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Contaminated Fuel Repair On An Industrial Diesel Hot Pressure Washer For An Aggregate Company In Leicester

What they needed

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.