Kobelt 2009 Bedienungsanleitung

Kobelt Manufacturing Co. Ltd.

2009 Control Head

Owner’s Operation, Installation &

Maintenance Manual

2009 Control Head Kobelt Manufacturing Co. Ltd.

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NOTES:

RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE

Model #:

Serial #:

Date of Purchase:

Date of Installation:

2009 Control Head Kobelt Manufacturing Co. Ltd. 
 
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Table of Contents 
1Introduction ..................................................................................................................4
1.1 Contact ...................................................................................................................................... 4 
1.2 Safety......................................................................................................................................... 4 
1.2.1 Safety Alerts .......................................................................................................................... 4 
1.2.2 Notice to Installer.................................................................................................................. 4 
1.2.3 Product Hazards .................................................................................................................... 5 
2Product Description .......................................................................................................6
2.1 Overview.................................................................................................................................... 6 
2.2 Technical Data ........................................................................................................................... 7 
2.3 Model Code Key......................................................................................................................... 7 
3Installation ....................................................................................................................8
3.1 Mechanical ................................................................................................................................ 8 
3.2 Control Cable............................................................................................................................. 8 
3.2.1 Hardware............................................................................................................................... 8 
3.2.2 Cable Routing ........................................................................................................................ 9 
3.2.3 Control Head Connection ...................................................................................................... 9 
3.2.4 Actuator End Connection .................................................................................................... 10 
3.3 Electrical .................................................................................................................................. 11 
4Commissioning ............................................................................................................12 
4.1 Inspection................................................................................................................................ 12 
4.2 Functional Test ........................................................................................................................ 12 
5Maintenance ...............................................................................................................13 
5.1 Preventative Maintenance ...................................................................................................... 13 
5.2 Inspection................................................................................................................................ 13 
5.3 Recommended Spare Parts and Kits........................................................................................ 13 
5.3.1 Accessories.......................................................................................................................... 13 
5.4 Troubleshooting ...................................................................................................................... 14 
6Warranty.....................................................................................................................15 
7Appendix A: Installation Dimensions ............................................................................16 
8Appendix B: Parts List ..................................................................................................17 
9Appendix C: Installation Cut-out Template....................................................................19 
 

2009 Control Head Kobelt Manufacturing Co. Ltd.

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1INTRODUCTION

1.1 CONTACT

Kobelt Manufacturing Co. Ltd.

8238 129th Street

Surrey, British Columbia

Canada, V3W 0A6

Sales Tel:

Fax:

Email:

Website:

+1-604-572-3935

+1-604-590-8313

[email protected]

www.kobelt.com

This document is intended to clearly present comprehensive product data and provide technical

information to assist the end user in design applications. Kobelt reserves the right, without notice, to

change the design, or construction, of any products and to discontinue or limit distribution of any

products. Kobelt also reserves the right to change, or update, without notice, any technical information

contained within this document.

Kobelt recommends that customers visit our website to check for updates to this Manual. Once a

product has been selected for use, it should be tested by the user to ensure proper function in all

possible applications. For further instructions, please contact our distributors or visit our website.

1.2 SAFETY

1.2.1 Safety Alerts

Throughout this manual, the following symbols, and their accompanying explanation, are used to alert

the user to special instructions concerning a service or operation that may be hazardous if performed

incorrectly or carelessly. The associated risk levels are stated below.

This symbol indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.

This symbol indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

This symbol indicates a hazardous situation, which if not avoided, could

result in minor or moderate injury.

This symbol informs the reader of events not related to personal injury

but which there is a risk of damage to property or equipment.

This symbol informs the reader of safety-related instructions or

procedures.

1.2.2 Notice to Installer

Disregarding the following safety measures can result in an accident causing severe injury to personnel

and damage to material assets.

•Only use the product as directed in this manual.

•Never put the product into service if there is evidence of visible damage.

•Never put the product into service before fully completing installation and commissioning.

•Do not carry out any modifications to the product.

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•Only use authentic Kobelt spare parts.

•Observe all local regulations, directives and laws during the installation of this product.

•All installation, commissioning, and maintenance work must only be conducted by qualified

personnel. (For the purpose of this manual, qualified personnel are persons who are familiar with

the assembly, installation, commissioning, and operation of the product and who have the

qualifications necessary for their occupation.)

•Observe all specifications in this manual. If these guidelines are not followed and damage occurs,

the warranty will be voided.

1.2.3 Product Hazards

Equipment Starts Automatically:

Vessel propulsion may activate suddenly while servicing

this product, causing bodily harm. Ensure that all power

sources are locked out prior to performing work.

Pinch Points:

The 2009 control head contains pinch points, which can

cause bodily harm. Ensure that hands and fingers

remain clear of the pinch points when performing work.

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2PRODUCT DESCRIPTION

2.1 OVERVIEW

The Kobelt 2009 push-pull control head can be configured to provide either;

a) twin-engine throttle control with friction hold,

b) Twin-engine clutch control with neutral, ahead & astern detents, or,

c) Single engine clutch and throttle control

For twin engine throttle control or single engine clutch control, the 2009 control head can also act as a

relay station for multi-station set-ups.

The 2009 is available in a combination of black and chrome, all black, or all polished chrome to suit your

appearance preference. Accessories, such as neutral safety switch kits or throttle extension kits can be

ordered with the units or as after market parts.

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2.2 TECHNICAL DATA

Handle Travel:

•Neutral: 0oDetented

•Clutch engage: +/- 30oDetented

•Full throttle: +/- 60o-

Stroke:1

•Pin position:

•Cable stroke:

2.18 in

[55 mm]

2.76 in

[70 mm]

3.34 in

[85 mm]

Force Output:2

•Extension: 125 lbf [556 N]

•Retraction: 230 lbf [1024 N]

Lever ratio: 2.7:1

Ambient Temperature: -40°F…+140°F [-40 °C… + 60 °C]

Weight: 5.4 lbs [2.5 kg]

1) Stroke from TDC is half of value shown.

2) Force output limited by rating of the cable. Values shown are for 40 series cable.

2.3 MODEL CODE KEY

The 2009 control head can be configured in several different ways. Below is a key defining the letter

code options:

1) Neutral safety switch must have a detented handle.

2) Prevents shifting at engine speeds above idle.

3) One red (throttle / friction) and one black (clutch / detented)

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3INSTALLATION

3.1 MECHANICAL

The control head must be mounted on a flat surface strong and stiff enough to withstand the cable

forces listed in the technical section without excessive flexing. Choose a location that has sufficient

room for the handles in both extreme positions.

The control head is equipped with (4) four clearance holes for #10 (M5) screws or bolts inserted from

underneath for direct mounting to the dash. Ensure the unit is securely fastened, preferable with an

anaerobic thread locker such as Loctite 243. Before securing the screws, ensure the detent roller

mechanism is in the forward position.

3.2 CONTROL CABLE

3.2.1 Hardware

The 2009 control head can be used with either 30 series or 40 series control cable. Kobelt

Manufacturing does not recommend solid core cables. A solid core cable would consist of a single wire

that is too stiff. Multi-stranded cores are more flexible and therefore generates less friction during

operation.

The cable ends must also be able to articulate approximately 8 degrees in either direction.

For terminating the cables Kobelt recommends a ball rod end. Rod ends are self-aligning and therefore

minimize friction and binding.

When installing hardware to the cable end, do not twist the core. If required, use a pair of pliers to hold

the cable core from turning while installing the terminating hardware. When gripping the cable end,

apply the pliers immediately under the threads and take care not to score the cable rod. A scored cable

rod will damage the cable seal allowing moisture and dirt to enter the casing.

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3.2.2 Cable Routing

Measure the cable along the path it will take from where the

cable hubs will be anchored at each end. Follow the actual

cable path as closely as possible, allowing for the largest

practical bend radii.

Do not force the cable into tighter bends than what is listed

in the table at below:

It is important to securely anchor the cable

hubs. Any free-play in the cable clamp or

mounting bracket will be perceived as lost

motion or “sponginess” and will reduce the

detent feel.

When securing the cable with clamps, it is recommended practice to position two clamps at the ends of

the bend rather than one in the middle.

When installing a push-pull cable, do not kink the

cable since this will permanently damage the core

and casing, rendering the cable stiff and

inoperable. Even minor kinks will result in

premature failure.

It should also be noted to avoid routing the cable

near sources of heat, such as exhaust pipes or

cold, such as refrigerated fish holds.

3.2.3 Control Head Connection

The 2009 control head has a cam mechanism for actuating the clutch and the throttle that permits the

cable to be installed in either push or pull.

In some marine applications with twin engines, both engines are turning in the same direction and

therefore one gear box is running in the reverse to drive the propeller ahead. In this particular

installation the shift cable must be connected on the opposite side of the support bracket and cam to

provide the proper push and pull mode for either gear.

The clutch valve mechanism on most marine transmission requires approximately 2¾” (70 mm) to 3” (76

mm) of travel. Consequently, the cable must be attached on the clutch cam in the outermost hole of

the support bracket (pin position 3). Reference the diagram in section 2.1

Optimum Life Bend Radii

Cable Size

Operating Life Minimum

30 series

3 inches1[76 mm]

40 series

4 inches [127 mm]

1) Solid core cables will require 6 in [152

mm] minimum bend radius.

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To correctly install the clutch control cables, follow the steps below:

1. Secure the cables to the support bracket with the appropriate cable clamps.

2. Move the control handles to the extreme forward position.

3. Ensure that the cable end extends

slightly past the clutch cam attachment

point.

4. Move the control handles to the

extreme aft position.

5. Ensure that the cable end, when in push

mode, extends beyond the cable

attachment point.

6. If the cable end points from one

extreme to the other are unequal, then

the cable end fitting must be threaded

out or in to correct.

7. Repeat steps 2 to 6

8. After the proper position is found, the

cable end is attached to the clutch

actuating pivot plate and the jam nut

tightened.

9. The final step is to test that the clutch

control valve goes from neutral to both forward and then reverse gear engaged positions without

bottoming. A slight amount of end play is essential.

The throttle cable is installed in the same manner. In order to obtain full handle travel in the speed range,

it is important to select the appropriate connection point for the adaptor kit on the throttle pivot plate.

3.2.4 Actuator End Connection

When connecting the actuating end of the cable to the throttle or

clutch lever, install the cable so that the greatest loads are in tension

(pulling) rather than compression (pushing), if possible.

Where the cable is connected to a lever, the cable must be

mounted so that it lies on a plane (A) midway on the arc (B)

described by the movement of the connection point on the

lever (C).

When connecting the actuating end of the cable to a spool valve such as

the Kobelt 4605 servo cylinder, maximum cable life and efficiency is

achieved when the cable is aligned with the lever in two planes.

Reference the figure at right:

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