We were called out to a site in Loughborough after a Nilfisk SH Truck static hot pressure washer suffered a burst high-pressure hose. The machine is used regularly on site, so restoring operation quickly was important to keep cleaning tasks running smoothly.

We attended the same morning to diagnose the issue and replace the damaged hose.

Problem / Requirement

• Machine type: Static hot Nilfisk SH Truck pressure washer.
• Main issue: Burst high-pressure hose preventing the machine from being used safely.
• Symptoms: Visible hose rupture and loss of pressure when the trigger gun was used.
• Operational impact: Cleaning operations temporarily stopped until the hose could be replaced.

A burst hose can quickly halt operations and may cause further issues if fittings or reels are not inspected at the same time.

Our Solution

• Attended site following the service call.
• Removed the damaged high-pressure hose from the hose reel.
• Re-tensioned the hose reel to ensure smooth operation and proper hose retraction.
• Supplied and fitted a replacement high-pressure hose.
• Re-greased fittings and moving components on the reel system.
• Cleaned down the machine and surrounding area.
• Tested the system to ensure correct pressure and safe operation.

Internal Hose Reel Modification

This machine features an internal hose reel mounted inside the cabinet, which is a modification we regularly install for customers.

This setup provides several benefits:

• Protection from frost damage during colder months.
• Longer hose and gun lifespan by keeping components protected.
• Cleaner installation with accessories stored neatly inside the machine.
• Improved usability with everything stored in one accessible location.

The Result

• New high-pressure hose fitted and fully operational.
• Hose reel correctly tensioned and running smoothly.
• Machine cleaned, greased, and tested.
• Pressure washer back in service the same morning.

A quick repair ensured the customer could continue using their pressure washer with minimal downtime.

We were called out to inspect a Nilfisk Contractor diesel hot pressure washer used by a company specialising in mobile fleet cleaning. The customer reported that the machine had stopped producing heat and the burner was not operating correctly.

Upon inspection we found the boiler coil had burst inside the boiler jacket, allowing water to leak into the combustion chamber. This had also mixed with unburnt diesel, filling the boiler jacket with contaminated liquid and preventing the burner from operating safely.

Problem / Requirement

• Machine: Nilfisk Contractor diesel hot pressure washer
• Main issue: Burst boiler coil inside the burner jacket
• Boiler condition: Jacket filled with water and unburnt fuel, coil burst and therefore not trapping pressure
• Burner problem: Burner unable to ignite correctly due to jacket being full of water
• Operational impact: Machine unable to produce hot water for fleet cleaning operations, or work on cold function

Our Solution

• Drained the contaminated mixture of water and diesel from the boiler jacket.
• Removed the damaged boiler coil from the machine.
• Cleaned the inside of the boiler jacket to remove contaminated fuel and debris.
• Installed a new replacement boiler coil.
• Reassembled the burner system
• Checked burner components including jet and electrodes.
• Set burner fuel pressure and adjusted air settings for correct combustion.
• Fully tested the machine to ensure safe operation and proper heat output.

The Result

• The Nilfisk Contractor is now producing hot water correctly again.
• The new boiler coil restored proper heat transfer inside the boiler system.
• The burner is now operating cleanly and reliably after being reset and tuned.
• The fleet cleaning company can continue using the machine for regular vehicle washdowns without further disruption.

Boiler coil failure is a fairly common issue on diesel hot pressure washers, particularly when machines are used heavily for commercial cleaning. Replacing the coil and correctly resetting the burner ensures the machine runs efficiently and safely again.

We were called out to replace a damaged water tank on a Nilfisk Delta Booster system. The original tank had deteriorated and was no longer suitable for reliable operation, so we arranged for a custom stainless steel replacement tank to be manufactured and installed.

Problem / Requirement

• The existing Delta Booster multi-pump tank had deteriorated and required replacement.
• The tank feeds multiple pumps, so reliability and durability were essential.
• The original setup also required new hoses to properly connect the replacement tank to the pump system.
• The customer wanted a long-term solution that would resist corrosion and wear.

Our Solution

• Arranged for a custom stainless steel tank to be manufactured specifically for the Nilfisk Delta Booster system.
• Removed the original tank and prepared the system for the new installation.
• Installed the new stainless steel multi-pump tank in place of the old unit.
• Fitted new hoses and connections to correctly supply water to each pump.
• Checked all connections and ensured the system was correctly supplied with water.

The Result

• The Delta Booster system now has a durable stainless steel tank that will resist corrosion and wear.
• New hoses ensure reliable water supply to each pump.
• The upgrade provides a long-term, robust solution for the multi-pump wash system.
• The machine is now back in operation and ready for continued heavy use.

We were called out to repair a Nilfisk Delta Booster multi-pump system at an abattoir in Telford. The system had begun experiencing issues due to corrosion on the capillary pipes connected to the pressure manifold.

Problem / Requirement

• Machine type: Nilfisk Delta Booster multi-pump system.
• Issue: Several capillary pipes on the pressure manifold had become heavily corroded.
• Risk: The corrosion was causing weakening of the pipes and potential leaks within the pressure monitoring system.
• Environment: The machine operates from a plant room in an abattoir 

If left unattended, the damaged pipes could lead to pressure control faults or leaks within the system.

Our Solution 

• Removed the corroded capillary pipes from the manifold assembly.
• Fabricated, bent into shape, and installed new replacement capillary pipes.
• Ensured all fittings were correctly sealed and secured.
• Checked the manifold system for leaks and confirmed correct operation.

The Result

• The Delta Booster system is now operating reliably again with new corrosion-free capillary pipes installed.
• The pressure monitoring system is working correctly with no leaks present.
• Replacing the damaged pipework has improved the reliability of the system in a demanding washdown environment

We were called out to repair an older multi-pump pressure washer system at a malt house in Burton. The system had developed multiple faults across both pumps and motors, affecting performance and reliability.

Problem / Requirement

• System type: Multi-pump pressure washer system.
• Issue: Both pump motors were worn out and causing ongoing problems.
• Fault 1: One pump head had expanded due to a failed safety valve, resulting in water leaking past the seals.
• Fault 2: One motor was constantly tripping due to an earth fault.
• Fault 3: The second motor was excessively noisy, with bearings worn and close to failure.
• Additional issue: One of the pumps required a full set of new seals.

The system was no longer reliable and required a combination of repairs and component replacement.

Our Solution

• Supplied and fitted two new motors.
• Replaced one complete pump due to irreparable damage.
• Repaired the second pump head and installed new seals.
• Checked and ensured correct operation of all components after installation.

The Result

• The system is now running smoothly with reliable motors and properly functioning pumps.
• All leaks and electrical faults have been resolved.
• The upgraded setup has restored performance and improved reliability for continued use at the site.

We were asked to carry out a major repair on an industrial diesel hot pressure washer for a haulage company in Dover. The machine is used regularly for vehicle cleaning and had developed multiple faults due to long-term wear and a lack of preventative maintenance.

The unit was no longer operating reliably and required a full inspection and mechanical overhaul to restore performance.

Problem / Requirement

• Machine type: Industrial diesel hot mobile pressure washer.
• Main issues: Multiple mechanical and burner-related faults caused by wear and insufficient servicing.
• Symptoms: Reduced performance, starting issues, fluid leaks, and unreliable hot water operation.
• Operational impact: Downtime affecting vehicle cleaning and fleet maintenance.

Several components had deteriorated simultaneously, leading to wider system failure.

Our Solution

• Removed and externally repaired a leaking radiator.
• Stripped, cleaned, and fully serviced the diesel burner assembly.
• Completely rebuilt the high-pressure pump with new seals, valves, and internal components.
• Replaced engine and pump fluids throughout.
• Renewed all filters.
• Replaced cracked and worn pipework.
• Replaced a faulty capacitor and recalibrated engine speed.
• Fitted a new starter motor and checked glow plugs.
• Replaced the failed pump-to-engine drive shaft.
• Drained, flushed, cleaned, and refilled the fuel tank with fresh diesel.
• Reassembled, pressure tested, and fully commissioned the machine.

The Result

• The industrial diesel hot pressure washer is now running smoothly and reliably.
• Burner performance restored for consistent hot water output.
• Pump rebuilt to full operating condition.
• Electrical and starting faults eliminated.
• Leaks resolved and fuel system refreshed.
• The machine is back in daily service supporting the haulage fleet.

This repair demonstrates the importance of preventative maintenance. Addressing wear early prevents costly breakdowns and extended downtime.

We were called out to a pooling company in Atherstone after their industrial hot pressure washer suffered a burst boiler coil. The machine is used regularly for cleaning equipment and vehicles, and the loss of hot water significantly impacted their operations.

Due to the urgency of the situation, we attended site and carried out a rapid coil replacement to minimise downtime.

Problem / Requirement

• Machine type: Industrial static hot pressure washer.
• Main issue: Burst boiler coil causing water leakage and loss of hot water function.
• Symptoms: Machine unable to generate heat and visible signs of coil failure.
• Operational impact: Cleaning operations disrupted due to loss of hot wash capability.

A burst coil renders the burner ineffective and can quickly escalate into further damage if not addressed immediately.

Our Solution

• Attended site promptly following the service call.
• Diagnosed burst boiler coil within the heating chamber.
• Removed the damaged coil assembly.
• Supplied and fitted a replacement boiler coil.
• Reassembled burner housing and heating system.
• Tested burner operation and checked for leaks.

Fully commissioned the system and verified safe hot water output

The result

• New boiler coil installed and fully operational.
• Hot water function restored.
• Machine back in service within 5 hours of receiving the call.
• Minimal downtime for the customer.
• Cleaning operations resumed the same day.

Rapid response and correct diagnosis ensured the customer avoided extended disruption.

We were called out to inspect a Nilfisk DTE 500HM hot pressure washer used by an aggregate company in Leicester. The customer reported that the machine was producing excessive black smoke, running extremely loud, and struggling to burn properly when the burner was activated.

On arrival it quickly became clear that the issue was caused by contaminated fuel and poor fuel quality, which had led to severe soot build-up inside the boiler and contamination throughout the fuel system.

We decided that it was best to take the machine back to our workshop in order to get the best result possible.

 Problem / Requirement

• Machine: Nilfisk DTE 500HM static diesel hot pressure washer
• Main issues: Excessive smoke, loud burner operation, and unstable combustion
• Fuel system condition: Blocked fuel lines, clogged filters, and contaminated fuel tank
• Boiler condition: Heavy soot build-up inside the coil and boiler jacket due to poor combustion
• Result: The burner was unable to burn cleanly and struggled to operate efficiently.

The contaminated fuel had restricted the fuel supply to the burner while also causing incomplete combustion, which led to heavy soot accumulation inside the boiler system.

Our Solution

• Drained and thoroughly cleaned the contaminated fuel tank.
• Removed and replaced blocked fuel lines using industrial-grade fuel hose.
• Installed a heavy-duty inline fuel filter to improve fuel quality and reliability.
• Fitted new hose tails and fuel connections throughout the system.
• Removed the boiler coil and carried out a full de-soot of both the coil and boiler jacket.
• Replaced the burner jet and inspected the ignition electrodes.
• Set the burner fuel pressure correctly.
• Adjusted burner air settings to achieve proper combustion and a clean burn.

The Result

• The burner now runs smoothly and burns cleanly without excessive smoke.
• Fuel supply is stable thanks to new fuel lines and upgraded filtration.
• The boiler system is free from soot build-up, allowing efficient heat transfer.
• The machine is now operating quietly and efficiently again.

Contaminated fuel is one of the most common causes of burner failure in diesel hot pressure washers. Proper fuel filtration and routine maintenance help prevent soot build-up, poor combustion, and unnecessary downtime.

We were called out to repair a wall-mounted Nilfisk DTE static pressure washer that had completely stopped running. The machine is used regularly for cleaning duties on site, so a quick diagnosis and repair was needed to get the unit operational again.

Problem / Requirement

• Machine type: Nilfisk DTE wall-mounted static pressure washer.
• Issue: The machine would not start or run at all.
• Diagnosis: The electrical contactor had burnt out, preventing power from reaching the motor.
• Additional fault: The overload protection had also failed due to the electrical failure.

Without a functioning contactor and overload, the motor could not safely start or run.

Our Solution

• Removed the failed electrical contactor from the control panel.
• Replaced the burnt-out contactor with a new unit.
• Installed a new overload to ensure proper motor protection.
• Checked electrical connections and tested the system to confirm correct operation

The Result

• The Nilfisk DTE wall-mounted pressure washer was quickly returned to full working order.
• With a new contactor and overload fitted, the machine now starts reliably and operates safely.
• A straightforward electrical repair that got the customer back up and running with minimal downtime.

We were asked to repair and restore an older Kew 1502V hot pressure washer for a farmer in Donisthorpe. The machine had seen plenty of use over the years but had developed several issues that prevented it from running properly.

Problem / Requirement

• Machine type: Kew 1502V hot water pressure washer. Issue: The pump required a full rebuild and the boiler system had become heavily sooted.
• Additional problem: The machine also required a new electrical plug to be made up so it could be safely powered on site.
• Condition: The unit had not been running properly and required several repairs to bring it back into reliable working order.

Our Solution

• Carried out a full pump recondition to restore proper pressure and reliability.
• Removed and cleaned heavy soot buildup from the boiler system to ensure efficient burner operation.
• Fabricated and installed a new electrical plug for safe power connection.
• Fully tested the machine to confirm correct pressure, heating performance, and safe electrical operation.

The Result

• The Kew 1502V pressure washer was restored to full working condition in a single day.
• With the rebuilt pump and cleaned boiler, the machine is now running efficiently again.
• The farmer was able to get back to using a reliable hot pressure washer without needing to replace the unit.

We were asked to carry out a full service and rebuild on a Kothar Turn & Clean chemical applicator. These units play a key role in controlled chemical application across industrial cleaning environments, and over time if not looked after properly and consistently flushed through, can suffer from wear, internal contamination, and seal deterioration, affecting performance and reliability.

Problem / Requirement

• Existing equipment: Kothar Turn & Clean chemical applicator used for industrial cleaning operations.
• Site conditions: Used in demanding environments where chemical application accuracy and reliability are essential.
• Usage: Regular, ongoing use as part of daily cleaning routines.
• Main issues: Reduced performance, inconsistent chemical dosing, and general wear from regular use.

Over time, internal components such as seals and moving parts begin to wear, and chemical residue can build up inside the unit, leading to reduced efficiency and potential failure if left unchecked.

What This Equipment Does

• Designed to accurately dose and apply cleaning chemicals through a high-pressure system.
• Draws chemical via a pickup line and mixes it with water at a controlled ratio.
• Allows operators to switch between rinse and chemical application quickly and efficiently.
• Ensures consistent chemical coverage across surfaces, improving cleaning results.
• Reduces chemical waste by maintaining correct dilution levels.
• Commonly used in food factories, abattoirs, agriculture, and industrial washdown environments.

These units are essential for maintaining cleaning standards where correct chemical application and consistency are critical.

Our Solution

• Fully stripped the unit down to its individual components.
• Carried out a complete internal clean and flush to remove chemical residue and contamination.
• Replaced all internal O-rings to restore proper sealing and performance.
• Re-greased all moving components to ensure smooth operation and longevity.
• Reassembled the unit carefully, checking all tolerances and connections.
• Fully tested the applicator to ensure correct operation and consistent chemical dosing before returning to service.

The Result

• The unit is restored to full working order with consistent and reliable chemical application.
• New seals eliminate leaks and ensure accurate dosing.
• Internal cleaning improves flow and overall efficiency.
• Re-greased components allow smooth operation and reduce wear moving forward.
• The applicator is ready for continued use in demanding industrial environments with improved reliability.

We were asked to upgrade an existing Nilfisk multi-pump system at a food factory in Birmingham that was struggling to keep up with demand during nightly clean-downs.

With multiple pumps running simultaneously, the system required increased water capacity and improved control to ensure consistent performance and prevent interruptions.

Problem / Requirement

• Existing setup: Multi-pump system with an 80 litre water tank.
• Main issues: System running out of water when all pumps were in use, causing pressure drops and inconsistent performance.
• Site conditions: High-demand environment with all pumps operating during nightly clean-downs.
• Usage: Intensive, regular cleaning requiring consistent flow and reliability across all pumps.

The goal was to increase system capacity and improve control so the setup could handle full demand without running dry or affecting performance.

Our Solution

• Upgraded the system with a larger 160 litre water tank to increase available capacity.
• Installed new level switches to maintain correct water levels and prevent both overflow and dry running.
• Fitted new solenoids to improve control of water entering the tank and ensure reliable refill operation.
• Installed a new thermostat to maintain stable operating conditions and protect system components.
• Replaced feed hoses to all pumps to improve flow and ensure even water distribution across the system.

The Result

• System now capable of handling full demand with all pumps running simultaneously.
• Eliminated water shortages during nightly clean-down operations.
• The site has since upgraded from a 5 pump system to a 6 pump system, and has not run out of water during clean-down since the tank upgrade.
• Improved consistency in pressure and overall performance.
• Reduced risk of pump damage caused by poor inlet conditions.
• More reliable and controlled system suited to a high-demand industrial environment.
• Long-term performance improved through increased capacity and upgraded components.

We were called back to a food processing factory in Mansfield where we had previously carried out a number of modifications to their cold pressure washer systems. These machines are fed with hot water to assist with heavy-duty factory clean downs, meaning the setup needs to handle both high usage and elevated temperatures reliably.

Problem / Requirement

• Existing setup: Previously modified cold pressure washer systems with plastic inlet tanks.
• Main issues: Tanks deforming due to hot water supply, lack of sealing causing condensation, and internal cabinet contamination.
• Site conditions: Food production environment requiring high hygiene standards and consistent daily washdown performance.
• Usage: Regular clean downs using hot water feed to improve cleaning efficiency.

The original plastic tanks were not suitable for prolonged exposure to hot water. They began to warp over time, and because they were not sealed, condensation built up inside the cabinets, leading to wet, dirty internal conditions and increased risk of component failure. 

Our Solution

• Removed the existing plastic inlet water tanks that had deformed under heat.
• Supplied and installed new stainless steel tanks, purpose-built to handle hot water applications.
• Fitted sealed lids to eliminate condensation and protect internal components.
• Retained and integrated previous system upgrades, including:
• Boost pumps for consistent inlet pressure.
• New hoses and upgraded pipework.
• Replacement unloaders for improved pressure control.
• Previously installed level switches for system protection.
• Ensured all modifications worked together as a complete, reliable system.

The Result

• A far more durable and heat-resistant water storage solution suited to hot feed applications.
• Elimination of tank deformation issues.
• Significant reduction in condensation inside the cabinet, improving cleanliness and reliability.
• Protection of internal components from moisture-related damage.
• Improved hygiene standards within the system, better suited to a food production environment.
• A long-term, reliable setup built to handle daily high-demand cleaning without recurring issues.

We were called out to a farm in Enderby where a Nilfisk SH Truck Booster system was repeatedly being brought back for repair due to ongoing issues with leaks and overheating. The machine required a preventative solution rather than repeated reactive repairs.

Problem / Requirement

• Existing setup: Nilfisk SH Truck Booster in regular farm use.
• Main issues: Leaking trigger guns causing the machine to run continuously, leading to overheating and component damage.
• Additional faults: Sticking ball valve causing the inlet tank to overflow.
• Site conditions: Unattended operation at times, increasing the risk of prolonged running.
• Usage: Frequent agricultural cleaning with risk of operator oversight.

The machine had previously been left running overnight due to leaking guns, which caused the pump to overheat, warp the tank, and ultimately melt the internal pump seals. This resulted in repeated breakdowns and ongoing repair costs. A solution was needed to both repair the damage and prevent it from happening again.

Our Solution

• Replaced damaged pump seals caused by overheating.
• Installed an over-temperature protection system to monitor pump head temperature.
• Configured the system to automatically shut the machine down if the pump exceeds 60°C.
• Integrated this with the machine’s programmed shutdown timer to provide an additional layer of protection.
• Replaced the faulty ball valve that was sticking and causing tank overflow.
• Carried out a full clean-down of the machine and internal components.
• Ensured all systems were operating correctly and safely following modification.

The Result

• Fully repaired system with new seals and restored pump performance.
• Automatic protection against overheating, preventing damage from unattended running.
• Dual-layer protection with temperature cut-out and programmed shutdown timer.
• Elimination of overflow issues with a properly functioning inlet valve.
• Reduced risk of costly breakdowns and repeat call-outs.
• A far more user-proof system designed to handle real-world farm conditions.
• Long-term reliability improved through preventative design rather than repeated repair.

This was a good example of putting a proper solution in place to stop the issue happening again, rather than just repairing the same fault repeatedly.