Kobelt 4605 Instruction Manual

Kobelt Manufacturing Co. Ltd.
4605 Hydraulic Servo Cylinder
Owner’s Operation, Installation &
Maintenance Manual
April 2019

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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
2Product Description ................................................................................................. 6
2.1 Technical Data ......................................................................................................... 7
3Operation................................................................................................................ 8
4Installation .............................................................................................................. 9
4.1 Mounting ................................................................................................................. 9
4.2 Hydraulic Installation ............................................................................................. 11
5Commissioning ...................................................................................................... 12
5.1 Hydraulic Fill & Bleed............................................................................................. 12
5.2 Functional Test ...................................................................................................... 12
6Maintenance ......................................................................................................... 13
6.1 Preventative Maintenance .................................................................................... 13
6.2 Recommended Spare Parts.................................................................................... 13
7Troubleshooting .................................................................................................... 14
8Warranty............................................................................................................... 15
9Appendix A: Parts List............................................................................................ 16
9.1 4605-4 and 4605-4S Parts Lists .............................................................................. 16
9.2 4605-6, 4605-6S, 4605-8, 4605-8S Parts Lists ........................................................ 17

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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]
[e-mail]
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.

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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.
•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
Hydraulic cylinders can produce large forces which can cause injury
to human body parts and damage to nearby components. Keep
body away from moving parts and pinch points. It is the
responsibility of the owner to ensure that the mechanism that the
cylinder is connected to can handle the loads that the cylinder
produces.
This product is powered by hydraulic fluid. Consumption and
contact with eyes can cause death and blindness. Pressurized fluid
jetting out can cause injuries such as hydraulic septicemia. Prior to
beginning work on this product always ensure:
•Safety glasses are being worn.
•Pressure has been exhausted and the pressure source
has been locked out.
•You are qualified to work on hydraulics.
Additionally, it is highly recommended that a relief valve set to the
maximum pressure of this unit is installed to the pressure line
supplying this unit.
To ensure the product does not get damaged during storage and
installation:
•Store the unit with the cylinder fully retracted.
•Ensure all plugs remain in place until unit is ready to be
connected to hydraulics.

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2PRODUCT DESCRIPTION
Controlled by a “push-pull” control but powered by fluid power, the 4605 hydraulic servo
cylinder allows the user to produce half-a-ton of force with minimal human effort. This
product can be used wherever large forces are needed at fingertip actuation. Possible
applications for this unit include waterjet reversing buckets, controlling CP propeller lever
mechanisms, controlling mechanical gearboxes, and steering systems. The 4605 is available in
4”, 6”, and 8” strokes and in either 1/4-28 UNF or 3/8-24 UNF threads on the valve spool and
is fully compatible with Kobelt’s 2000-series Push-Pull control heads and cables.
The 4605 unit consists of two main subunits, the valve and the cylinder. The operating
principles of the cylinder are very simple; pressurized fluid is directed to either end of the
cylinder causing it to retract or extend and exert a force on whatever it is connected to. The
valve is what is used to control the operation of the cylinder; it takes input from the user via
the spool and directs the pressurized fluid where it needs to go to complete the desired
action (i.e. extend, retract, or stay in the current position). See Figure 1 below for a depiction
of the components.
Figure 1: 4605 Components.
This product comes in a few different configurations allowing for a custom-tailored solution
to your needs. Refer to Table 1 on the following page for a listing of the models available and
their operating parameters.

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2.1 TECHNICAL DATA
Table 1: 4605 Technical Data
Operating outside of the ambient temperature range and above the
maximum pressure can result in failure of the unit and will void the
warranty.
MODEL
4605
KOBELT PART #
4605-4
4605-6
4605-8
4605-4S
4605-6S
4605-8S
STROKE,
CYLINDER
4”
10 cm
6”
15 cm
8”
20 cm
4”
10 cm
6”
15 cm
8”
20 cm
STROKE, SPOOL
VALVE
0.62”
15.8 mm
FORCE OUTPUT,
EXTENSION
1160 lbf
5170 N
FORCE OUTPUT,
RETRACTION
1010 lbf
4490 N
FORCE INPUT
< 5 lbf
< 20 N
MAXIMUM
PRESSURE
500 psi
35 bar
VOLUME
9.8 in3
160 mL
14.6 in3
240 mL
19.4 in3
320 mL
9.8 in3
160 mL
14.6 in3
240 mL
19.4 in3
320 mL
AMBIENT
TEMPRATURE
-40 to 140 °F
-40 to 60 °C
WEIGHT
6.6 lbs
3.0 kg
7.8 lbs
3.5 kg
8.9 lbs
4.1 kg
6.6 lbs
3.0 kg
7.8 lbs
3.5 kg
8.9 lbs
4.1 kg
VALVE SPOOL
THREAD
1/4-28 UNF
3/8-24 UNF

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3OPERATION
Note the ambient temperature and maximum pressure specified in
Table 1: 4605 Technical Data on page 7. Exceeding these values can
cause failure of the unit.
The valve takes input from the user mechanically via the spool. Moving the spool valve causes
the cylinder to move in the opposite direction the spool (see Figure 2). It takes approximately
3.1 lbs [14 N] of input force to overcome spool friction.
Figure 2: Cylinder Movement Given a Spool Input.

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4INSTALLATION
4.1 MOUNTING
See Figure 3 on the next page for the dimensions of the 4605 hydraulic servo cylinder. The
mounting of the 4605 to the mechanism to be controlled should precede the connection of
the unit to a source of hydraulic power if possible; for hydraulic installation instructions and
related safety information refer to section 4.2 Hydraulic Installation.
If the cylinder is connected to a hydraulic power source, ensure that
pressure has been exhausted and the pressure source has been
locked out.
The mounting of the 4605 is done as follows:
1. Remove cotter pins and retaining rings from the clevis pins.
2. Remove the clevis pins from the holes they are in.
3. Align clevis pin holes with mechanism cylinder is to be mounted to. Note that the
axial position of the rod end clevis relative to the piston-rod can be adjusted by
loosening the jam nut and screwing or unscrewing the clevis and retightening the
jam nut.
4. Reinstall clevis pins through both holes.
5. Reinstall cotter pins and retaining rings to clevis pins.
6. Connect the valve to the input mechanism (e.g. a Kobelt Push-Pull control) via the
thread on the spool or by another means. Ensure that the spool’s neutral position
lines up with input device’s neutral position to the best of your ability (see Figure 2
for spool neutral positioning). Secure/tighten the connection.
7. Without system pressurization, ensure unobstructed movement of the system for
the full stroke of the cylinder.
Ensure that the mechanism that the cylinder is attached to can
either accommodate the full stroke of the cylinder or is able to
withstand the full load that the cylinder produces at maximum
pressure; damage and failure of the mechanism can occur if this is
not taken into consideration. Note that due to manufacturing
tolerances, the strokes can vary up to 0.08” (2 mm) over the
nominal value (e.g. a cylinder with a nominal stroke of 4” can have
an actual stroke up to 4.08”).

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Figure 3: 4605 Dimensions in Inches [Millimetres]