriented
training as well as well-structured training materials. Hence we
oer regular basic, advanced and expert training programs
covering the enre product range for all cered distributor
technicians. In addion to this, we also prepare service manu-
als for important appliances—these can be inially used as
instrucon guides and later on as reference guides. Apart from
this, we oer regular informaon about product enhance-
ments and their servicing.
If you should require addional assistance, have correcons or
quesons regarding this document, please do not hesitate
contacng us at: www.Hotsy.com and click on customer feed-
back to enter any info you may have for us or you can also
contact any of our Technical Support Specialists at 800-220-
5409.
Copying and duplicaon of texts and diagrams as well as
third-party access to this informaon is permied only with
the explicit permission of the company: KARCHER NORTH
AMERICA 6398 N Kärcher Way, Aurora, CO 80019.
1Preface
Service and maintenance tasks may only be performed
by qualified and specially trained specialists.
Observe safety information in the chapters!
DANGER
Please read the operating instructions for your
machine before using it, and pay particular attention to
the following safety instructions.
Warning and information plates on the machine
provide important directions for safe operation.
Apart from the notes contained herein, the gen-
eral safety provisions and rules for the prevention of acci-
dents of the legislator must be observed.
Switch off the appliance and, in case of applianc-
es connected to mains, pull out the power cord before
cleaning and performing any maintenance tasks on the
machine.
Relieve the high pressure system of all pressure
prior to all work on the appliance and the accessories.
Only use accessories and spare parts which have
been approved by the manufacturer. The exclusive use of
original accessories and original spare parts ensures that
the appliance can be operated safely and trouble free.
Only use the fuels specified in the Operations
Manual. Risk of explosion due to the use of inappropriate
fuels.
In petrol engine appliances, ensure that no petrol
comes in contact with hot surfaces.
Ensure that there is adequate ventilation or provi-
sion for diverting the exhaust gas while operating the ap-
pliance in closed rooms (risk of poisoning).
Do not close the exhaust.
Please ensure that there are no exhaust emis-
sions near the air inlets.
Do not use high pressure cleaners when there
has been an oil spill; move the appliance to another spot
and avoid any sort of spark formation.
Do not store, spill or use fuel in the vicinity of
open flames or appliances such as ovens, boilers, water
heaters, etc. that have an ignition flame or can generate
sparks.
Do not use unsuitable fuels, as they may be dan-
gerous.
Keep even mildly inflammable objects and mate-
rials away from the muffler (at least 2 m).
Warning
Do not bend over the exhaust or touch it.
2Safety instrucons
2.1 Hazard levels
DANGER
For an immediate danger which can lead to severe injuries or
death.
WARNING
For a possibly dangerous situaon which could lead to severe
injuries or death.
CAUTION
For a possibly dangerous situaon which can lead to minor
injuries or property damage.
ATTENTION
Pointer to a possibly dangerous situaon, which can lead to
property damage.
9.808-216.0 English Rev B (01/21) 6
Example: Remove/install ANRA wheel axle
3 Descripon in this service manual
3.1 Service groups
AN RA Remove/install wheel axle
Service group Component Acvity
4Technical Features
High performance burner with upright heang coil
High limit hot water safety cut o
3-piston cranksha pump, piston with ceramic sleeves
Pump head made of brass
Sucon and high-pressure valves made of stainless steel
Unloader / bypass valve
Trigger gun
Single wand spray lance
3 power nozzles
Compact frame
Flat free res
4.1 Intended use
Mobile hot water high-pressure cleaner in various perfor-
mance classes for commercial use.
4.2 Field of applicaon
This service manual describes the following appliance:
Appliance type Appliance no. Operating instructions Spare parts list
555 HE 1.109-137.0 9.808-140.0 Available in DISIS
4.3 Safety installaons
Safety devices serve to protect the user and must not be
rendered in operational or their functions bypassed. Observe safety information in the chapters!
4.4 Connecon performance of appliance
20 Amp (555 HE).
4.5 Pump
3 piston direct drive pump with ceramic pistons
Cylinder head made of cast iron with special “HR” coating
Working pressure: 1300 psi
Water quantity: 2.2 gpm
9.808-216.0 English Rev B (01/21) 7
The safety catch on the trigger gun prevents the appli-
ance from being switched on unintentionally.
4.6 Safety catch
4.7 Unloader / bypass valve
4.8 Thermal relief valve
If the hand trigger bar or trigger gun is closed, the unload-
er / bypass valve opens and the entire water volume will
flow back to the suction side of the pump.
The unloader / bypass valve is set by the manufacturer
and sealed. Setting should only be performed by trained
technical service personnel.
The thermal relief valve helps to protect the high-pressure
pump from unacceptable heating during released trigger
operation.
4.10 Type plate
The type plate is located on the burner coil wrap.
1. Code consisting of 2 digit for week and 2 digit for year
machine was manufactured.
2. Bar code consisting of part number and serial number.
3. Code consisting of part number—serial number.
4.9 Symbols on the machine
Hot items, caution could burn or melt skin or material.
Disconnect from electrical supply before servicing.
Read operator’s manuals for both this unit and the attached machine before operating. This ma-
chine to be used only by qualified operators. High pressure developed by the machine attached to
this unit can cause personal injury. Use caution when operating. Do not direct discharge stream at
persons or severe injury will result. High pressure can cause dirt and other particles to become air-
borne and fly at high speeds. Eye protection, safety clothing and foot protection must be worn when
using this equipment. Spray gun kicks back — hold with both hands. Before disconnecting hose,
turn attached machine off and open spray gun to relieve pressure.
3
2
1
9.808-216.0 English Rev B (01/21) 8
1 Water filter
2 High-pressure pump
3 Unloader valve
4 Thermal relief valve
5. Heat exchanger
4.11 Flow paern
9.808-216.0 English Rev B (01/21) 9
5Overview of the appliance
5.1 Call outs 555 HE
8
5
12
9
10
346
7
11
12
8
12
11
14
13
15 16
9.808-216.0 English Rev B (01/21) 10
1Trigger gun
2Spray lance
3Motor switch
4Burner switch
5Hour meter
6Adjustable thermostat
7Spray nozzles
8Hose reel opon
9Power cord with GFCI
10 Flat free re
11 Pump
12 Unloader
13 Electric motor
14 Hose holder
15 Fuel cap with gauge
16 Fuel tank
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