Kobelt 2544 Instruction Manual

Kobelt Manufacturing Co. Ltd.
2544 Pneumatic Control
Head
Owner’s Operation, Installation &
Maintenance Manual

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NOTES:
RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE
Model #:
Serial #:
Date of Purchase:
Date of Installation:

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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
2.4 Schematic Symbol...................................................................................................................... 8
3Installation ....................................................................................................................9
3.1 Mechanical ................................................................................................................................ 9
3.2 Control Head Connections......................................................................................................... 9
3.3 Piping....................................................................................................................................... 10
3.4 Multi-Station Connection........................................................................................................ 11
4Commissioning ............................................................................................................12
4.1 Adjustment.............................................................................................................................. 12
4.2 Functional Test ........................................................................................................................ 12
5Maintenance ...............................................................................................................13
5.1 Preventative Maintenance ...................................................................................................... 13
5.2 Adjustment.............................................................................................................................. 13
5.3 Recommended Spare Parts and Kits........................................................................................ 14
6Warranty.....................................................................................................................15
7Appendix A: Installation Dimensions ............................................................................16
8Appendix B: Parts List ..................................................................................................17
9Appendix C: Installation Cut-out Template....................................................................21

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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:
[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.

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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 2544 control head contains pinch points, which can
cause bodily harm. Ensure that hands and fingers
remain clear of the pinch points when performing work.
High Pressure Fluids:
The 2544 control head uses compressed air. Ensure all
pressure is exhausted and the pressure source locked
out prior to performing work.

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2PRODUCT DESCRIPTION
2.1 OVERVIEW
The Kobelt 2544 pneumatic control head permits engine control with both the clutch and throttle
control integrated into one lever. More specifically, this control head is intended to;
1. Control the engine throttle using Kobelt 4106, 4107 or 4108 throttle actuators.
2. Control the engine transmission by;
a. Direct connection to air-piloted shift valves, or
b. Connection to Kobelt 4204 or 4207 clutch actuators.
The 2544 is available in a combination of black and chrome, all black, or all polished chrome to suit your
appearance preference.

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2.2 TECHNICAL DATA
Handle Travel:
•Neutral: 0oDetented
•Clutch engage: +/- 20oDetented
•Full throttle: +/- 80o-
Pressure Output:
•Throttle: configurable (see model code)
•Clutch: 150 psi [10.1 bar] (maximum)
Port sizes: 1/8 NPT
Ambient Temperature: -40°F…+140°F [-40 °C… + 60 °C]
Weight: 9 lbs [4.1 kg]
2.3 MODEL CODE KEY
The 2048 control head can be configured in several different ways. Below is a key defining the letter
code options:

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2.4 SCHEMATIC SYMBOL

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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 operating
forces without excessive flexing. Choose a location that has sufficient room for the handle to swing to
both extreme positions.
Use the template in Appendix C to provide the correct cut-out on the control console.
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, preferably with an
anaerobic thread locker such as Loctite 243.
3.2 CONTROL HEAD CONNECTIONS
To make the proper piping connections at the control
head, refer to the diagram at left.
The 2544 control head is equipped with four 1/8 NPT
pressure ports and two 1/8 NPT exhaust ports. The
exhaust ports do not need to be connected. Install the
port fittings using thread sealant and tighten to 2 - 3
turns from finger tight. Use brass pipe fittings for the as
steel fittings are too heavy and may split the port.
Do not over tighten the fittings as damage to the control head may occur.

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3.3 PIPING
The piping to the throttle and clutch actuators must be adequately sized to ensure adequate response
times. The piping must be selected to safely withstand the pressures required to operate the actuators.
Secure the piping against vibration with pipe clamps per the schedule in the table below.
Table 1: Pipe Clamp Table
PIPE CLAMP TABLE
PIPE SCHEDULE
3/8”-½” tube
[DN6]
¼” – 1/2” pipe
½”-3/4” tube
[DN8-DN15]
¾”pipe
1”-1.25” tube
[DN20]
1”pipe
1.50” tube
[DN25]
CLAMP SPACING
3 ft [914 mm]
4 ft [1219 mm]
5 ft [1524 mm]
6.5 ft [1981 mm]
All piping must be cleaned prior to connection to the actuators. Welded carbon steel piping must be
pickled to remove the scale produced by welding.
Kobelt 2544 control head valves are equipped with “U” cups and “O” rings and therefore require
lubrication in order to provide long service life. Unlubricated seals will have excessive friction and wear.
The oil that is required for the lubricator should be a hydraulic type with a viscosity grade of 10 to 32
centistokes. Heavy oils do not work well for lubricators.
The main supply line to the control head should be equipped with a filter, regulator and lubricator. The
filter’s function is to remove moisture and dirt in the system, and the regulator will provide a constant
air pressure to the control system.