7800 Series Operators Manual

Operation and Maintenance Manual
7800 Series Automatic Parts Washers

Distributed By:
REV. AB
MACHINE IDENTIFICATION TAG

The machine identification tag contains electrical specifications and other important information about your machine. Please fill out the machine identification tag below before you begin to install and use your machine. You can copy the information directly from the tag that is permanently affixed to the outside wall of the main electrical enclosure on your machine. When contacting Hotsy Customer Service, please keep this information handy to enable your customer service representative to assist you quickly and efficiently.
MODEL NO. SERIAL NO. MFG. DATE B.O.M. NO. VOLTAGE
__________________________ __________________________ __________________________ __________________________ HERTZ
F.L. AMPS
PHASE
Custom er Service
WROO IUHH H[W HPDLO WH.K#KRWV\.RP
Warranty Registration
IMPORTANT: To validate your warranty, please take a moment to complete and return this registration sheet within 10 days of purchase. For your convenience, you can either mail this sheet to the address printed on the back, or you can fax it to our offices at 303-792-0547.
PURCHASE DATE: ___ ___ / ___ ___ / ___ ___ (mm/dd/yy)
First Name
Last Name
Title
Company
Street Address
City
State/Province
Zip/Postal Code
Country
Telephone
Fax
Dealer/Distributor Name
Street Address
Street Address
City
State/Province
Zip/Postal Code
Country
Telephone
Fax
Model
Electrical Power Source
Y Y Y Y Y
7230 7320 7520 7630
Y Y Y Y
7642 7732 7742 7862
Y Y Y
120V Single Phase 230V Single Phase
Y Y
230V Three Phase 460V Three Phase
Other___________________________________
Other_____________________________
Serial Number of Machine
Serial Number of Pump
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
Thank you for purchasing a HOTSY Automatic Parts Washer!

...//techdocs/manual/common/reg-hotsy
PLACE POSTAGE HERE

Post Office will not deliver without postage
Customer Service Department 21 Inverness Way East Englewood, Colorado 80112 U.S.A.
FOLD ALONG THIS LINE
TAPE HERE (NO STAPLES PLEASE)

Made in the U.S.A copyright 2001 The Hotsy Corporation. All rights reserved.
SECTION 1
Introduction and Safety

Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 1-1 1-2 1-3
Installation
Before you Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1: Make Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 2: Connect a Water Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 3: Fill the Machine with Water and Add Detergent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 2-1 2-1 2-2 2-2
Operation
Main Operating Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Debris Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Skimmer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Level Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Water Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detergent Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing the Machine for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutting Down the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-2 3-2 3-3 3-4 3-4 3-5 3-6 3-6 3-6 3-7
SECTION 4
Troubleshooting
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting the Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Individual Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 4-1 4-3 4-5
Maintenance and Repair

Maintaining the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Semi-Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Using the Oil Skimmer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Cleaning and Aligning the Spray Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Cleaning out the Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Repairing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Heating Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Turntable Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Timers and Switches on the Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Oil Skimmer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Appendix
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
One-Year Limited Warranty
ii
S E C T IO N

USING THIS MANUAL
This manual is intended as a guide for safely assembling, installing, operating, and maintaining the Hotsy 7800 Series Automatic Parts washer.
Section 2: Installation
Includes all the information you need to install the machine and prepare it for operation.
Section 3: Operation
Includes detailed information about the individual components on the machine, and also provides detailed procedures for starting up the machine, washing parts, and shutting down the machine.
Section 4: Troubleshooting
Includes problem-specific troubleshooting tips, a block diagram for troubleshooting the electrical panel, and detailed procedures for testing individual components.
Section 5: Maintenance and Repair

Includes a maintenance schedule and detailed procedures for replacing specific components on the machine.
Appendix
Includes documentation to support components that are specific to your machine. The documentation includes a comprehensive list of replacement parts, an electrical diagram, a detailed diagram of the main electrical panel, and documentation for any non-standard options and accessories.
NOTE
Ordering Replacement Parts Part numbers listed throughout this manual are for a typical Hotsy machine; they may not be the correct parts for your machine. When ordering replacement parts, please refer to the Replacement Parts List in the Appendix for a complete, up-to-date list of replacement parts for your specific machine.
The Hotsy Corporation
1-1
OVERVIEW OF THE MACHINE

The Hotsy 7800 Series aqueous automatic parts washers are designed to operate safely and efficiently with a minimum of required maintenance. Before you begin to install and use the machine, please familiarize yourself with the major components (see Figures 1-1 and 1-2). Figure 1-1: Major Exterior Components of the Hotsy 7800.
FRONT
Control Panel
Door Handle
Sump Cover (part # 100.164)
Sump Cover with Water Level Guage (part # 100.165)
Sump Drain
Debris Screen
REAR
Steam Vent Door Safety Switch (part # 500.421)
Machine Identification Tag Main Electrical Panel Turntable Drive Enclosure
Oil Skimmer Assembly Automatic Water Fill Solenoid Valve and Hose Connection
7.5 H.P. Pump (part # 500.305)
Heating Element and Thermostat Enclosure
1-2
Figure 1-2:
Major Interior Components of the Hotsy 7800 Series.
Spray Pipes and Nozzles Optional Removable Accessory Tree
Turntable Assembly with Optional Removable Containment Ring
SAFETY
Observe the following safety issues while installing, operating, and maintaining the machine.
WARNING
Improper installation could cause serious damage to the machine: The machine must be installed by a licensed professional electrician to insure safe and proper installation. The machine can only operate on the type of electrical power indicated on the electrical specifications tag. Operating the machine on any other power supply will permanently damage the motors. Electrical shock could cause serious injury or death: Install the machine in compliance with the National Electric Code, connect it to a properly sized lockable disconnect, and ground the machine using the grounding stud inside the main electrical panel. While operating the machine, keep all electrical panels in place and securely fastened at all times. Disconnect the machine completely from the outside power source before servicing. Hot, high-pressure cleaning solution could cause serious injury: Do not operate the machine with the door in the open position, and do not override the door safety switch. After the machine stops, wait 10 seconds before opening the door. Always wear approved eye protection while operating the machine. Always wear rubber gloves when loading and unloading the machine or servicing components in the wash chamber or sump. Slips and falls could cause serious injury: Maintain an unobstructed work area around the machine and keep the floor free of water, oil, grease, or other foreign substances.
1-3
NOTES
1-4
S E C T IO N
Installation
BEFORE YOU BEGIN
To prepare to install the machine, choose an unobstructed, 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 you have any questions regarding the installation, please contact your distributor or call a Hotsy customer service representative at 1-800-525-1976, ext. 5301. When contacting Hotsy 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.
Figure 2-1:
Typical Main Electrical Panel.
Terminal Block (part # 500.248)
2-1
STEP 2: CONNECT A WATER LINE

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 feature requires that you connect the machine to a dedicated water supply line. To connect the machine to a water supply line, connect a suitable burst-proof hose from your shop water supply to the hose connection on the back of the machine (see Figure 2-2). For more information about the automatic water fill feature, refer to Automatic Water Fill on page 3-5. Figure 2-2: Automatic Water Fill Inlet.
Hose Connection
STEP 3: FILL THE MACHINE WITH WATER AND ADD DETERGENT

1. Familiarize yourself with the water level gage located on the left sump cover (see Figure 2-3). Figure 2-3: Water Level Gage. High Water Level
Low Water Level
Float Rod (indicator end)
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 100 gallons. 3. When the water level indicator indicates that the sump is full, 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.
2-2
Installation
NOTE
Monitor the water level carefully do not overfill 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.
4. Turn the heater timer to the 2 Hour position. The sump water will reach operating temperature (160 180 F) in approximately one hour. 5. While the sump water is heating, add the appropriate quantity of Hotsy TubMate All-Purpose Detergent to the wash chamber. For normal operating conditions add 12 pounds (24 cups); for heavy-duty operating conditions add 24 pounds (48 cups). Spread the detergent evenly throughout the wash chamber to ensure that it dissolves properly.
NOTE
Hotsy TubMate All-Purpose Detergent is the only detergent approved for use with Hotsy automatic parts washers. 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.
6. Close and latch the door. 7. Turn the wash cycle timer to 30 minutes, and allow the machine to complete the cycle to thoroughly dissolve the detergent into the water. 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.
2-3
NOTES
2-4
S E C T IO N
Operation
MAIN OPERATING COMPONENTS
Familiarize yourself with the main operating components before operating the machine.
Control Panel
Wash Cycle Control
The 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 manually shut off.
Heater Control
The heater control is a 12-hour timer switch. It controls 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 on page 3-2).
Skimmer Switch
The skimmer switch is a simple on/off rocker switch. It controls the automatic oil skimmer system.
Turntable Jog Button

The turntable jog button enables you to manually rotate the turntable with the door open. This feature is useful for loading and unloading the machine; instead of reaching to the rear of the wash chamber while loading and unloading, you can rotate the turntable to easily add or remove parts. Figure 3-1: Control Panel.
Wash Cycle Control (part # 500.074)
Heater Control (part # 500.075) Skimmer Switch (part # 500.787) Turntable Jog Button ((part # 500.206)
3-1
Thermostat
The thermostat is located on the right side of the heating element and thermostat enclosure. The thermostat is factory-set to heat the wash solution to a maximum temperature of 180F.
Adjusting the Thermostat

To adjust the thermostat, rotate the control knob clockwise to increase the temperature, or counter-clockwise to decrease the temperature (see Figure 3-2). Figure 3-2: Adjusting the Thermostat.
Decrease Temperature
Increase Temperature
Door Safety Switch

The door safety switch is located on the top rear corner of the machine. 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

! 1. Disconnect power to the machine.
2. Remove the two screws from the rear of the safety switch cover, and pull the cover free of the switch assembly. 3. Loosen the adjustment nuts on both sides of the switch bracket (see Figure 3-3). 4. Adjust the switch accordingly. 5. Tighten the adjustment nuts. 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.
3-2
Operation
Figure 3-3:
Safety Switch.
Switch Bracket
Adjustment Nuts
Safety Switch (part # 500.421)
Debris Screen
The debris screen is located just below the wash chamber, and is accessible from the front of the machine (see Figure 3-4). 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 nozzle clogging or water pump failure.
Figure 3-4:
Debris Screen.
3-3
Oil Skimmer System

The oil skimmer system is located on the right rear corner of the machine (see Figure 3-5). It automatically removes oil from the wash solution to prolong its useful life. Refer to Using the Oil Skimmer System on page 5-3 for detailed operating instructions. Figure 3-5: Oil Skimmer System. Skimmer Disk (part # 500.218) Skimmer Motor (part # 500.244) and Vented Housing (part # 500.688)
Wiper Blades (part # 500.349)
Oil Collection Container
Water Level Gage

The water level gage is located on the left sump cover (see Figure 3-6). Under typical operating conditions the machine loses 3 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 Detergent Concentration on page 3-6).
Figure 3-6:
Water Level Gage. High Water Level
Low Water Level
Float Rod (indicator end)
3-4
Operation
Automatic Water Fill

The automatic water fill system automatically maintains a proper water level in the sump. It is available as on option on Series 7800 machines. 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. Figure 3-7 describes the operation of the automatic water fill system. Figure 3-7: Automatic Water Fill Operation.
WATER LEVEL OK: Both switches OPEN, Automatic Water Fill Valve (if installed) CLOSED, Heating Element ON.
LOW WATER: Top Switch CLOSED, Bottom Switch CLOSED, Automatic Water Fill Valve (if installed) OPEN, Heating Element OFF.
SUMP FILLING: Top Switch CLOSED, Bottom Switch OPEN, Automatic Water Fill Valve (if installed) OPEN, Heating Element OFF.
open
closed
closed
open
closed
open
Wall of Sump Chamber
UP Float Water Level
UP
UP
Float Water Level
Float Water Level
3-5
DETERGENT CONCENTRATION
Hotsy TubMate All-Purpose Detergent is the only detergent approved for use with Hotsy automatic parts washers. 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. To monitor the approximate concentration of detergent in the wash solution, periodically examine the wash solution in the sump chamber for the following indicators: 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 add detergent each month after cleaning the sump chamber. The recommended detergent quantity for normal operating conditions is 12 pounds (24 cups). For heavy duty operating conditions use 24 pounds (48 cups).
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 Detergent Concentration); verify that none of the spray nozzles are clogged; and clean the debris screen.
WASHING PARTS
The 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 unloading the machine.
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 optional small parts basket, if provided with your machine.
3-6
Operation
NOTE
For optimum cleaning performance, provide a slight clearance between parts to allow adequate flow of cleaning solution around and between them.
2. Close and latch the door. 3. Set the wash cycle timer to between 1 and 60 minutes for a timed wash cycle, or set it to Hold for a continuous wash. 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 water at the supply spigot (if a dedicated water supply is 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 programmable heater timer, periodically verify the settings to prevent inadvertent unattended operation.
3-7
NOTES
3-8
S E C T IO N
Troubleshooting
OVERVIEW
The following table lists common operating problems and possible solutions. If your machine exhibits problems not listed here, or if the suggested solution does not solve your problem, contact a Hotsy customer service representative at 1-800-525-1976, ext. 5301. When contacting Hotsy Customer Service please refer to the machine identification tag inside the front cover of this manual for detailed machine specifications. Problem Poor cleaning performance Possible Cause Parts are obstructing each other Low water level in sump Clogged or improperly aligned spray nozzles Low detergent concentration Wash solution is not properly heated Pump is not operating properly Wash solution not heating NOTE: The desired wash solution temperature is between 160 and 180 F, and should be achieved within a 1 to 2-hour period from initial start-up. Blown fuse Thermostat is incorrectly set Excess debris is built up around heating element Line voltage is too low Failed heater timer Failed thermostat Failed heating element Wash solution too hot Thermostat is incorrectly installed Failed thermostat Solution Check the position of parts on turntable; position parts to allow flow of cleaning solution around and between them Check sump water level; add water if necessary (see Water Level Gage on page 3-4) Check spray nozzles for obstructions and alignment; clean and align if necessary (see Cleaning and Aligning the Spray Nozzles on page 5-4) Add 1 2 scoops of detergent and observe cleaning performance; add 1 2 scoops more if necessary (see Wash solution not heating) (see Pump does not operate properly) Refer to Figure 4-1 or to check the electrical panel for a blown fuse Check thermostat setting; set to 180 F (see Adjusting the Thermostat on page 3-2) Check for debris buildup around heating element; clean out if necessary (see Cleaning out the Sump on page 5-5) Contact a licensed electrician to verify that the incoming line voltage meets requirements Test the heater timer; replace if necessary (see Wash Cycle and Heater Timers on page 4-5) Test the thermostat; replace if necessary (see Thermostat on page 4-6) Test the heating element; replace if necessary (see Heating Element on page 4-5) Check the thermostat to ensure that it is correctly installed into the mounting bracket (see Thermostat on page 5-7) Replace the thermostat (see Thermostat on page 5-7)
4-1
Problem Machine fails to start when Washing Parts procedure is followed (continued)
Possible Cause Main power disconnect is off Door is not closing properly Failed door safety switch Failed wash cycle timer Pump is not operating properly
Solution Verify that no service is being performed on the machine, then turn the main power disconnect on Check the door latch and door safety switch; adjust if necessary (see Adjusting the Safety Switch on page 3-2) Test the door closure safety switch; replace if necessary Test the wash cycle timer; replace if necessary (see Wash Cycle and Heater Timers on page 4-5) (see Pump does not operate properly) Ensure that the turntable switch is in the ON position Check for parts obstructing rotation of the turntable; rearrange if necessary Check drive chain; realign on drive pulley if necessary Check the turntable motor compression spring; install if necessary (see Figure 5-10 on page 5-8) Refer to Figure 4-1 to check the electrical panel for a blown fuse Test the wash cycle timer; replace if necessary (see Wash Cycle and Heater Timers on page 4-5) Test the start capacitor; replace if necessary (see Start Capacitor on page 4-6) Contact a licensed electrician to test the motor; replace if necessary (see Turntable Motor on page 5-8). Check sump water level; add water if necessary (see Water Level Gage on page 3-4) Check pump intake for obstructions; clean out if necessary Reset the pump overload relay (see Figure 4-1 on page 4-4) Refer to Figure 4-1 to check the electrical panel for a blown fuse Contact a licensed electrician to verify that the incoming line voltage meets requirements Contact a licensed electrician to test the pump; replace if necessary Hotsy TubMate All-Purpose Detergent, when used at the proper concentration, contains adequate rust inhibitors to prevent rust. Verify that you are using Hotsy TubMate AllPurpose Detergent at the correct concentration (see Detergent Concentration on page 3-6)
Turntable does not turn
Turntable Switch is OFF Parts are obstructing turntable rotation Drive chain is not on the drive pulley Turntable motor compression spring is not installed Blown fuse Failed wash cycle timer Failed start capacitor Failed turntable motor
Pump does not operate properly
Low water level in sump Pump intake is plugged Pump overload relay is tripped Blown fuse Line voltage is too low Failed pump
Interior of machine is rusting
Low detergent concentration or improper detergent usage
4-2
Troubleshooting
Problem Oil skimmer does not operate properly
Possible Cause Blown fuse Skimmer blades are too tight
Solution Refer to Figure 4-1 to check the electrical panel for a blown fuse Turn on the skimmer motor and observe the contact 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 skimmer disk Turn off power to the machine, remove the skimmer motor housing, and ensure that the cooling fan is free of obstructions Test the skimmer timer; replace if necessary (see Wash Cycle and Heater Timers on page 4-5) Contact a licensed electrician to test the motor; replace if necessary (see Oil Skimmer Motor on page 5-10)
Cooling fan on skimmer motor is jammed Failed skimmer timer Failed skimmer motor
TROUBLESHOOTING THE ELECTRICAL SYSTEM

To troubleshoot the electrical system, use Figure 4-1 to eliminate the possibility of a blown fuse or a bad connection, then refer to Testing Individual Components on page 4-5 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.
4-3
Figure 4-1:
Troubleshooting a Typical Electrical Panel. Primary Fuses Terminal Block Secondary Fuse Transformer Pump Fuses Heater Fuses
Heater Contactor Pump Contactor Pump Overload Relay
PO
Measure Voltage Across L1, L2, and L3Terminals on Junction Block
None
Electrical Panel is OK, Check Main Power Disconnect
ER
ON
within specs listed on Machine ID tag Remove Primary Fuses; Measure the Resistance of Each approx. 0
F
PO
One of the Primary Fuses is Blown; Replace the Blown Fuse
ER OF
OF
PO
Remove Secondary Fuse; Measure the Resistance approx. 0 Remove Heater Fuses; Measure the Resistance of Each approx. 0 Remove Pump Fuses; Measure the Resistance of Each approx. 0 Electrical Panel is OK; Refer to Testing Individual Components
Secondary Fuse is Blown; Replace Fuse
ER
PO
One of the Heater Fuses is Blown; Replace the Blown Fuse
ER
OF
4-4
PO
One of the Pump Fuses is Blown; Replace the Blown Fuse
ER
OF
Troubleshooting
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 assistance please contact your distributor or call a Hotsy customer service representative at 1-800-525-1976, ext. 5301.
Wash Cycle and Heater Timers

2. Remove the timer from the control panel and disconnect all wires (see Timers and Switches on the Control Panel on page 5-10). 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. 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 Switch

2. Remove the switch from the rear of the machine and disconnect all wires (see Door Safety Switch on page 3-2). 3. With the switch fully open (not depressed), test for continuity. If there is continuity the switch is no longer functional; replace the switch. 4. With the switch fully closed (depressed), test for continuity. If there is not continuity the switch is no longer functional; replace the switch.
Heating Element
7800 Series machines use two three-phase heating elements. Three-phase heating elements are complex components; they are difficult to test in the field. Please contact your Hotsy Customer Service representative at 1-800-525-1976. ext. 5301) for testing instructions. Figure 4-2: Heating Elements and Thermostat.
Heating Elements
Thermostat
4-5
Thermostat
7800 series machines use a three-phase thermostat. A three-phase thermostat is a complex component; it is difficult to test in the field. Please contact your Hotsy Customer Service representative at 1-800-525-1976, ext. 5301 for testing instructions.
Start Capacitor
2. Remove the turntable motor cover (two 5/16-inch screws, see Figure 4-3). Figure 4-3: Removing the Turntable Motor Cover.
NOTE:
Slide housing toward rear to remove
Screws
3. Visually inspect the start capacitor (see Figure 4-4). If it appears swollen or deformed, it is no longer functional; replace the start capacitor. Figure 4-4: Location of the Start Capacitor. Start Capacitor (part # 500.823)
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, the start capacitor is no longer funtional; replace the start capacitor.
4-6
S E C T IO N

MAINTAINING THE MACHINE
To ensure optimum performance and trouble-free operation, observe the following maintenance schedule consistently.
Daily Maintenance
Check the water level; add water if necessary. Clean the debris screen.
Weekly Maintenance
Remove oil from the wash solution using the Oil Skimmer System (see Using the Oil Skimmer System on page 5-3). Examine the spray nozzles; clean and align if necessary (see Cleaning and Aligning the Spray Nozzles on page 5-4). Wipe down the exterior of the machine using spray degreaser and a soft, damp cloth. TO PREVENT ELECTRICAL COMPONENT FAILURE, DO NOT SPRAY THE MACHINE WITH WATER.
NOTE
Spray degreaser and a damp cloth will usually remove all dirt and grime from the machine. For particularly stubborn soap deposits, use a soft cloth dampened with warm solution from the wash chamber.
Monthly Maintenance
Drain and clean out the sump chamber and detail sump (see Cleaning out the Sump on page 5-5). 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 5-1). Figure 5-1: Lubricating the Door Spindle Grease Fitting
Joint
5-1
Semi-Annual Maintenance
Lubricate the pivot pin on the turntable motor assembly with machine oil or anti-seize (see Figure 5-2 on page 5-2). Figure 5-2: Lubricating the Turntable Motor Assembly.
Pivot Pin
If the pump motor has external grease fittings: Lubricate the upper and lower pump bearings using high- quality automotive grease (see Figure 5-3). Do not overgrease the bearings; overgreasing could cause premature failure. For 3HP pumps, add 1 stroke of grease every six months; for 5HP pumps, add 12 strokes of grease every six months; for pumps larger than 5HP, add 23 strokes of grease every six months. Figure 5-3: Pump Bearing Grease Fittings.
Upper Bearing Grease Fitting
Lower Bearing Grease Fitting
5-2
Using the Oil Skimmer System

The Oil Skimmer System is most effective if used after the cleaning solution in the sump has been sitting for at least 30 minutes. The frequency at which you must remove the oil from the wash solution will depend on machine usage. Under typical operating conditions you can expect to remove the oil once a week. To remove oil from the cleaning solution, perform the following procedure: 1. Allow the machine to sit idle for at least 30 minutes to allow the oil to float to the surface of the wash solution. 2. Ensure that the oil collection container is in place (see Figure 5-4), then turn the skimmer switch to the 30-minute position. 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.
4. Dispose of the oil in the collection container in accordance with local and state regulations, then replace the container. Figure 5-4: Oil Skimmer System. Skimmer Disk (part # 500.218) Skimmer Motor (part # 500.244) and Vented Housing (part # 500.688)
Wiper Blades (part # 500.349)
Oil Collection Container
5-3
Cleaning and Aligning the Spray Nozzles

To 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 Figure 5-5 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 appropriate pipe.
Figure 5-5:
Spray Nozzle Alignment. TOP NOZZLES SIDE NOZZLES Cabinet Pivot Assembly Align the notch in each spray nozzle with the center of the door pivot assembly Door
BOTTOM NOZZLES Turntable
Align the notch in each spray nozzle with the center of the turntable
Rotate each nozzle approximately 3 from the centerline of the pipe
5-4
Cleaning out the Sump

1. Remove oil from the cleaning solution using the Oil Skimmer System (see Using the Oil Skimmer System on page 5-3). 2. If your machine is equipped with the Auto-Fill feature, turn off the water at the supply line. 3. 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.
NOTE
Hotsy recommends that you reuse the wash solution. To do so, transfer it to a suitable holding container (such as a 55-gallon drum) while you clean out the sump chamber.
4. 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 element is free of debris. A build up of debris around the element will decrease heating performance and may cause the element to overheat and fail.
5. Transfer the wash solution back to the sump chamber, and add fresh water if necessary. 6. Replace the sump covers, heat the wash water to operating temperature. 7. Add the appropriate amount of Hotsy TubMate All-Purpose Detergent (12 cups normal conditions, 24 cups heavy conditions). Then run the machine through a 30-minute wash cycle.
NOTE
Hotsy TubMate All-Purpose Detergent is the only detergent approved for use with Hotsy automatic parts washers. 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.
5-5
REPAIRING THE MACHINE

The following procedures outline the steps necessary to replace specific items on the machine that could wear out or otherwise fail.
Heating Element
Required Tools and Equipment
5/16-inch wrench or socket 2-inch socket and breaker bar sealing tape or compound medium phillips-head screwdriver
Replacement Procedure
2. Drain the wash solution from the sump. 3. Remove the cover from the heating element and thermostat enclosure (two 5/16 - inch screws). 4. Detach the power leads from the heating element, taking care to mark them for reassembly (see Figure 5-6). Figure 5-6: Heating Element and Thermostat.
Heating Elements
Thermostat
5. Using a 2-inch socket and breaker bar, unscrew the heating element from the machine.
NOTE
Since the heating element is in continuous contact 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 and to prevent leaks.
6. Install the new heating element. Installation is the reverse of removal.
5-6
Thermostat
5/16-inch wrench or socket medium phillips-head screwdriver large flat-head screwdriver
2. Remove the cover from the heating element and thermostat enclosure (two 5/16 - inch screws). 3. Remove the thermostat knob and the two screws to remove the thermostat from the housing (see Figure 5-7. Figure 5-7: Thermostat Screws.
Screws
4. Detach the electrical leads from the thermostat (see Figure 5-8). Figure 5-8: Thermostat Electrical Leads. Electrical Leads
5. Remove the thermostat from the machine. 6. Install the new thermostat. Installation is the reverse of removal.
5-7
Turntable Motor
5/16-inch wrench or socket 3/32-inch hex key medium phillips-head screwdriver
2. Disengage the drive chain from the turntable. 3. Taking care not to kink or tangle the chain, place it on the turntable. 4. Remove the turntable motor cover (two 5/16-inch screws, see Figure 5-9). Figure 5-9: Removing the Turntable Motor Cover.
Screws NOTE: Slide housing toward rear to remove
5. Remove the compression springs between the motor and the rear wall of the wash chamber (see Figure 5-10). 6. Remove the drive pulley access plate (two 5/16 - inch screws, see Figure 5-10). Figure 5-10: Turntable Motor Assembly. Compression Springs (part # 500.165) Pivot Pin
Drive Pulley Access Plate
5-8
7. Disconnect all power leads from the motor, taking care to mark them for reassembly. 8. Raise the motor and bracket to remove the assembly from the pivot pin (see Figure 5-10).
NOTE
You may have to reach into the drive pulley access hole with your fingers to free the chain from the drive pulley. 9. Use a 1/8-inch hex key to remove the pulley and steam shield disk from the drive motor shaft, then remove the four screws holding the motor to the mounting bracket (see Figure 5-11). Figure 5-11: Removing the Drive Motor from the Mounting Bracket. Four Screws
Drive Pulley
Steam Shield Disk
10. Install the new motor. Installation is the reverse of removal. 11. Reconnect the drive chain to the turntable (see Figure 5-12). Figure 5-12: Connecting the drive chain to the turntable. 1. Pull the chain tight.
2. Align the chain around the perimeter of the turntable beginning along the right side 3. Rotate the turntable clockwise until the chain reaches completely around. Rotate
5-9
Timers and Switches on the Control Panel

5/16-inch wrench or socket -inch wrench or deep socket small phillips-head screwdriver small flat-head screwdriver
2. Remove the rear cover from the control panel. 3. Remove the knob from the timer you wish to remove. 4. Remove the two screws, retaining nut, and o-ring that hold the timer switch to the control panel (see Figure 5-13). Figure 5-13: Removing a Timer.
Screws
Retaining Nut and O-ring
5. Detach the power leads from the timer. 6. Attach the power leads to the new timer. 7. Install the new timer. Installation is the reverse of removal.
Oil Skimmer Motor

5/16-inch wrench or socket -inch wrench or socket small phillips-head screwdriver
2. Remove two 5/16-inch screws to remove the skimmer motor cover (see Figure 5-14).
5-10
Figure 5-14: Skimmer Motor Cover.
Screws (two on each side)
NOTE:
Slide Cover Toward Rear to Remove
3. Remove the two wire nuts from the power leads to disconnect the leads from the motor, and disconnect the conduit from the motor housing (see Figure 5-15). Figure 5-15: Skimmer Motor Power Leads.
Wire Nuts
4. Remove the two -inch bolts from the skimmer assembly mounting plate to remove the skimmer assembly from the machine (see Figure 5-16).
5-11
Figure 5-16: Removing the Skimmer Assembly from the Machine.
Bolts
5. Remove the two screws from the center of the skimmer disk to detach the disk from the skimmer assembly (see Figure 5-17). To Remove the disk, disengage it from the center pin then slide it down. Figure 5-17: Removing the Skimmer Disk from the Skimmer Assembly.
NOTE:
Slide the Disk Down to Remove Screws
6. Remove the three screws from the skimmer motor mounting plate to remove the motor from the skimmer assembly (see Figure 5-18). Figure 5-18: Removing the Skimmer Motor from the Skimmer Assembly.
Screws
7. Reassemble the skimmer assembly and replace it on the machine. Assembly is the reverse of removal.
5-12
Appendix
OVERVIEW
This appendix includes documentation to support components that are specific to your machine. The documentation includes a comprehensive list of replacement parts, an electrical diagram, a detailed diagram of the main electrical panel, and documentation for all non-standard options and accessories.
One-Year Limited Warranty

Hotsy products are warranted by the Hotsy Corporation to be free of defects in material and workmanship under normal use, for a period of ONE YEAR from the date of the original purchase. Items that fail due to normal wear such as hoses, pH probes, seals, etc. or damage resulting from neglect, abuse, tampering, or modification are not covered under this warranty. All defects must be verified by an authorized Hotsy service location. (Some components carry the original manufacturers warranty in lieu of the standard Hotsy warranty. Any warranty claim for these items will be processed through the original manufacturer and the results passed on accordingly.) Limitation Of Liability To the extent allowable under applicable law, Hotsy liability for consequential and incidental damages is expressly disclaimed. Hotsy liability in all events is limited to, and shall not exceed, the purchase price paid for the equipment. Hotsy liability excludes field labor charges and is limited to repair or replacement of defective parts only, at the option of the Hotsy Corporation. Warranty Disclaimer Hotsy has made a diligent effort to illustrate and describe the product in this literature accurately; however, such illustrations and descriptions are for the sole purpose of identification, and do not express or imply a warranty that the product is merchantable, or fits a particular purpose, or that the product will necessarily conform to the illustrations or descriptions. Product Suitability Many states and locations have codes and regulations governing sales, construction, installation, and/or use of products for certain purposes, which may vary from those in neighboring areas. While attempts to assure that its products comply with such code, Hotsy cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a product, please review the product application, and national and local codes and regulations, and be sure that the product, installation, and use will comply with them. Prompt Disposition Hotsy will make a good faith effort for prompt correction or other adjustments with respect to any product that proves to be defective within limited warranty. For any product believed to be defective within limited warranty, contact the dealer from which the product was purchased. The dealer will give additional directions. If you are unable to resolve the matter satisfactorily, write to Hotsy at the address below. Provide the dealers name, address, date of purchase, model, serial number, BOM number, and describe the nature of the defect. If the product was damaged in transit to you, file a claim with the freight carrier. The Hotsy Corporation 21 Inverness Way East Englewood, Colorado 80112 1-800-525-1976 ext. 5301
Index
A Adjusting Water Temperature see Thermostat Automatic Water Fill 3-5 Connecting 2-2 C Control Panel 3-1 D Debris Screen 3-3 Detergent Concentration 3-6 Requirements 2-3 Door Safety Switch Adjusting 3-2 Location of 1-2 Testing 4-5 Door Spindle Lubricating 5-1 E Electrical Panel 4-4 Testing 4-4 G Greasing see Lubrication H Heater Timer Replacing 5-10 Testing 4-5 Heating Element Replacing 5-6 I Installation 2-12-3 Prepare a Site 2-1 Electrical Connections 2-1 Water Supply 2-2 Adding Water and Detergent 2-2 J Junction Block Location of 4-4 L Low Water see also Automatic Water Fill see Automatic Water Fill Lubrication Door Spindle 5-1 Turntable Motor 5-2 Water Pump 5-2 O Oil Skimmer Replacing the Motor 5-10 Using 5-3 P Pump Overload Relay Location of 4-4 R Replacement Parts Ordering 1-1 S Safety Switch see Door Safety Switch Shut-down Procedure 3-7 Skimmer see Oil Skimmer Soap see Detergent Spray Nozzles Cleaning and Aligning 5-4 Start Capacitor Testing 4-6 Start-up Procedure 3-6 Sump Cleaning 5-5 Filling 2-2 Rust in 3-6, 4-2 T Thermostat Replacing 5-7 Transformer Location of 4-4 Troubleshooting 4-1?? Turntable Connecting Drive Chain 5-9 Turntable Motor Lubricating 5-2 Replacing 5-8 W Wash Cycle Timer Replacing 5-10 Testing 4-5 Water Level Gage 2-2, 3-4 Water Pump Lubricating 5-2 Water Supply Connecting to 2-2 Water Temperature see Thermostat
Index-1
Index
Index-2
The Hotsy Corporation 21 Inverness Way East Englewood, Colorado 80112 phone: 800-525-1976 fax: 303-792-0547 www.hotsy.com

7800 Series Operators Manual

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Operation and Maintenance Manual

7800 Series Automatic Parts Washers

MACHINE IDENTIFICATION TAG

MODEL NO. SERIAL NO. MFG. DATE B.O.M. NO. VOLTAGE

__________________________ __________________________ __________________________ __________________________ HERTZ

Electrical Power Source

7230 7320 7520 7630

7642 7732 7742 7862

120V Single Phase 230V Single Phase

230V Three Phase 460V Three Phase

Serial Number of Machine

Serial Number of Pump

Thank you for purchasing a HOTSY Automatic Parts Washer!

PLACE POSTAGE HERE

FOLD ALONG THIS LINE

TAPE HERE (NO STAPLES PLEASE)

7800 Series Automatic Parts Washers

Introduction and Safety

Maintenance and Repair

One-Year Limited Warranty

Introduction and Safety

Section 5: Maintenance and Repair

The Hotsy Corporation

7800 Series Automatic Parts Washers

OVERVIEW OF THE MACHINE

Sump Cover (part # 100.164)

Sump Cover with Water Level Guage (part # 100.165)

Machine Identification Tag Main Electrical Panel Turntable Drive Enclosure

7.5 H.P. Pump (part # 500.305)

Heating Element and Thermostat Enclosure

The Hotsy Corporation

Introduction and Safety

Major Interior Components of the Hotsy 7800 Series.

Spray Pipes and Nozzles Optional Removable Accessory Tree

Turntable Assembly with Optional Removable Containment Ring

The Hotsy Corporation

7800 Series Automatic Parts Washers

The Hotsy Corporation

STEP 1: MAKE ELECTRICAL CONNECTIONS

Typical Main Electrical Panel.

Terminal Block (part # 500.248)

The Hotsy Corporation

7800 Series Automatic Parts Washers

STEP 2: CONNECT A WATER LINE

STEP 3: FILL THE MACHINE WITH WATER AND ADD DETERGENT

Low Water Level

Float Rod (indicator end)

The Hotsy Corporation

The Hotsy Corporation

7800 Series Automatic Parts Washers

The Hotsy Corporation

Turntable Jog Button

Wash Cycle Control (part # 500.074)

The Hotsy Corporation

7800 Series Automatic Parts Washers

Adjusting the Thermostat

Door Safety Switch

Adjusting the Safety Switch

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Safety Switch (part # 500.421)

The Hotsy Corporation

7800 Series Automatic Parts Washers

HERTZ