HOTSY - 7660 Automatic Parts Washer (Operators Manual)

For technical assistance or the dealer nearest you, visit our website at www.Hotsypartswashers.com

9.800-980.0

7660AutomAtic pArts wAsHer

operAtor's mAnuAl

CHECKWATER LEVEL

DAILYCAUTIONHOT ALKALI

DO NOT USE

FLAMMABLE

SOLUTIONS

DO NOTOPEN WHILE

PUMP ISRUNNING

OPERATING INSTRUCTIONS

MAINTENANCE INSTRUCTIONS

TURNTABLE

ON

OFF

LOWWATER

OFF TURNPAST

10

TURNPAST

2 OFF

HOURS

OFF TURNPAST

5

contents

�7660 • 9.800-980.0 • Rev. 1/08

section 1

introduction and safety

General Safety Information 5-6

Component Identification 7-9

section 2

installation

Before You Begin 10

Step 1: Make Electrical Connections 10

Step �: Configure the �4-hour, 7-day Timers 10

Step 3: Connect a Water Line 10

Step 4: Fill the Machine with Water and Add Detergent 10-11

section 3

operation

Main Operating Components 1�

Control Panel 1�

�4-hour, 7-day Timers 1�

Thermostat 1�

Door Safety Switch 13

Debris Screen 13

Oil Skimmer 13

Water Level Gauge 14

Low Water Shut-off 14

Filtration and Sump Sweep Systems 15

Filtration System 15

Sump Sweep System 15

Detergents and Additives 15

Detergents 15

Rust Inhibitor Additive 15

Preparing the Machine for Use 16

3

contents

7660 • 9.800-980.0 • Rev. 1/08

Washing Parts 16

Shutting Down the Machine 16

section 4

troubleshooting

Overview 17-19

Troubleshooting the Electrical System 19

Troubleshooting Single and Three Phase Panels �0

Testing Individual Components �1-��

section 5

maintenance and repair

Maintaining the Machine �3

Daily, Weekly, Monthly, Semi-Annual Maintenance �3

Cleaning and Aligning the Spray Nozzles �3

Using the Oil Skimmer �5

Cleaning out the Sump �5

Manual Sump Cleanout �5-�6

Cleaning the Filters �6

Repairing the Machine �6

Heating Element �6-�7

Thermostat �7

Turntable Motor �7-�8

Timers and Switches on the Control Panel �8-�9

Oil Skimmer Motor �9-30

Front Exploded View & Parts List 31-3�

Spray Arm Exploded View & Parts List 33

Rear Exploded View & Parts List 34-36

TT Motor Exploded View & Parts List 37

Side Control Exploded View & Parts List 38

contents

47660 • 9.800-980.0 • Rev. 1/08

Model Number ______________________________

Serial Number ______________________________

Date of Purchase ____________________________The model and serial numbers will be found on a decal attached to the machine. You should record both serial number and date of purchase and keep in a safe place for future reference.

Oil Skimmer Exploded View & Parts List 39

Electrical Panel - �08V 1ph Exploded View Parts List 40-41

Electrical Panel - �30V 1ph Exploded View Parts List 4�-43



Electrical Panel - 460V 3ph Exploded View Parts List 48-49

Electrical Panel - 575V 3ph Exploded View Parts List 50-51

wArrAntY

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section 1: introduction & sAfetY

This manual covers the operation and maintenance of your automatic parts washer. All information in this manual is based on the latest product information available at the time of printing.

We reserve the right to make changes at any time without incurring any obligation.

owner/user responsibility:The owner and/or user must have an understanding of the manufacturer’s operating instructions and warn-ings before using this machine. Warning information should be emphasized and understood. If the operator is not fluent in English, the manufacturer’s instructions 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 com-prehends 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 machine if machine is resold.

when ordering parts, please specify model and serial number.

GenerAl sAfetY informAtion

WARNING: To reduce the risk of injury, read operating instruc-tions carefully before using.

1. Read the owner’s manual thoroughly. Failure to fol-low instructions could cause a malfunction of the parts washer and result in death, serious bodily injury and/or property damage.

WARNING: This is a heated parts cleaner. Use only nonflammable, noncombustible, water-based cleaning compounds in this ma-chine. Do not fill or contaminate with any flammable or combus-tible material such as gasoline, alcohol, mineral spirits, etc. Drain parts to be cleaned of any

combustible or flammable material before placing inside cabinet. Failure to observe this warning will create an extremely hazardous condition.

�. All installations must comply with local codes. Contact your electrician, plumber, utility company or the selling distributor for specific details.

3. 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 grounded receptacle of proper voltage and amperage ratings. Do not touch machine with wet hands or while standing in water. Always disconnect the power before servicing.

4. Never make adjustments on machine while it is in operation except those prescribed in this manual.

WARNING: Use extreme caution when opening the door of this parts washer. Hot water/de-tergent vapors will be emitted. Stand Back!

5. Do not allow high concentra-tions of flammable fluids, acids, or caustics to be intro-duced into this machine.

WARNING: Flammable liquids can create fumes which can ignite causing property damage or severe injury.

6. Do not locate this machine in the vicinity of any flammable vapors, liquids or solids.

7. Before servicing the ma-chine, refer to all MSDS’s on

the material identified in the waste stream. You must comply with all warnings and wear all protective clothing stated on the MSDS.

8. When the machine is working, do not cover or place in a closed space where ventilation is insufficient. Avoid installing machines in small confined areas.

9. In cold climates, this parts washer will freeze if not in operation and must be located in a heated enclosure.

10. Running this machine without water will damage the heating elements and will void the warranty.

WARNING: Eye protection, gloves and foot protection must be worn while loading and un-loading parts.

11. Eye protection, gloves, foot protection and other safety devices must be worn when loading and unloading parts to be cleaned.

wArninG

reAd operAtor’s mAnuAl

tHorouGHlY prior to use.

wArninG

risk of explosion: Avoid flAmmAble

liquids.

wArninG

extremelY Hot: use cAution wHen

openinG lid.

wArninG

risk of explosion: Avoid flAmmAble

liquids.

wArninG

use protective eYeweAr, Gloves

And footweAr wHen operAtinG.

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section 1: introduction & sAfetY

1�. Use caution when lifting items in and out of parts basket to prevent back injuries.

13. Always ensure that your parts washer is clean. Pump and heating elements could be damaged by continued build-up of sludge.

14. Check water level daily. Never allow water level to drop below pump inlet screen or heating ele-ments.

15. Before discarding the spent washing solution, check with your local EPA or sewer district for disposal regulations.

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CHECKWATER LEVEL

DAILYCAUTIONHOT ALKALI

DO NOT USE

FLAMMABLE

SOLUTIONS

DO NOTOPEN WHILE

PUMP ISRUNNING



TURNTABLE

ON

OFF

LOWWATER

OFF TURNPAST

10

TURNPAST

2 OFF

HOURS

OFF TURNPAST

5

section 1: component identificAtion - front

for detail see control

box illus.

steam vent

door safety switch plunger

revolving door pivot

Assy.

revolving door

debris screen

sump cover w/water

level Gauge

door latch

pump

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KEEPDRY



section 1: component identificAtion - reAr

sump cover w/level

indicator

solenoid valve

(optional)

fresh water in

low water shut-off

Assy.pump

Heating element & thermostat enclosure

oil skimmer Assy

steam vent

for detail see main

control panel illus.

door safety switch

for detail see side

control box illus.

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turntAble

on

off

low

wAter

off turn

pAst10

turn

pAst2 off

Hours

off turn

pAst5

section 1: component identificAtion - front-options

door switch rod

door spacer

door spindle

door

parts tree

oil drain container

sump cover

door latch

small parts basket

containment ring

turntable chain

turntable

swing down spray

manifold

tool tray(optional)

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section 2: instAllAtion

before You beGinTo prepare to install the machine, choose an unob-structed, level site that allows convenient access for operators and maintenance personnel. Sources for water and electrical power should be located near the installation site. If your machine is equipped with the optional power brush and hand detail brush you must also run a compressed air line to the installation site.

If you have any questions regarding the installation, please contact your distributor or call a customer service representative.

When contacting customer service please refer to the machine identification tag inside the front cover of this manual for detailed machine specifications.

step 1: mAke electricAl connections

note: All electrical installation tasks must be performed by a licensed, professional electrician to ensure safe and proper operation. The installation must comply with the National Electric Code and all applicable state and local codes.

the machine can only operate on the type of electrical power indicated on the electrical specifications tag.

Read and understand the electrical specifications tag to determine the electrical power requirements before installing the machine.

step 2: confiGure tHe 24-Hour, 7-dAY timers

note: This step is required for machines equipped with an optional �4-hour, 7-day heater timer or a �4-hour, 7-day heater and oil skimmer timer. If your machine does not have a �4-hour, 7-day timer, skip this step.

The optional �4-hour, 7-day heater timer controls the heating system. The optional �4-hour, 7-day heater and oil skimmer timer controls the heating system and the oil skimmer.

The parts washer requires approximately 3 to 4 hours to heat the wash solution to operating temperature, and the oil skimmer requires up to 30 minutes to effectively remove oil from the wash solution. Using either timer, you can schedule the heating system to turn on several hours before you begin to use the machine each day. In addition, the optional �4- hour, 7-day heater and oil skimmer timer allows you to schedule the oil skimmer to operate while the machine sits idle.

The timer is located below the electrical panel inside the main electrical enclosure. To configure the timer, refer to the instruction label inside the timer door.

step 3: connect A wAter line

note: This step is required for machines equipped with the optional automatic water fill feature. If your machine does not have this option, skip this step.

The optional automatic water fill feature automatically maintains the correct water level in the sump. The fea-ture requires that you connect the machine to a dedi-cated water supply line.

To connect the machine to a water supply line, attach a suitable burst-proof hose to the hose connection on the rear of the machine below the oil skimmer assembly (See Figure Below), then connect the hose to a nearby water spigot.

note: The machine is designed for portability, and some maintenance tasks require that you move the machine. DO NOT make a permanent connection from your shop water supply to the machine.

step 4: fill tHe mAcHine witH wAter And Add

deterGentstep 1:

Familiarize yourself with the water level gauge located on the left sump cover (See Figure Below).

fresh water in

solenoid valve

High water level

float rod indicator

low water level

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step 2:

Fill the sump with water. If your machine is equipped with the automatic water fill feature, simply open the water inlet valve; if not, add water through the wash chamber. The sump capacity is 40 gallons.

step 3:

When the water level gauge indicates that the sump is full and the low water light has gone out, shut off the water. If your machine is equipped with the automatic water fill feature the water will shut off automatically when the sump is full.

note: monitor the water level carefully – do not over-fill the machine. If you overfill the machine, remove excess water using a small submersible pump or a suitable container. The correct water level is two inches from the top of the sump tank when the pump is off.

step 4:

Turn the heater timer to the 4-hour position. The sump water will reach operating temperature (160–180°F) in approximately three hours.

note: To avoid waiting for the sump water to heat to operating temperature every day, manufacturer recom-mends a �4-hour, 7-day heater timer. With a �4-hour, 7-day timer you can set the heating system to turn on several hours before you begin to use the machine each day. For more information about �4-hour, 7-day timers refer to 24-hour, 7-day timers.

step 5:

While the sump water is heating, add the appropriate quantity of factory approved detergent to the wash chamber. We recommend mixing the detergent with warm water in a separate bucket/container and then pouring the dissolved detergent into the sump.

note: Factory approved detergent is the only detergent approved for use with this automatic parts washer. It is specially formulated with rust inhibitors and anti-foaming agents to optimize performance and minimize maintenance. The use of any other detergent during the warranty period will void the warranty. In addition, using factory detergents will extend your 90 day labor warranty to 1 year.

step 6:

Close and latch the door.

step 7:

Turn the wash cycle timer to � hours for the first time, and allow the machine to complete the cycle to thor-oughly dissolve the detergent into the water.

step 8:

After the machine stops, remove the right sump cover and transfer approximately two gallons of wash solution into the detail sump using a small submersible pump or a suitable container.

wArninG: Hot cleaning solution could cause serious injury. Always wear rubber gloves and approved eye protection when handling hot cleaning solution.

step 9:

Replace all sump covers.

When the machine stops, and after the wash water reaches operating temperature, it is ready for use. Refer to section 3: operation for complete operating instructions.

section 2: instAllAtion

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section 3: operAtion

mAin operAtinG components

Familiarize yourself with the main operating compo-nents before operating the machine.

control pAnel

Heater controlThe heater control is a 1�-hour timer switch. It con-trols the heating element in the sump chamber. The heating system is thermostatically set at the factory to reach a high temperature of 180°F. The temperature is adjustable using the thermostat (See Adjusting the thermostat).

wash cycle controlThe wash cycle control is a 60-minute timer switch with a hold feature. When set between 1 and 60 minutes, the timer automatically shuts off the pump and turntable when the wash cycle is complete. When set to Hold, the pump and turntable run continuously until manu-ally shut off.

skimmer controlThe skimmer control is a 30-minute timer switch. It controls the automatic oil skimmer.

turntable switchThe turntable switch is a simple rocker switch that en-ables you to disconnect power to the turntable motor. Set to on, the turntable rotates during the wash cycle. Set to off, the turntable does not rotate during the wash cycle. The switch is useful for washing large parts that would otherwise impede turntable rotation.

low water indicatorThe low water indicator light illuminates if the wash solution in the sump is low. For more information refer to low water shut-off.

24-hour, 7-day timersModels �840, H�O-�836, and 7660 machines are available with a �4-hour, 7-day heater timer or a �4-hour, 7-day heater and oil skimmer timer. The heater timer controls the heating system. The heater and oil skimmer timer controls the heating system and the oil skimmer.

The timer is located below the electrical panel inside the main electrical enclosure. To configure the timer, refer to the instruction label inside the timer door.

thermostatThe thermostat is located inside the heating element and thermostat enclosure. Single phase thermostats have an adjustment screw that is accessible only from inside the enclosure. Three phase thermostats have an adjustment knob mounted on the outside of the enclosure.

The thermostat is factory-set to heat the wash solution to a maximum temperature of 180°F.

Adjusting the thermostat

To adjust the thermostat, rotate the adjustment screw or knob clockwise to increase the temperature, or counter-clockwise to decrease the temperature (See Figure Below).

single phase

three phase

Adjustment screw

decrease temperature

increase temperaturedecrease

temperature

increase temperature

TURNTABLE

ON

OFF

LOWWATER

OFF TURNPAST

10

TURNPAST

2 OFF

HOURS

OFF TURNPAST

5

Heater control oil skimmer control

low water indicatorturntable Jog

switch

wash cycle control

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door safety switchThe door closure safety switch is located on the rear of the machine, to the right of the main electrical panel. The switch is activated with a push-rod that extends through the wash chamber.

The switch disconnects power to the water pump and turntable motor if the wash chamber door is opened during a wash cycle. The water pump and turntable motor will not operate if the door is not closed and latched correctly.

Adjusting the safety switch

step 1:

Disconnect power to the machine.

step 2:

Remove the two screws from the rear of the safety switch cover, and pull the cover free of the switch as-sembly.

step 3:

Loosen the adjustment nuts on both sides of the switch bracket (See Figure Below).

step 4:

Adjust the switch accordingly.

step 5:

Tighten the adjustment nuts.

step 6:

Replace the cover.

When properly adjusted, you should hear a slight “click” as the door latch engages and compresses the door seal and the door closure safety switch.

debris screenThe debris screen is located just below the wash cham-ber, and is accessible from the front of the machine (See Figure Below). The debris screen continuously filters debris particles from the cleaning solution to ensure blockage-free spray nozzle operation, and also provides

a safeguard against small parts that might accidentally be washed through from the cleaning chamber.

The frequency at which you must clean the debris screen depends on machine usage. In general, you should clean the screen before operating the machine each day.

note: Never operate the machine without the debris screen in place and never remove the screen while the machine is operating. The screen is specially sized to filter particles that could clog the spray nozzles or damage the water pump.

Operating the machine without the debris screen in place could cause spray nozzles to clog or the water pump to fail.

oil skimmerThe oil skimmer is located on the right rear corner of the machine (See Figure Below). It automatically removes oil from the wash solution to prolong its useful life. Re-fer to using the oil skimmer for detailed operating instructions.

debrisscreen

switchHousing

safetyswitch

Adjustment nuts

switchbracket

skimmer motorskimmer disk

wiper blades

optional oil container

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water level GaugeThe water level gauge is located on the left sump cover (See Figure Below). Under typical operating conditions the machine loses 3 to 5 gallons of water per day to evaporation.

It is important that you monitor and maintain the water level daily to minimize the risk of burning out the heating element or ruining the pump.

note: Water evaporates from the sump chamber, but the detergent does not. It is not necessary to add detergent each time you add water. Only add detergent after you clean the sump chamber each month, or if you notice specific low-detergent indicators (See detergents and Additives).

Automatic water fillThe optional automatic water fill system automatically maintains a proper water level in the sump.

The automatic water fill system uses the low water shut-off proximity switches to open and close a water solenoid valve, which automatically maintains a proper water level in the sump. The figure below describes the operation of the automatic water fill system.


low water shut-offThe low water shut-off system shuts down the machine if the wash solution in the sump chamber drops below a safe level. The system uses two proximity switches and a float rod mounted near the rear of the sump chamber to monitor the water level.

If the wash solution drops below the lower proximity switch, the low water indicator light on the control panel turns on and the system disconnects power to machine. To reset the system, add water to the sump until the low water indicator light turns off.

note: If your machine is equipped with the optional automatic water fill feature, the sump will automatically fill when the water level drops below the lower low water proximity switch.

wAter level ok:both switches open, Automatic

water fill valve (if installed) closed, Heating element on.

low wAter level:top switch closed, bottom switch

closed, Automatic water fill valve (if installed) open, Heating element off.

low wAter level:top switch closed, bottom switch open, Automatic water fill valve (if

installed) open, Heating element off.

High water level

low water level

float rod indicator

float rodfloat

proximity switches

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filtration and sump sweep systemsThe optional filtration and sump sweep systems reduce or eliminate the need to manually clean out the sump.

The filtration system continuously filters solid particles from the wash solution, and you can use the sump sweep system to periodically remove waste build up from the bottom of the sump chamber.

filtration systemThe filtration system uses a filter canister with a nylon or polyester felt filter bag to continuously filter solid par-ticles from the wash solution. The filter system includes pressure gauges which allow you to monitor the condi-tion and performance of the filter bag inside the canister. Under typical operating conditions, the inlet and outlet pressure gauges read approximately 45 psi. As the filter bag becomes soiled, the outlet pressure decreases. If the difference between the inlet and outlet pressure is 15 psi or greater, stop the machine and clean or replace the filter bag (See cleaning the filters).

wArninG: Operating the machine with a clogged filter system could damage the filter bag. STOP THE MACHINE IMMEDIATELY if the difference between the inlet and outlet pressure is 15 psi or greater.

sump sweep systemThe sump sweep system uses a three-way valve to divert solution from the wash chamber to a spray bar on bottom of the sump chamber. The spray bar generates a high-pressure spray pattern that agitates the sump solution and suspends solid particles. The solution then flows through the filtration system which removes the solid particles (See cleaning out the sump).

deterGents And AdditivesdetergentsManufacturers detergents are the only detergents ap-proved for use with our Automatic Parts washers. They are specially formulated with rust inhibitors and anti-foaming agents to optimize performance and minimize maintenance. The use of any other detergent during the warranty period will void the warranty.

To monitor the approximate concentration of detergent in the wash solution, periodically examine the wash solution in the sump chamber for the following indica-tors:

• rust inside the machine: not enough detergent

• excessive foaming: not enough detergent

• thick, white residue on parts after washing: too much detergent

To maintain proper detergent concentration under typical operating conditions, add detergent each month after cleaning the sump chamber.

rust inhibitor AdditiveHotsy RI Rust Inhibitor protects the entire inside of your machine against the degenerative effects of water evaporation. Where the rust inhibitors in Hotsy 100Z and �00Z detergents work in liquid water, Hotsy RI works in the vapor phase. It actually evaporates with the water and continuously coats and protects metal surfaces, even while your machine is sitting idle.

For more information, contact your distributor or call customer service.

inlet pressure

Gauge

outlet pressure

Gauge

to main tank

filter

sump sweep

position

wash position

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prepArinG tHe mAcHine for use

Before you begin to wash parts, it is important that you properly prepare the machine. Before you begin to use the machine each day:

• check the water level and add water to the sump tank if necessary;

• heat the water to operating temperature;

• add detergent if necessary (see detergents);

• verify that none of the spray nozzles are clogged; and

• clean the debris screen.

wAsHinG pArtsThe following procedure assumes that the heater is on and the sump water is at operating temperature.

To wash parts, perform the following procedure.

wArninG: Hot, high-pressured cleaning solution could cause serious injury. Always wear rubber gloves and approved eye protection when loading and unload-ing the machine.

step 1:

Load parts into the machine.

Load large, heavy parts directly onto the turntable.

Secure large, light parts (valve covers for example) to the turntable using suitable rubber tie-downs.

Load small, light parts into the small parts basket pro-vided with your machine.

note: For optimum cleaning performance, provide a slight clearance between parts to allow adequate flow of cleaning solution around and between them.

step 2:


step 3:

Set the wash cycle timer to between 1 and 60 minutes for a timed wash cycle, or set it to Hold for a continu-ous wash.

step 4:

When the machine automatically stops (or after you manually stop the wash cycle), open the door and wait a few moments to allow the parts to cool and dry before removing them. Most parts will flash-dry in seconds.

sHuttinG down tHe mAcHine

To shut down the machine at the end of the day:

• set the wash cycle timer to off;

• set the heater timer to off; and

• shut off the compressed air at the supply line (if installed).

wArninG: If the heater is left on unattended, the wash solution could evaporate and the oil and grease in the sump chamber could catch fire.

• For periods of extended shut-down, disconnect all power to the machine.

• If your machine is equipped with an optional �4-hour, 7-day heater timer, periodically verify the settings to prevent inadvertent unattended opera-tion.


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section 4: troublesHootinG

problem possible cAuse solution

poor cleAninG performAnce

Parts are obstructing each other Check the position of parts on turntable; posi-tion parts to allow flow of cleaning solution around and between them.

Low water level in sump Check sump water level and add water if necessary.

Clogged or improperly aligned spray nozzles

Check the spray nozzles for obstructions and alignment; clean and align if necessary.

Wash solution is not properly heated Check wash solution temperature; tempera-ture should be between 160°F and 180°F (See wash solution is not Heating Section)

Pump is not operating properly See pump does not operate properly section.

wAsH solution is not HeAtinG

Blown fuse Check the electrical panel for a blown fuse.

Thermostat is set incorrectly Check the thermostat setting; set to 180°F.

Line voltage is too low Contact a licensed electrician to verify that the line voltage is between �08V and �40V.

Excess debris is built up around heat-ing element

Check for debris build up around the heating element; clean out if necessary. (See clean-ing out the sump Section).

Failed heat timer Test the heater timer; replace if necessary.

Failed thermostat Test the thermostat; replace if necessary (See thermostat Section).

Failed heating element Test the heating element; replace if necessary.

foAminG Machine operating with cold water Bring water up to correct temperature.

Grease, high detergent motor oils, transmission oil, gear lubes

Do not place oil pan or transmission pan.

Not enough detergent Add more detergent, check pH level. Use defoamer.

wHite powder on pArts

Solution is old Change sump water and recharge with fresh detergent and vapor corrosion inhibitor.

Water hardness and TDS (totally dis-solved solids)

Use a water softener and/or change your sump water more frequently.

Large parts can dry before solution runs off, leaving powdery residue

Turn heat down to approximately 140°.

wAsH solution is too Hot

Thermostat is incorrectly installed Check the thermostat to ensure that it is correctly installed into the mounting bracket. (See thermostat Section).

Failed thermostat Replace the thermostat (See thermostat Section).

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mAcHine fAils to stArt wHen “wAsHinG pArts” procedure is followed

Main power disconnect is off Verify that no service is being performed on the machine, then turn the main power disconnect on.

Lid is not closing properly Check the lid closure safety switch; adjust if neces-sary.

Failed lid closure safety switch Test the lid closure safety switch; replace if neces-sary (See Adjusting the lid safety switch).

Failed washer cycle timer Test the wash cycle timer; replace if necessary (See lid safety switch).

Pump is not operating properly

See pump does not operate properly section.

turntAble does not operAte properlY

Parts are obstructing turntable rotation

Check for parts obstructing rotation of the turn-table; rearrange if necessary.

Drive chain is not on the drive pulley

Check drive chain; realign on drive pulley if neces-sary.

Turntable motor compression springs are not installed

Check the turntable motor compression springs; install if necessary (See turntable motor Assem-bly).

Blown fuse Check electrical panel for blown fuse; replace if necessary.

Failed wash cycle timer Test the electrical panel to eliminate the possibility of a blown fuse then contact a licensed electrician or a service representative to test the turntable motor.

pump does not operAte properlY

Low water level in sump Check sump water level; add water if necessary.

Pump intake is plugged Check pump intake for obstructions; clean out if necessary.

Pump overload relay is tripped Reset the motor overload relay.

Blown fuse Check electrical panel for a blown fuse; replace if necessary.

Line voltage is too low Contact a licensed electrician to verify that the line voltage is between �08V and �40V.

Pump is failed Test the electrical panel to eliminate the possibility of a blown fuse then contact a licensed electrician or a customer service representative to test the pump motor.

oil skimmer does not operAte properlY

Blown fuse Check electrical panel for a blown fuse; replace if necessary.

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oil skimmer does not operAte properlY (continued)

Skimmer blades are too tight Turn on the skimmer motor and observe the con-tact between the skimmer blades and the skimmer disk. If the blades skip, bind, or leave a significant scratch on the disk, they are too tight. To loosen the blades, gently bend them away from the skim-mer disk.

Cooling fan on skimmer motor is jammed

Turn off power to machine, remove skimmer motor housing, ensure that cooling fan is free of obstruc-tions.

Failed skimmer timer Test the skimmer timer; replace if necessary (See wash cycle, Heater, and skimmer timers).

Failed skimmer motor Contact a licensed electrician to test the motor; replace if necessary.

lid leAks Lid closure safety switch is not adjusted properly

Check the lid closure safety switch; adjust if neces-sary.

interior of mAcHine is rustinG

Low detergent concentration or improper detergent usage

Our detergents, when used at proper concentra-tions of 10 to 1� scoops (�0 to �4 cups) per 50 gallons of water, contains adequate rust inhibitors to prevent rust. Verify that you are using our deter-gents at the correct concentration.

Condensation on door and cabinet causing rust during idle periods

Leave door open.

troublesHootinG tHe electricAl sYstem

To troubleshoot the electrical sys-tem use the following diagrams to eliminate the possibility of a blown fuse or a bad connection, then refer to Testing Individual Components to determine which component is causing the problem.

Warning: Electrical shock could cause serious injury or death.

• Electrical troubleshooting should be performed by qualified personnel only.

• Avoid contact with power leads, terminals and fuses when power is connected.

• Disconnect power to machine before removing fuses or other electrical components.

wArninG

keep wAter sprAY AwAY from

electricAl wirinG.

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troubleshooting a single phase panel

troubleshooting a three phase panel

∞

∞

∞

∞

None

▲▲

▲▲

▲

▲

▲

▲

▲

▲

power on

power off

power off

power off

power off

Measure Voltage Across L1, and L� Terminals on Junction Box

Electrical Panel is OK, Check Main Power Disconnect

Remove Primary Fuses; Measure the Resistance of Each

Fuse is Blown; Replace Blown Fuse

Remove Secondary Fuse; Measure the Resistance

Secondary Fuse is Blown; Replace Fuse

Remove Heater Fuses; Measure the Resistance of Each

One of the Heater Fuses is Blown; Replace the Blown Fuse

Remove Pump Fuses; Measure the Resistance of Each

One of the Pump Fuses is Blown; Replace the Blown Fuse

Elect r ica l Panel is OK, Refer to Testing Individual Components

�08 to �40V

approximately 0 Ohms




∞

∞

∞

∞

None

▲▲

▲▲

▲

▲

▲

▲

▲

▲

power on

power off

power off

power off

power off

Measure Voltage Across L1, L� and L3 Terminals on Junction Box

Electrical Panel is OK, Check Main Power Disconnect

Remove Primary Fuses; Measure the Resistance of Each

Fuse is Blown; Replace Blown Fuse

Remove Secondary Fuse; Measure the Resistance

Secondary Fuse is Blown; Replace Fuse

Remove Heater Fuses; Measure the Resistance of Each

One of the Heater Fuses is Blown; Replace the Blown Fuse

Remove Pump Fuses; Measure the Resistance of Each

One of the Pump Fuses is Blown; Replace the Blown Fuse

Electrical Panel is OK, Refer to Testing Individual Components

�08 to �40V





GROUND

Junction block

transformer

secondary fuse

primary fuses

Heater fuses

pump fuses

pump contactor

GROUND

Junction block

transformer

secondary fuses

primary fuses

Heater fuses

pump fuses

pump overload

relay

pump contactor

pump overload

relay

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testinG individuAl components

note: The following troubleshooting procedures require the use of a volt/ohm meter. If you are not familiar with using a volt/ohm meter do not attempt to perform the following troubleshooting procedures. If you need assis-tance please contact your distributor or call a customer service representative.

wash cycle, Heater, and oil skimmer timersstep 1:


step 2:

Remove the timer from the control panel and disconnect all wires (See timers and switches on the control panel).

step 3:

With the timer in the off position, test for continuity using an ohm meter.

If there is continuity the timer is no longer functional; replace the timer.

step 4:

With the timer in the on position, test for continuity using an ohm meter.

If there is not continuity the timer is no longer functional; replace the timer.

door safety switchstep 1:


step 2:

Remove the switch from the rear of the machine and disconnect all wires (See door safety switch).

step 3:

With the switch fully open (not depressed), test for continuity.

If there is continuity the switch is no longer functional; replace the switch.

step 4:

With the switch fully closed (depressed), test for con-tinuity.

If there is not continuity the switch is no longer func-tional; replace the switch.

single phase Heating elementstep 1:


step 2:

Remove the cover from the heating element and ther-mostat enclosure (four screws; use a 5/16” wrench or socket).

step 3:

Detach the power leads from the heating element (See Figure Below).

step 4:

Use an ohm meter to measure the resistance of the heating element. The resistance should be approxi-mately 10 Ohms; if not, replace the heating element (See Heating element).

three phase Heating elementA three phase heating element is a complex component. Please contact your customer service representative for testing instructions.

single phase thermostatstep 1:


step 2:

Remove the cover from the heating element and ther-mostat enclosure (four screws; use a 5/16" wrench or socket).

Heating elements

power leads

thermostat

power leads

thermostat

screw

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step 3:

Detach the power leads from the thermostat (See Figure Below).

step 4:

Using a large flat-head screwdriver, pry the thermostat out of the mounting bracket, then remove it from the machine (See Previous Figure).

step 5:

Set the thermostat to 1�0°F, warm it to just above 1�0°F, then test for continuity.

If there is continuity, the thermostat is no longer func-tional; replace the thermostat.

step 6:

Allow the thermostat to cool to room temperature, then test for continuity.

If there is not continuity the thermostat is no longer functional; replace the thermostat.

three phase thermostatA three phase thermostat is a complex component. Please contact your customer service representative for testing instructions.

start capacitorstep 1:


step 2:

Remove the main electrical panel cover (eight screws; use a 5/16” wrench or socket). The turntable motor as-sembly is located just below the electrical panel.

step 3:

Visually inspect the start capacitor (See Figure Below). If it appears swollen or deformed, it is no longer func-tional; replace the start capacitor.

step 4:

If the start capacitor is not visibly failed, remove it from the motor bracket, disconnect the wires, and test it for shorts using an ohm meter.

If the ohm meter reads approximately 1 Ohm, the start capacitor is no longer functional; replace the start capacitor.

start capacitor

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section 5: mAintenAnce And repAir

mAintAininG tHe mAcHineTo ensure optimum performance and trouble-free op-eration, observe the following maintenance schedule consistently.

daily maintenance• Check the water level; add water if necessary.• Clean the debris screen.• Remove oil from the wash solution using the oil

skimmer system (See using the oil skimmer system).

weekly maintenance• detergent concentration level: Check deter-

gent level weekly to maintain concentration level which decreases when water is added. The pH level of this detergent must be in accordance with the detergent manufacturer's recommendation.

• Examine the spray nozzles; clean and align if necessary (See cleaning and Aligning the spray nozzles).

• Wipe down the exterior of the machine using degreaser spray and a soft, damp cloth. TO PREVENT ELECTRICAL COMPONENT FAIL-URE, DO NOT SPRAY THE MACHINE WITH WATER.

• Check detergent level to maintain proper concen-tration level which decreases as water is added. The pH level of detergent must be in accordance with the manufacturer's recommendation.

note: Degreaser spray and a damp cloth will usually remove all dirt and grime from the machine. For particu-larly stubborn soap deposits, use a soft cloth dampened with warm solution from the wash chamber.

monthly maintenance• Clean out the sump chamber and detail sump

(See cleaning out the sump).• Lubricate the door spindle using high-quality

automotive grease. Add grease until it begins to flow out of the joint beneath the grease fitting, then wipe excess grease from the fitting and the joint (See figure below).

semi-Annual maintenance• Lubricate the pivot pin on the turntable motor

assembly with machine oil or anti-seize (See Figure Below).

• Lubricate the upper and lower pump bearings

using high-quality automotive grease (See Figure Below). do not over grease the bearings; over greasing could cause premature failure.

For 5HP pumps, add 1–� strokes of grease every six months; for pumps larger than 5HP, add �–3 strokes of grease every six months.

cleaning and Aligning the spray nozzlesTo ensure optimum cleaning performance, it is important that you examine the spray nozzles periodically and clean and align them if necessary.

To clean a plugged nozzle, remove it from the spray pipe and use a small wire brush to free the nozzle of any obstructions. When you replace the nozzle on the spray pipe, make sure you align it according to the figure on top of the following page to maintain a proper spray pattern.

note: The spray nozzles are sized and positioned to optimize the distribution of cleaning solution in the wash chamber. If you remove the nozzles make sure you replace them in the correct position on the appro-priate pipe.

door spindle

Grease fitting

pivot pin

compression spring Assy.

Grease fitting

Grease fitting

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using the oil skimmer systemThe oil skimmer system is most effective if used when the cleaning solution in the sump is cool.

The frequency at which you must remove the oil from the wash solution will depend on machine usage. Under typical operating conditions you may need to remove the oil every day.

importAnt: The skimmer motor is equipped with a thermal overload switch which protects the skimmer from overheating. If you attempt to use the oil skimmer system when the wash solution is hot, the thermal overload will probably trip and the motor will shut off until it cools. Under normal skimming conditions (when the wash solution is cool) the thermal overload should not trip.

To remove oil from the cleaning solution, perform the following procedure:

step 1:

Allow the machine to sit idle for at least 30 minutes to al-low the oil to float to the surface of the wash solution.

step 2:

Ensure that the oil collection container is in place (See figure next column), then turn the skimmer switch to the “ON” position.

step 3:

Allow the oil skimmer to operate until it is no longer extracting oil from the cleaning solution.

tip: While extracting oil from the cleaning solution, oil will flow off the wiper blades in a fine continuous stream. Water will flow off the blades in droplets. Once droplets begin to flow off the wiper blades, stop the skimmer motor.

step 4:

Dispose of the oil in the collection container in accor-dance with local and state regulations, then replace the container.

oil container

oil skimmer Assy.

Align the notch in each spray nozzle with the

center of the turntable.

rotate each nozzle approximately 3° from the

centerline of the pipe.

bottom noZZles

side noZZles

top noZZles

3°

turntable

door

cabinet

pivot Assy.

Align the notch in each spray nozzle with the

center of the door pivot assembly.

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cleaning out the sumpfiltrAtion And sump sweep sYstem

note: The effectiveness of the filtration and sump sweep system for cleaning out the sump will depend on the type of filter bag(s) you use in the filter canister(s). If you find that the filtration and sump sweep systems do not adequately clean the sump on your machine, contact your distributor or customer service for other filter bag recommendations.

To clean out the sump using the optional filtration and sump sweep system, perform the following proce-dure:

step 1:

If your machine is equipped with a detail sump, dump the contents of the detail sump into the main sump chamber.

step 2:

Remove oil and grease from the cleaning solution using the oil skimmer system (See using the oil skimmer system).

step 3:

Position the three-way wash solution valve as shown in figure below.

step 4:


step 5:

Run the machine through a 30-minute wash cycle.

note: While the sump sweep is operating, monitor the outlet pressure on the filter system to ensure that it does not drop below 30 psi. If the pressure drops below 30 psi, immediately stop the machine and either clean or replace the filter bag(s) (See cleaning the filters).

step 6:

After the machine stops, position the three-way wash solution valve as shown in figure top of next column.

step 7:

Add the appropriate amount of detergent and run the machine through a 30-minute wash cycle. Use a pH kit to determine the proper amount of detergent to add.


note: Our detergent is the only detergent approved for use with our automatic parts washers. It is specially for-mulated with rust inhibitors and anti-foaming agents to optimize performance and minimize maintenance. The use of any other detergent during the warranty period will void the warranty.

mAnuAl sump cleAn out

To manually clean out the sump, perform the following procedure:

step 1:

If your machine is equipped with a detail sump, dump the contents of the detail sump into the main sump chamber.

step 2:

Remove oil and grease from the cleaning solution using the oil skimmer system (See using the oil skimmer system).

step 3:

If your machine is equipped with the Auto-Fill feature, turn off the water at the supply line.

step 4:

Remove both sump covers, then drain the wash solution from the sump chamber. To drain the solution either use the sump drain or a small submersible pump.

step 5:

Remove sand and other debris from the bottom of the sump chamber and the detail sump. To remove the debris, either flush it out through the sump drain or vacuum it out using a wet/dry vac. Dispose of the debris in accordance with applicable local, state, and federal regulations.

note: Take special care to ensure that the heating ele-ment is free of debris. A buildup of debris around the element will decrease heating performance and may cause the element to overheat and fail.

step 6:

Refill the sump with fresh clean water.

step 7:

Replace the sump covers and heat the wash water to operating temperature.

sump sweep

position

wash position

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step 8:

Add the appropriate amount of detergent and run the machine through a 30-minute wash cycle. Use a pH kit to determine the proper amount of detergent to use.

note: Our detergent is the only detergent approved for use with our automatic parts washers. It is specially for-mulated with rust inhibitors and anti-foaming agents to optimize performance and minimize maintenance. The use of any other detergent during the warranty period will void the warranty.

cleaning the filtersOur filtration systems are available in single or multiple canister configurations. Each canister uses a nylon or polyester felt filter bag to remove solid particles from the wash solution. Nylon bags are reusable; polyester felt bags are designed for a single use. To clean or replace the filters, perform the following procedure:

step 1:

Turn off the machine and open the door.

step 2:

If your machine is equipped with the Auto-Fill feature, turn off the water at the supply line.

step 3:

Slowly unscrew the pressure-release plug on the lid of the filter canister to release the pressure in the filtration system (See figure below).

step 4:

Loosen the three lid nuts, then swing the lid free of the canister (See figure below).

step 5:

Remove and empty the filter bag and screen (See figure below).

step 6:

If you are using a nylon filter bag, you can clean and reuse it several times before replacing it. If you are using a polyester felt filter bag, you must replace it. Contact your distributor or call customer service for filter bag recommendations and ordering information.

step 7:

Replace screen and filter bag in the filter canister.

step 8:

Install and tighten the lid.

step 9:

Tighten the pressure-release plug.

step 10:

Turn on machine and continue washing.

repAirinG tHe mAcHineThe following procedures outline the steps necessary to replace specific items on the machine that could wear out or otherwise fail.

Heating elementsrequired tools And equipment

• 5/16” wrench or socket• �” socket and breaker bar• sealing tape or compound• medium phillips-head screwdriver

replAcement procedure

step 1:

disconnect power to the machine.

step 2:

Drain the wash solution from the sump.

step 3:

Remove the cover from the heating element and ther-mostat enclosure (two 5/16” screws).

filter bag

pressure release plug

filter lid

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step 4:

Detach the power leads from the heating elements, taking care to mark them for reassembly (See Figure Below).

step 5:

Using a �” socket and breaker bar, unscrew the heating element(s) from the machine.

note: Since the heating element is in continuous con-tact with the cleaning solution the threads may corrode slightly. The element may be difficult to remove. When you install a new heating element, use sealing tape or compound on the threads to deter corrosion.

step 6:

Install the new heating element(s). Installation is the reverse of removal.

thermostatrequired tools And equipment

• 5/16” wrench or socket• medium phillips-head screwdriver• large flat-head screwdriver


step 1:


step 2:

Remove the cover from the heating element and ther-mostat enclosure (two 5/16” screws).

step 3:

Remove the thermostat knob and the two screws to remove the thermostat from the housing (See Figure Below).


step 4:

Detach the electrical leads from the thermostat (See Figure Below).

step 5:

Remove the thermostat from the machine.

step 6:

Install the new thermostat. Installation is the reverse of removal.

turntable motorrequired tools and equipment

• 5/16” wrench or socket• 1/8” hex key• medium phillips-head screwdriver

replacement procedure

step 1:


step 2:

Remove the main electrical panel cover (eight screws; use a 5/16” wrench or socket). The turntable motor as-sembly is located just below the electrical panel.

step 3:

Remove the drive pulley access plate (See Figure Below).

To remove the plate, remove the two screws using a 5/16” wrench or socket, then slide the plate toward the

power leads

Heating element

thermostat screwdriver

power leads

thermostat

mounting bracket

screws

drive pulley Access

7660 • 9.800-980.0 • Rev. 1/08

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rear of the machine through the slot in the housing (See Previous Figure).

step 4:

Remove the compression spring from the motor as-sembly using a 9/16” wrench and socket.

step 5:

Push the motor assembly toward the front of the ma-chine, then reach into the drive pulley access hole with your fingers to free the chain from the drive pulley. Take care not to let the chain slip into the wash chamber. Use a piece of wire to secure the chain while you replace the motor (See Figure Below).

step 6:

Disconnect all power leads from the motor, taking care to mark them for reassembly.

step 7:

Raise the motor and bracket to remove the assembly from the pivot pin.

step 8:

Use a 3/3�” hex key to remove the pulley and steam shield disk from the drive motor shaft, then remove the four mounting screws holding the motor to the mounting bracket (See Figure Below).

step 9:Install the new motor. Installation is the reverse of removal.

timers and switches on the control panelrequired tools and equipment

• 5/16” wrench or socket• 1/�” wrench or deep socket• small phillips-head screwdriver• small flat-head screwdriver

replacement procedure

step 1:


step 2:

Remove the control panel face plate (four 10/3�” screws; See Figure Below).

compression spring

motor pulley

Hex bolt steam shield disk

mounting screws

TURNTABLE

ON

OFF

LOWWATER

OFF TURNPAST

10

TURNPAST

2 OFF

HOURS

OFF TURNPAST

5

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step 1:


step 2:

Remove two 5/16” screws to remove the skimmer motor cover (See Figures Below).

step 3:

Remove the two wire nuts from the power leads to dis-connect the leads from the motor, and disconnect the conduit from the motor housing (See Figure Below).

step 3:

Disconnect the wiring harness from the rear of the face plate.

step 4:

Remove the knob from the timer you wish to remove.

step 5:

Remove the two screws, retaining nut, and o-ring that hold the timer switch to the control panel (See Figure Below).

step 6:

Detach the power leads from the timer.

step 7:

Attach the power leads to the new timer.

step 8:

Install the new timer. Installation is the reverse of re-moval.

oil skimmer motorrequired tools And equipment

• 5/16” wrench or socket• 1/�” wrench or socket• small phillips-head screwdriver


screws (two on each side)

slide cover toward rear to remove

wire nuts

oil skimmer motor

OFF TURNPAST

10

TURNPAST

2 OFF

HOURS

screws

knob

retaining nut

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step 6:

Remove the three screws from the skimmer motor mounting plate to remove the motor from the skimmer assembly (See Figure Below).

step 7:

Reassemble the skimmer assembly and replace it on the machine. Assembly is the reverse of removal.

step 4:

Remove the four 1/�” bolts from the skimmer assembly mounting plate to remove the skimmer assembly from the machine (See Figure Below).

step 5:

Remove the two screws from the center of the skimmer disk to detach the disk from the skimmer assembly (See Figure Below). To remove the disk, disengage it from the center pin, then slide it down.


nut

screws

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turntAble

on

off

low

wAter

off turn

pAst10

turn

pAst2 off

Hours

off turn

pAst5

exploded view - front view

1

2

3

4

5

6

7

8

910

11

12

13

14

15

16

17

18 19

20

21

22

23

24

25

2627

28

29

3031

3233

3435

36

37

38

3940

4142

43

44

29

2827

32

3334

33

3435

field installed

50

46

45

48

48

47

49

51

5231

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exploded front view pArts list

item pArt no. description qtY 1 8.915-�08.0 Assy, Cabinet 1 8.915-447.0 Assy, Cabinet �648 w/1�" HGT EXT 1

� 8.915-�13.0 Assy, Door 1 8.915-45�.0 Assy, Door �848 w/1�" EXT 1

3 8.915-141.0 Assy, Turntable 1

4 8.915-130.0 Assy, Debris Tray 1

5 8.930-�75.0 Cover, Sump 10" x 16.5" w/o Gauge 1

6 500.059 Bearing, Ball Upper TT 6�06RS 1

7 500.060 Bearing, Ball Lower TT 6007RS 1

8 500.64� Spindle, Turntable 1

9 500.176 Washer Lock 3/4 1

10 500.104 Bolt, 3/4", -16 x 1-1/�" Grade � Hex Head 1

11 500.13� Pin Cotter 1/8" x 1-1/4" 4

1� 500.�13 Pin Clevis 3/4" x 3-1/�" 4

13 500.347 Wheel Polyolefin 4" x �" x 3/4" Bore 4

14 500.66� Latch, Sump Cover �

15 8.706-349.0 Pipe, Cap, 1-1/�" Galv. 1

16 500.�00 Spindle, Door 1

17 8.930-�38.0 Spacer, Door Hub 1

18 501.507 Nut, Nyloc, 5/8"-18 Zinc GR5 1

19 8.71�-85�.0 Grease Fitting 1

�0 8.930-�4�.0 Assy, Door Latch 1

�1 8.915-37�.0 Angle, Door Side 1 8.915-446.0 Angle, Door Side �848 w/1�" EXT 1

�� 8.915-�00.0 Angle, Door Top 1

�3 500.�3� Foam Strip 1/8" x 1" Adhesive Back 51" w/1�" HGT EXT 63"

�4 500.�3� Foam Strip 1/8" x 1" Adhesive Back 13"

�5 500.073 Seal, Bulb Type Epdm Side Profile 15.5"

�6 500.073 Seal, Bulb Type Epdm Side Profile 64.5" w/1�" HGT EXT 64.5"

�7 8.718-794.0 Screw, 10/3�" x 3/4", HEX SS 13 w/1�" HGT EXT 16

�8 7.31�-�64.0 Washer R 5.5 13 w/1�" HGT EXT 16

�9 9.804-567.0 Nut, 10/3�", ESNA 13 w/1�" HGT EXT 16

30 500.348 Wheel, Track 6

31 500.685 E-Clip, 1/4" Mild Steel 1�

3� 8.718-603.0 Bolt, 1/4" x 3/4", NC HH SS 3

item pArt no. description qtY 33 8.718-965.0 Washer, 1/4", FLAT, SAE, SS 5

34 9.80�-773.0 Nut, 1/4", ESNA, NC 5

35 8.718-568.0 Washer, 1/4" FLAT SS Sealing Rub 4

36 9.80�-779.0 Nut, 3/8", ESNA, NC 3

37 8.930-�39.0 Latch, Spray Pipe 1

38 9.804-373.0 Spring- Extension. 440 Dia. x �", 6.5 lb/inch 1

39 9.804-373.0 U-Bolt, 1/4"-�0 Plated 1

40 8.718-8�0.0 Nut, 1/4 HEX NC �

41 8.713-�46.0 Screw -5/16"-18 x 1" Socket Head �

4� 8.718-980.0 Washer, 5/16", Flat, SAE �

43 9.80�-776.0 Nut, 5/16", ESNA, NC �

44 500.073 Seal, Bulb Type Epdm Side Profile 48"

45 801.986 Label, Hotsy Spray Logo 1

46 50�.010 Label, Hotsy Arrow 1

47 500.3�0 Sleeve, Vinyl 1

48 500.684 Cap, Vinyl Black, 1/4" x 3/4" LG 1

49 9.804-�03.0 Handle, Strainer 1

50 9.80�-807.0 Washer, 3/8" SAE Flat 3

51 8.930-307.0 Stop, Spray Pipe 1

5� 8.714-150.0 Chain 1

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sprAY Arm exploded view

sprAY Arm exploded view pArts list

item pArt no. description qtY 1 8.713-136.0 Union, 1-1/�" Black 1

� 8.735-006.0 Nipple, 1-1/�" x 6.75" LG SCH 40 1

3 8.706-195.0 Elbow, 90° 1-1/�" Black 1

4 8.915-367.0 Lower Assy, Spray Manifold 1 8.915-44�.0 Assy, Lower Manifold �848 w/1�" EXT 1

5 8.706-�19.0 Tee, 1-1/�", Female, Pipe, Black 1

6 8.915-369.0 Nipple, 1-1/�" x �3" LG SCH 40 1 8.915-445.0 Pipe, Upper �848 w/1�" EXT 1

7 8.71�-996.0 Elbow, 90° 1-1/�" x 1" Reducing Black 1

8 8.915-137.0 Pipe, Upper Spray Manifold 1

9 8.706-081.0 Cap, Pipe 1 NPT 150WP Non PL �

7

8

10

96

5

1413

16

12

11

9

10

12

3

4

1817

15

rotate each nozzle Approx. 3° from

center line of pipe

Align notch in each spray nozzle

with the center of the turntable

side view

top view

item pArt no. description qtY 10 500.�65 Nozzle, 50° #6 18 8.749-193.0 Nozzle 50° #5 (1�" HGT EXT) ��

11 8.915-�17.0 Assy, Swing Arm, Spray Arm 1 8.915-444.0 Assy, Swing Down Spray Arm �848 w/1�" EXT 1

1� 500.648 Swivel, Bushing HEX 1

13 500.�76 O-Ring, Swivel #1�5 BUNA 1.�99" ID x 1.505" OD �

14 8.7�4-360.0 Pin, Roll 3/16" x 1-5/8" 1

15 9.80�-779.0 Nut, 3/8", ESNA, NC �

16 8.713-187.0 Rubber Bumper, 1/4" Stem 1

17 9.80�-773.0 Nut, 1/4", ESNA, NC 1

18 8.718-965.0 Washer, 1/4", FLAT, SAE, SS 1

19 9.80�-807.0 Washer, 3/8" SAE Flat �

19

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operAtinG instructions

mAintenAnce instructions

keepdrY

dAnGerHiGH voltAGe

wArninG

wArninG

Ground

exploded view - reAr view

1

2

5

6

7

8

9

10

11

12

13

1415

16

17

18

19

3

21

22 23

24

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52

3738

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40

41

4243

44

5150

36

48

53

35

4514

49

15

12

60

14

15

2

56

595754

64

6362

60

61

49

55

58

47

46

68

69

65 66

71

20

74

75

5

70

73

67

77

for details, see electrical

panel exploded

views76

72

58

3

see details page 37

see details page 39

4

79

5

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exploded reAr view pArts list

item pArt no. description qtY 1 8.915-377.0 Assy, Control Box 1

� 8.716-549.0 Connector, 3/4" L/T Str.Blk �

3 8.706-193.0 Elbow, 1-1/�" Galv. 90° �

4 9.803-83�.0 Conduit, Flex 3/4" 15"

5 9.80�-778.0 Nut, Whiz Loc 5/16" Flange 10

6 8.930-�37.0 Panel, Electrical 10" x �5.5" 1

7 8.915-�56.0 Assy, Electrical Box 1

8 8.930-�5�.0 Cover, Electrical Box 1

9 8.930-331.0 Cover, Heating Element 1

10 50�.558 Heating Element, 9KW/�08V/1PH/3PH (1.043-410.0) (1.043-411.0) 1 500.�38 9KW/�30V/1PH/3PH (1.043-41�.0) (1.043-413.0) 1 500.5�7 9KW/460V/3PH (1.043-414.0) 1 500.5�6 9KW/575V/3PH (1.043-415.0) 1

11 8.706-037.0 Bushing, �" x 1" Black Pipe 1 PH Only 1

1� 501.148 Thermostat, Snap Disc 180°F, 1 Phase 1 500.338 Thermostat, Blb & Cpllry 195°F, 3 Phase 1

13 8.706-350.0 Pipe, Cap, 1/�" Galv. 1

14 8.718-794.0 Screw, 10/3�" x 3/4", Hex SS 14

15 9.80�-791.0 Nut, Cage, 10/3�" x 16 Ga 14

16 500.4�1 Switch Lid/Door 15 amp, Non- Enclosed 1

17 8.930-�65.0 Box, Electrical Door Switch 1

18 8.716-377.0 Terminal, Ring Tongue, 14 ab-10 �

19 8.735-007.0 Rod, Door Switch 5/16" x 19.5" Acrylic 1

�0 11-3566 Label, ETL 1

�1 8.706-343.0 Pipe, Barbed/Male NPT 1-1/�" Galv 1

�� 500.976 Grommet, Pipe Vinyl 1-1/�" 1

�3 500.446 Gasket, Pump Plate 1

�4 500.447 Gasket, Pump Plate Center Self Adhesive �

�5 8.709-081.0 Clamp, Screw, #�8 p/n 68�8 �

�6 8.749-190.0 Hose -1 1/�" AG �00 8.5"

�7 8.713-135.0 Pipe, Barbed/Male NPT 1-1/�" 1

�8 8.706-195.0 Elbow, 1-1/�" Female Black 90° 1

�9 8.735-005.0 Nipple, 1-1/�" x 3.0" Lg Sch 40 1

item pArt no. description qtY 30 503.�08 Pump, 5HP �08V 1PH (1.043-410.0) 1 5-�39�3 Pump, Scot 5HP �30V 1PH (1.043-411.0) 1 5-�39�4 Pump, 5HP �08/�30/460V 3PH (1.043-41�.0) (1.043-413.0) (1.043-414.0) 1 500.471 Pump, 5HP 575V/3PH (1.043-415.0) 1

31 9.80�-779.0 Nut, 3/8", ESNA, NC 4

3� 9.80�-807.0 Washer, 3/8" SAE Flat 4

33 500.66� Latch, Sump Cover �

34 8.930-�53.0 Assy, Sump Cover 10 x 16.5 w/Gauge 1

35 8.706-518.0 Float, Poly Cyl �-3/4" Dia. x 1-3/4" 1

36 8.930-�77.0 Rod, Float 5-7/8" Long SS 1

37 500.107 Cap, Rubber Float Rod 1

38 8.706-3�7.0 Plug, 1.5", Pipe, Galv 1

39 8.913-717.0 Strap, Brass Float 1

40 8.718-76�.0 Screw, 8-3� x 1/�", M PH RDH Pl 1

41 6-0�071 Switch, Magnetic Reed Sensor, NC 1

4� 6-0�07� Switch, Mag. Reed Sensor, NO 1

43 6-0�073 Magnet, Reed Sensor Target 1

44 8.718-847.0 Nut, 4-40 KEPS, Zinc 1

45 8.731-134.0 Screw, 4-40 x 1/�" Slotted P/H M/S Zinc 1

46 500.�90 Decal, Caution (Check Water Level) 1

47 500.�56 Decal, Operator Install 1

48 500.�54 Label, Level Gauge 1

49 10-080�1 Label, Disco Power Supply �

50 500.1�3 Decal, Danger High Voltage 1

51 500.334 Decal, Warning, Yellow & Black 1

5� 50�.8�� Decal, Warning Grade Level, Wire Temp Rating 1

53 500.073 Seal, Bulb Type EPDM Side Profile 48"

54 11-5507 Label, Hour Meter 1

55 8.706-755.0 Bushing, .875" 1

56 8.735-008.0 Plug, Plastic 1.�5" 1

57 9.80�-105.0 Plug, 7/8", Hole �

58 9.80�-517.0 Connector, 1/�" L/T, 90° Black 3

59 9.80�-515.0 Strain Relief, Strt, LQ Tite 3�00 1

60 8.716-547.0 Connector, 1/�" L/T, Str, Blk 4

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item pArt no. description qtY 61 8.716-015.0 Conduit Sealtite 1/�" 1�"

6� 8.716-015.0 Conduit Sealtite 1/�" 3�"

63 8.716-015.0 Conduit Sealtite 1/�" 18"

64 9.80�-4�3.0 Cord, Service, SEO, 16/3 60"

65 8.718-980.0 Washer, 5/16" Flat 4

66 9.80�-776.0 Nut, 5/16" ESNA NC 4

67 8.7�5-300.0 Plug, Plastic 1.1�5" 1

68 8.718-611.0 Bolt, 1/4-�0" x 3-1/�" NC HH Tap 1

69 8.913-741.0 Spacer, Pump 1

70 9.804-361.0 Label, Patent Number 1

71 9.80�-773.0 Nut, 1/4" ESNA NC 1

7� 9.80�-77�.0 Bolt, 3/8" x 1-1/4" Lg 1

73 500.684 Cap, Vinyl Black 1/4" x 3/4" LG 1

74 9.800-013.0 Label, Assembled USA 1

75 9.800-034.0 Label, Clear Lexan 1

76 8.930-�71.0 Assy, Control Box 1

77 9.80�-781.0 Nut, 3/8" Flg Whiz Loc 1

78 500.�54 Label, Level Gauge 1

79 9.80�-073.0 Weatherstrip 1/8 x 1/� x 75 131"

exploded reAr view pArts list

7660 • 9.800-980.0 • Rev. 1/08

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tt motor exploded view

tt motor exploded view & pArts list item pArt no. description qtY 1 500.116 Gear Motor -ac Fract 85 Rpm, w/7.5 Mfd 1

� 8.718-936.0 Screw, #8 x 1/�", Phillips, Zinc Plated 3

3 8.930-�6�.0 Cover, Gear Motor Box Chain Access 14g 1

4 8.930-�68.0 Assy, Gear Motor Swing Arm 1

5 8.713-036.0 Washer -rubber Bonded #10 4

6 8.718-813.0 Screw, 10/3�" x 1/�" BH SocSS 4

7 8.913-708.0 Washer, Gear Motor 1

8 501.881 Torque Limiter -Std Size 1

9 50�.09� Chain w/Connector Link �840 1

10 9.80�-779.0 Nut, 3/8", ESNA, NC 1

11 9.80�-807.0 Washer, 3/8" SAE Flat �

1

2

4

1011

7

8

5

6

2

3

9

1311

12

item pArt no. description qtY 1� 501.794 Spring, .875 OD x �.50 Lg x .1�0- 74 lb/in 1

13 8.718-685.0 Bolt, 3/8", 16 x 5" Hex HD. Plated 1

14 8.716-377.0 Terminal Ring, Tongue 14AB-10 1

15 9.804-511.0 Screw, Set 1/4"-�8 x 3/8" SS 1

14

15

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TURNTABLE

ON

OFF

LOWWATER

OFF TURNPAST

10

TURNPAST

2 OFF

HOURS

OFF TURNPAST

5

exploded view - side control pAnel

side control pAnel pArts list

item pArt no. description qtY 1 9.80�-073.0 Foam Strip 1/8" x 1/�" Adhesive 8.915-375.0 Back 30"

� 8.930-�40.0 Cover, Control Box 1

3 8.718-813.0 Screw, 10/3� x 1/� BH SOC, SS 4

4 500.074 Timer, 60 Min. Spring Wound w/Hold Wash 1

5 500.075 Timer, 1� Hr. Spring Wound Heater 1

6 500.8�� Timer, 30 Min. Spring Wound Oil Skimmer 1

7 500.773 Knob, Timer Black 3

8 9.804-564.0 Screw, 6-3� x 1/� PL SLTD RHD 6

9 500.787 Switch, Lighted Rocker Skimmer/TT On/Off 1

10 501.964 Light, Indicator Red 1�0v .50" Dia. 1

item pArt no. description qtY 11 501.313 Connector, Electrical 9 Pin Female 1

1� 501.314 Connector, Electrical 9 Pin Male 1

13 501.165 Connector, Electrical Pin Female 9

14 501.4�5 Connector, Electrical Pin Male 9

15 9.80�-784.0 Nut, 6-3� KEPS 1

16 8.716-375.0 Terminal, Ring Tongue, RC10-516 1

17 9.80�-791.0 Nut, Cage, 10/3�" x 16 GA 4

18 10-080�1 Label, Disco Power Supply 1

19 50�.14� Cord, 16/9 SOOW Black Rubber Jacket 80"

�0 8.931-099.0 Label, Control Panel 1

17

1

19

18

5

6

15

16

42

3

8

7

9

10

14

11

12

13

20

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exploded view - oil skimmer AssemblY

KEEPDRY

1

2

1 1 4

6

13

8, 9

7

7

15

10

10

13

oil skimmer AssemblY pArts list

12

11

item pArt no. description qtY 1 8.718-813.0 Screw, 10/3�" x 1/�" BH, SOC, SS 11

� 8.913-733.0 Cover, Motor, Disc Skimmer SS 1

3 10-080�1 Label, Disc. Power Supply 1

4 9.804-10�.0 Blade, Wiper, Disc Skimmer SS �

5 9.80�-776.0 Nut, 5/16 ESNA 4

6 9.804-097.0 Disc, Skimmer SS 1

7 9.80�-791.0 Nut, Cage, 10/3�" x 16 Ga 4

8 9.80�-514.0 Strain Relief, STRT, LQ Tite 1

9 9.80�-5�5.0 Locknut, 1/�" 1

10 5-1097 Motor, Disc Skimmer 1

item pArt no. description qtY 11 8.719-987.0 Hub, Disc Mount, Disc Skimmer 1

1� 8.719-068.0 Pin, Roll 1/8" x 1" Steel 1

13 9.804-564.0 Screw, 6-�� x 1/�" �

14 8.718-980.0 Washer, 5/16 Flat 4

15 8.913-751.0 Oil Skimmer, Large 1

16 8.718-568.0 Washer, 1/4" Sealing 3

17 9.804-567.0 Nut, 10/3� ESNA 4

18 9.804-6�1.0 Gasket, Skimmer 1

19 8.718-968.0 Washer, #10 Flat Zinc Plt 4

�0 10-10004 Label, Keep Dry 1

116

5

14 17

18

3 20

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electricAl pAnel - 208v 1pH exploded view

electricAl pAnel - 208v 1pH exploded view pArts list

1

GROUND

23

24

2324

25

26

2224

timer option

oil skimmer

Auto fill option

6

2

5

16

30

18

283

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30204

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1112,13

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7

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19

30

29

10

9

27

item pArt no. description qtY 1 500.357 Contactor, 3 Pole (C30) 45 Amps 1

� 500.391 Fuse, � Amp FNM -� 1

3 500.400 Ground, Lug � Hole Alum 1

4 9.804-595.0 End Bracket, Entrelec, 103-00�-�6 �

5 500.709 Fuse, Class R � Amp FNQ-R-�1 �

6 500.714 Fuse Block (H�PR) �-Pole 1

7 50�.057 Fuse Block -60A 1

8 500.716 Overload 1�-3�A 1 PH 1

9 500.707 Fuse, Class R 30 Amp �

10 500.718 Fuse, 45 Amp �

11 8.716-398.0 Terminal Block, Blue Intrelec 9

1� 8.716-396.0 Terminal Block, Intrelec �

item pArt no. description qtY 13 8.716-40�.0 Bridge, Fix, Entrelec �

14 500.81� Relay, SPDT (K36) 1

15 500.8�0 Relay, Base (1�1) 1

16 8.716-895.0 Transformer, ��0/440V - 1�0V �00 KVA 1

17 50�.119 Terminal Block, � position (Surface) BL-BL 1

18 9.800-040.0 Label, Ground Symbol 1

19 50�.501 Contactor, 3 Pole, 40 Amp 1

�0 9.80�-457.0 Din Rail, 35 mm 7"

�1 8.716-599.0 Terminal, Grounding, Green w/Yellow �

�� 501.31� Connector, Elect 6 Pin Male 1

�3 501.164 Connector, Elect 3 Pin Male �

�4 501.165 Connector, Elect Pin Female 1�

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item pArt no. description qtY �5 501.�49 Connector, Elect 3 Pin Female 1

�6 501.4�5 Connector, Elect Pin Male 3

�7 8.931-186.0 Panel, Elect, �840/7660 1

�8 8.716-375.0 Terminal Ring Tongue RC10-516 1

�9 8.718-937.0 Screw, #8 x 3/4" Phillips, Zinc Plated, Hex Tek 7

30 8.718-936.0 Screw #8 x 1/�" Phillips Zinc Plated 8

31 8.716-399.0 End Cover, Entrelec 1

3� 8.718-980.0 Washer, 5/16" Flat 1

33 9.80�-775.0 Nut, 1/4" Flange NC 1


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23

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2526

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oil skimmer

Auto fill option

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� 500.391 Fuse, � Amp FNM -� 1




6 500.714 Fuse Block (H�PR) �-Pole 1

7 50�.057 Fuse Block 60A 1

8 500.716 Overload 1�-3�A 1 PH 1


10 500.718 Fuse, 45 Amp �




14 500.81� Relay, SPDT (K36) 1

15 500.8�0 Relay, Base (1�1) 1

16 8.716-875.0 Transformer, �40/480V-1�0/�40V �00KVA 1

17 50�.119 Terminal Block, � position (Surface) BL-BL 1


19 50�.501 Contactor, 3 Pole, 40 Amp 1

�0 9.80�-457.0 Din Rail, 35 mm 7"





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�7 8.931-186.0 Panel, Elect, �840/7660 1





3� 8.718-980.0 Washer, 5/16" Flat 1

33 9.80�-775.0 Nut, 1/4" Flange NC 1

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GROUND


1

23

24

2324

25

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oil skimmer

Auto fill option

6

2

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� 500.391 Fuse, � Amp FNM -� 1




6 500.705 Fuse Block, 3-Pole, 30A 1

7 8.713-�8�.0 Fuse Block, 3-Pole, 30A 1

8 500.410 Overload, 1�-3�A (EAIGB/EDIEB) 1

9 500.717 Fuse, Class R �0 Amp FRN-R-�0 3

10 8.713-�91.0 Fuse, 30 Amp 3




14 500.81� Relay, SPDT (K36) 1

15 500.8�0 Relay, Base (1�1) 1

16 8.716-895.0 Transformer, ��0/440V - 1�0V �00 KVA 1

17 50�.733 Terminal Block, 3 Position 1


19 500.356 Contactor, 3 Pole (C�3) 30 Amp 1

�0 9.80�-457.0 Din Rail, 35 mm 9"





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33

1.043-412.0

7660 • 9.800-980.0 • Rev. 1/08

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electricAl pAnel - 208 3pH exploded view pArts list



�7 8.931-186.0 Panel, Elect, �840/7660 1





3� 8.718-980.0 Washer, 5/16" Flat 1

33 9.80�-775.0 Nut, 1/4" Flange, NL 1

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� 500.391 Fuse, � Amp FNM -� 1




6 500.705 Fuse Block (H�PR) 3-Pole 1

7 500.705 Fuse Block (H�PR) 3-Pole 1

8 500.410 Overload 1�-3�A (EAIGB/EDIEB) 1

9 500.717 Fuse, Class R �0 Amp FRN-R-�0 3

10 500.715 Fuse, 30 Amp 3




14 500.81� Relay, SPDT (K36) 1

15 500.8�0 Relay, Base (1�1) 1

16 8.716-875.0 Transformer, �40/480V - 1�0/�40V �00 KVA 1



19 500.356 Contactor, 3 Pole (C�3) 30 Amp 1

�0 9.80�-457.0 Din Rail, 35 mm 9"





GROUND

1

23

24

2324

25

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oil skimmer

Auto fill option

6

2

5

16

30

18

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30204

151431

1112,13

1121

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32

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�7 8.931-186.0 Panel, Elect, �840/7660 1





3� 8.718-980.0 Washer, 5/16" Flat 1

33 9.80�-775.0 Nut, 1/4 Flange NC 1

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GROUND



1

23

24

2324

2526

2224

timer option

oil skimmer

Auto fill option

6

2

5

16

30

18

283

1729

30204

15

1431

1112,13

1121

7

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29

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27


� 500.391 Fuse, � Amp FNM -� 1




6 500.374 Fuse Block (C3P) 3-Pole 1


8 500.�78 Overload -3.7-1�A (EA1FB/ ED1DB 1

9 500.380 Fuse, Class CC 1� Amp 3

10 500.376 Fuse, Class CC 15 Amp 3




14 500.81� Relay, SPDT (K36) 1

15 500.8�0 Relay, Base (1�1) 1

16 8.716-875.0 Transformer, �40/480V - 1�0/�40V �00 KVA 1



19 500.355 Contactor, 3 Pole (C16) 16 Amp 1

�0 9.80�-457.0 Din Rail, 35 mm 9"





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33

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�7 8.931-186.0 Panel, Elect, �840/7660 1





3� 8.718-980.0 Washer, 5/16" Flat 1

33 9.80�-775.0 Nut, 1/4 Flange NC 1

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GROUND



1

23

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2324

2526

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oil skimmer

Auto fill option

6

2

5

16

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283

17293020

4

15

143111

12,13

1121

7

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9 500.379 Fuse, Class CC 10 Amp 3

10 500.380 Fuse, Class CC 1� Amp 3




14 500.81� Relay, SPDT (K36) 1

15 500.8�0 Relay, Base (1�1) 1

16 8.716-875.0 Transformer, �00VA 575V/115V 1



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Hotsy LIMITED NEW PRODUCT WARRANTYAUTOMATIC PARTS WASHERS

WHAT THIS WARRANTY COVERSAll Hotsy automatic parts washers are warranted by Hotsy to the original purchaser to be free from defects in materials and workmanship under normal use, for the periods specified below. This Limited Warranty, subject to the exclusions shown below, is calculated from the date of the original purchase, and applies to the original components only. Any parts replaced under this warranty will assume the remainder of the part’s warranty period.

ONE YEAR PARTS AND 90 DAYS LABOR WARRANTY:All components and accessories excluding normal wear items as described below. A one year labor warranty will apply if Hotsy parts washer detergents are used. (Rust and vapor corrosion inhibitor must be used).

WHAT THIS WARRANTY DOES NOT COVERThis warranty does not cover the following items:

1. Normal wear items, such as nozzles, seals, filters, gaskets, O-rings, fuses, calrods, oil skimmer, disk and scraper blade.

2. Damage or malfunctions resulting from accidents, abuse, modifications, alterations, incorrect installation, improper servicing, failure to follow manufacturer’s maintenance instructions, or use of the equipment beyond its stated usage specifications as contained in the operator’s manual.

3. Damage due to freezing, chemical deterioration, scale build up, rust, or corrosion.4. Damage to components from fluctuations in electrical or water supply.5. Normal maintenance service, including adjustments, system cleaning, and clearing of obstructions.6. Transportation to service center, field labor charges, or freight damage.

WHAT YOU MUST DO TO OBTAIN WARRANTY SERVICEWhile not required for warranty service, we request that you register your Hotsy product by returning the completed registration card. In order to obtain warranty service on items warranted by Hotsy, you must return the product to your Authorized Hotsy Distributor, freight prepaid, with proof of purchase, within the applicable warranty period. Your authorized Hotsy Distributor will file a claim with Hotsy, who must subsequently verify the defect. In most cases, the part must be returned to Hotsy freight prepaid with the claim. For warranty service on components warranted by other manufacturers, your Authorized Hotsy Distributor can help you obtain warranty service through these manufacturers’ local authorized service centers. If you are unable to resolve the warranty claim satisfactorily, write to Hotsy at 4275 NW Pacific Rim Blvd, Camas, WA 98607 ATTN: Warranty Dept., detailing the nature of the defect, the name of the Authorized Hotsy Distributor, and a copy of the purchase invoice.

LIMITATION OF LIABILITYHotsy’s liability for special, incidental, or consequential damages is expressly disclaimed. In no event shall Hotsy’s li-ability exceed the purchase price of the product in question. Hotsy makes every effort to ensure that all illustrations and specifications are correct, however, these do not imply a warranty that the product is merchantable or fit for a particular purpose, or that the product will actually conform to the illustrations and specifications. Our obligation under this warranty is expressly limited at our option to the replacement or repair at a service facility or factory designated by us, of such part or parts as inspection shall disclose to have been defective. THE WARRANTY CONTAINED HEREIN IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITYOR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTENWARRANTY. This warranty gives you specific legal right and you may also have other rights which vary from state to state Hotsy does not authorize any other party, including authorized Hotsy Distributors, to make any representation or promise on behalf of Hotsy, or to modify the terms, conditions, or limitations in any way. It is the buyer’s responsibility to ensure that the installation and use of Hotsy products conforms to local codes. While Hotsy attempts to assure that its products meet national codes, it cannot be responsible for how the customer chooses to use or install the product. Some states do not allow limitations or exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

Form #9.800-980.0 • Revised 1/08 • Printed in U.S.A.

Documents

HOTSY - 7660 Automatic Parts Washer (Operators Manual)