Kobelt 2009 Instruction Manual

Kobelt Manufacturing Co. Ltd.
2009 Control Head
Owner’s Operation, Installation &
Maintenance Manual

2009 Control Head Kobelt Manufacturing Co. Ltd.
Rev A mnl_2009.docx 2 of 20
NOTES:
RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE
Model #:
Serial #:
Date of Purchase:
Date of Installation:

2009 Control Head Kobelt Manufacturing Co. Ltd.
Rev A mnl_2009.docx 3 of 20
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.
Rev A mnl_2009.docx 4 of 20
1INTRODUCTION
1.1 CONTACT
Kobelt Manufacturing Co. Ltd.
8238 129th Street
Surrey, British Columbia
Canada, V3W 0A6
Sales Tel:
Fax:
Email:
Website:
[phone]
[phone]
[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.

2009 Control Head Kobelt Manufacturing Co. Ltd.
Rev A mnl_2009.docx 5 of 20
•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.

2009 Control Head Kobelt Manufacturing Co. Ltd.
Rev A mnl_2009.docx 6 of 20
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.

2009 Control Head Kobelt Manufacturing Co. Ltd.
Rev A mnl_2009.docx 7 of 20
2.2 TECHNICAL DATA
Handle Travel:
•Neutral: 0oDetented
•Clutch engage: +/- 30oDetented
•Full throttle: +/- 60o-
Stroke:1
•Pin position:
1
2
3
•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)

2009 Control Head Kobelt Manufacturing Co. Ltd.
Rev A mnl_2009.docx 8 of 20
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.

2009 Control Head Kobelt Manufacturing Co. Ltd.
Rev A mnl_2009.docx 9 of 20
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.

2009 Control Head Kobelt Manufacturing Co. Ltd.
Rev A mnl_2009.docx 10 of 20
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: