Kärcher HD 1050 DE Cage Operating and installation instructions

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
HD 1050 DE Cage
1.810-993
5.905-870

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
Equipment
1 High-pressure hose
2 Pressure and flow control
3 Servopress handgun
4 Spray lance
5 Three-way nozzle
6 Yanmar diesel engine
7 Throttle lever engine stop
8 Oil dipstick
9 Recoil hand starter
10 Fuel tank
11 Battery
12 Pressure gauge
13 High-pressure connection
14 Water inlet
15 Oil reservoir (high-pressure pump)
16 High-pressure pump
17 Cleaning agent metering valve
18 Cleaning agent suction hose with filter

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
Technical features
General
HD1050DECageisthesameasHD1050DE1.810-988 (ServiceInformationHD1050DEdated
Jun 22nd,1999), but has an additional frame with side protection screen.
Drive
 Yanmar 1-cylinder, 4-phase diesel engine L 90 AE
 Aircooled
 Electrical starter / recoil hand starter
 Decompression lever for engine start, trigger for engine stop
 Automatic r.p.m. control: engine r.p.m. decreases during circulation mode.
High-pressure pump
 Similar to HD 895 S
 3-piston axial pump
 Piston made of stainless steel (diameter:16 mm)
 High-pressure seals, low-pressure seals, oil seals
 Cylinder head made of brass
 Suction and pressure valves made of stainless steel
 Swash plate with axial ball bearing
 Pressure and flow control
 Injector to cleaning agent supply
 Pressure gauge at cylinder head
 Safety valve at cylinder head
Cleaning agent system
 Cleaning agent supply in low-pressure mode (injector)
 Non-return at cylinder head
 Metering valve at cylinder head
Electric system
 Electric starter with key start switch
 Alternator
 Charging regulator (15 A, 12 V)
Standard accessory
 Servopress handgun
 Spray lance with three-way nozzle (0°, 25°, 40°)
 Connecting system 2000

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
Technical features: high-pressure pump
1 Pressure gauge
2 Non-returnvalve
3 Pressurevalve
4 Oil reservoir
5 Shaft seal
6 Swash plate bearing
7 Swash plate
8 Axial roller bearing
9 Oil drain plug
10 Piston
11 Oil seal
12 Low-pressure seal
13 High-pressureseal
14 Suction valve
15 Suction chamber

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
Unit function: overflow valve
1 High-pressureoutlet
2 Cleaning agent injector
3 Cleaningagentconnection
4 Controlpressureinjector
5 Pressure gauge
6 Non-returnvalvescrewplug
7 Pressurechamber
8 Connection bore from pressure
chamber to ball (9)
9 Ball
10 Spring
11 Suction chamber
12 Connection bore from overflow valve to
suctionchamber
13 Water inlet
14 Spring
15 Adjustingnutwithlockingnut
16 Overflowvalvespindle
17 Connection bore from injector to
overflowvalve(controlpressure)

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
1. Servopress handgun is open.
When the servopress handgun is completely
open, water flows from the pressure chamber (7)
through the non-return valve (6) and through both
injectors (2+4) to the high-pressure outlet (1).
The ball (9) is pressed against the valve seat by
the pump pressure, thus sealing the connection
bore (12) to the suction chamber (11).
The pressure gauge (5) indicates the operating
pressure.
The pressure in the connection bore (17) is
approx. 30 bar less due to the injector influence
(4) (control pressure).
The motor runs with operating speed when the
handgun is open.
2. Servopress handgun is partly closed.
When the handgun is partly closed, the pressure
in the pressure chamber (7) does not increase.
Due to the decreased water flow rate, the
influence of the injector (4) is reduced so that the
control pressure in the connection bore (17)
increases. The increasing control pressure
pushes the overflow valve spindle (16) against
the spring (14) and slightly to the right. The tip of
the spindle pushes the ball (9) off its seat so that
part of the water can flow through the connection
bores (8) and (12) to the suction chamber (11).
3. Servopress handgun is completely
closed.
When the handgun is completely closed, the
pressure in the pressure chamber (7) increases.
The increased control pressure pushes the
overflow valve spindle (16) via connection bore
(17) completely to the right. The tip of the spindle
pushes the ball (9) off its seat, so that the entire
water volume can flow through the connection
bores (8) and (12) to the suction chamber.
As soon as the handgun is closed, the non-return
valve closes (6). Therefore the entire pressure
in the system between handgun and non-return
valve (6) is trapped.
The pump continues running with decreased
pressure in circulation operation.
The motor continues running via automatic r.p.m.
control with decreased circulation r.p.m.
4. Servopress handgun is opened.
When the handgun is opened, the pressure in
the system decreases.
The overflow valve spindle (16) is pushed back
by the spring (14) to its original position to the
left. The spring (10) and the pump pressure of
the connection bore (8) push the ball (9) back
onto the valve seat.
The connection bore (8) is thereby closed and
the operating pressure can be built up again.
The engine r.p.m. increases to the operating
speed.
Unit function: overflow valve

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
Basic setting: bowden cable
Note:
The governor springs (3) and (4) must be
attached in the holes of the governor
levers (5) and (6).
1 Adjusting screw
2 Spring
3 Clamping screw
4 Governor spring
5 Governor spring
6 Governor lever
7 Governor lever
- Switch off engine and release pressure.
- Adjust bowden cable as indicated:
5 mm : with adjusting screw (1)
40 mm : with clamping screw (3)

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
Basic setting: overflow valve
1 Shut-off valve
2 Testing pressure gauge
3 High-pressure outlet
4 Adjusting nut with locking nut
5 Overflow valve spindle
6 Water inlet
Note:
Before any adjustments check the high-
pressure nozzle and the air filter for
damage or wear. All defective parts must
be replaced.
- Mounttesting pressure gauge (2), shut-off
valve (1), high-pressure hose and servopress
handgunwithouthigh-pressurenozzleon high-
pressureoutlet(3).The unit pressure gauge is
notto be used to check the operating pressure
because it measures too inaccurate !
- Setservopress handguntomax. watervolume,
open it and operate the unit.
- Closeshut-offvalve(1)slowlyuntillowpressure
flow rate has been achieved (see technical
data). This corresponds to the smallest
servopress setting. Measure flow rate and
compare it with technical data.
- Adjust max. operating pressure with adjusting
nut (4) (see technical data) and check with
testing pressure gauge (2):
Increase spring tension: operating pressure
increases.
Decrease spring tension: operating pressure
decreases.
- Mount servopress handgun with new high-
pressure nozzle (see technical data)and open
again shut-off valve (1) completely. Close and
openservopresshandgunseveraltimes.Check
max. flow rate and max. operating pressure
duringhighpressure.
- Set servopress handgun to min. water volume
(low pressure operation) to check and check
low pressure flow rate. If required repeat the
above mentioned steps.
- Finallysecuretheadjusting nut (4) with locking
nut and seal with safety paint.

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
- Mount shut-off valve with testing pressure
gauge on high-pressure outlet (see page 8
step 1, 2), set servopress handgun to max.
watervolume,set three-waynozzleto0° pencil
jet and operate the unit.
- Measure operating pressure and flow rate
(see technical data).
- Adjust engine r.p.m. with adjusting screw (3)
so that max. operating pressure (see
technical data) at testing pressure gauge is
achieved. With this operating pressure the
corresponding operating speed must also be
achieved (see technical data).
- Close and open servopress handgun several
times and check the adjustment. When the
handgun is closed, the pump pressure
decreases (circulation operation) and the
enginer.p.m.reduces.
- Finallysealscrews(3), (5) and (13) with safety
paint.
1 Operating speed control
2 Locking nut
3 Adjusting screw
4 Locking nut
5 Adjusting screw
6 Bowden cable
7 Adjusting screw for max. operating speed
8 Locking nut
9 Engine stop lever
10 Regulator lever
11 Spring
12 Spring
13 Clamping screw
14 Spring
Note:
Before adjusting the operating speed, the
overflow valve must be adjusted correctly. The
operating speed can only be adjusted during
high pressure (max. operating pressure / flow
rate).
Basic setting: operating speed

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International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
Troubleshooting
Problem Remedy
Engine does not start. Check / clean fuel system.
Check engine stop lever.
Check decompression lever.
Check starter battery and charging regulator.
Engine r.p.m. fluctuates. Check / clean / replace air filter.
Eliminate leakages in high-pressure system:
handgun, high-pressure hose, cleaning agent system,
non-return valve, overflow valve, valve seat of the ball.
Low operating pressure and flow
rate Check / replace high-pressure nozzle. Check / clean water inlet filter.
Check / adjust engine r.p.m.
Eliminate leakages in high-pressure system (as
mentioned above).
Check / adjust spring at overflow valve.
Replace suction and pressure valves.
Replace high-pressure and low-pressure seals.
Pump does not draw in any
cleaning agent. Clean cleaning agent system and eliminate leakages. High-pressure hose is too long or its inner diameter too
small.
Note:
Cleaning agent is only drawn in during low-
pressure operation when the servopress handgun
is completely opened.
Replace injector:
- Unscrew front injector as much as possible.
- Then slowly pull through hand start rope.
While doing so, the engine must not start.
- The resulting pump pressure pushes both
injectors out of the high-pressure outlet.

Page 11/11
International Service Information
International Service Information
Dec. 22nd,1999
HD 1050 DE Cage
New Unit Information
Technical data
Special tools
Shut-off valve 4.580-034
Adapter for system 2000 4.401-072
Testing pressure gauge 4.742-025
R.p.m. tester (mechanical) 6.491-361
Valve pliers 4.901-012
Torques
Cylinder head screws 40 - 45 Nm
Screws for piston housing 5 - 7 Nm
Oil drain plug 25 - 30 Nm
Fastening screw for pressure valve 40 - 45 Nm
Injector 1,5 - 2,5 Nm
Valve seat for safety valve 8 - 10 Nm
The technical data sheet and circuit diagram are on the next edition of the Spare Parts CD-ROM
(DISIS) and in the Intranet (KMN), folder: "Central / Service Info Int`l / Technical Data resp. Circuit
Diagram".
Further operating instructions and spare parts lists can be ordered with the corresponding part
number from our Spare Parts Dept.
unit technical
data circuit diagram operating instructions maintenance booklet spare parts list
HD 1050 DE Cage
Yanmar-Diesel L 90 AE 1.810-993 0.087-634 5.959-276 - 5.958-483