Kobelt 7012 Series Instruction Manual

June 2020
(Rev A)
HELM PUMP
7012
Owner’s Operation, Installation &
Maintenance Manual

Helm pump-7012 Kobelt Manufacturing Co. Ltd.
Rev A MNL-7012 2 of 32
NOTES:
RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE
Model #:
Serial #:
Date of Purchase:
Date of Installation:

Helm pump-7012 Kobelt Manufacturing Co. Ltd.
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TABLE OF CONTENTS
1Introduction ............................................................................................................ 4
1.1 Contact .................................................................................................................... 4
1.2 Compliant Use ......................................................................................................... 4
1.3 Copyrights & Trademarks ........................................................................................ 4
2Safety...................................................................................................................... 5
2.1 Safety Alerts............................................................................................................. 5
2.2 Notice to Installer .................................................................................................... 5
3About Helm Pump ................................................................................................... 6
3.1 Product Description ................................................................................................. 6
3.2 Ordering Options ..................................................................................................... 7
3.3 Technical Specifications ........................................................................................... 7
4Unpacking the Product............................................................................................. 8
5Installation .............................................................................................................. 9
5.1 Mechanical .............................................................................................................. 9
5.2 Hydraulic................................................................................................................ 10
6Commissioning ...................................................................................................... 12
6.1 Hydraulic Fill & Bleed............................................................................................. 12
6.2 Calibration and Adjustment................................................................................... 13
7Operation.............................................................................................................. 14
8Maintenance ......................................................................................................... 15
8.1 Preventative Maintenance..................................................................................... 15
8.2 Recommended Spare Parts.................................................................................... 15
9Troubleshooting .................................................................................................... 16
10 Warranty............................................................................................................... 17
11 Appendix A: Installation Dimensions...................................................................... 18
12 Appendix B: Parts List ............................................................................................ 20
13 Appendix C: Typical System Arrangement .............................................................. 28
14 Appendix D: Shaft Seal Replacement...................................................................... 29
15 Appendix E: Lock Valve Sub-Assembly.................................................................... 30

Helm pump-7012 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:
[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 COMPLIANT USE
This device is only intended for use by persons trained in operating marine systems.
The installer shall:
•Only use non-defective products.
•Check the safety of operation and the condition of the device before each use.
•Verify that the product is operational at all times and keep it in good working
conditions.
Only Kobelt Manufacturing Co. Ltd. Authorized Dealers or Authorized Technicians are to
repair Kobelt products.
1.3 COPYRIGHTS &TRADEMARKS
All product names, logos and brands are property of their respective owners. All company,
product and service names used in this manual are for identification purposes only. Use of
these names, logos, and brands does not imply endorsement.

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2SAFETY
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.
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.

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3ABOUT HELM PUMP
3.1 PRODUCT DESCRIPTION
Kobelt Manufacturing produces different Helm Pumps, all of which are made from bronze
and stainless steel, except for the thrust and roller bearings and, of course, hardened and
ground pistons. These Helm Pumps can be installed in any location on the vessel because of
their durable materials and watertight construction.
The Helm Pumps incorporate lock valves, filler plugs and interconnecting plugs for multi
station applications. A front mounting plate is available (optional) for all pumps, where the
pump is mounted behind the console face. The following Kobelt Hydraulic Pumps are based
on the same design and are of the VARIABLE DELIVERY TYPE.
The delivery of these pumps is fully adjustable, with easy-to-alter output flow as simple as
turning an external adjusting screw on the pumps’ front face with a standard screwdriver.
Figure 1: Product Overview Diagram
These pumps have been extremely well received by the industry, because of their variable
displacement capability, which allows the operator to select the number of turns from
hardover to hardover, without installing a different pump. For manual hydraulic systems,
under normal conditions, the load on the steering wheel rim should not exceed 36 ft. lbs. (16
kg), and generally the hydraulic system pressure should not exceed 650 psi (45 bar). For
electro-hydraulic systems on emergency-driven hydraulic pumps, the steering angle that must
be maintained manually, in case the power fails, is only 15ᵒto either side. At 15ᵒthe rudder
torque is easily controlled with a helm pump and the helmsman will have no problem
maintaining the steering. One must remember that producing 12 cubic inches per turn at 600
to 1000 PSI requires a tremendous amount of human effort, and it is not practical to expect a
person to produce this kind of pressure and volume continuously.

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3.2 ORDERING OPTIONS
Ordering options
Finish A Bronze Finish
B Black Epoxy Finish
Shaft L Long Shaft (for behind console mount)
N Short Shaft (for through console mount)
Connection block P Porting Block (no lock valve)
Omit for lock valve option
Plug V Vent plug
Omit for non vented plug
3.3 TECHNICAL SPECIFICATIONS
MODEL
7012
KOBELT P/N
7012L
7012N
DISPLACEMENT PER TURN
4 - 12 in3[65 - 197 cc]
MAXIMUM PRESSURE
1000 PSI [69 bar]
RECOMMENDED FLUID
ISO VG 32, VI 60 hydraulic oil
LOCK VALVE PORT SIZES
-10 SAE ORB
REAR TOP/BOTTOM THREAD SIZE
1/4” NPT
FILLER CAP THREAD SIZE
5/8” NUF
STEERING WHEEL DIAMETER
24” to 40” [600 mm to 1000 mm]
PHYSICAL DIMENSIONS (L x W x H)
17.5”x 6.2”x 7.0”
[445 mm x 158 mm x 177 mm]
15.0”x 6.2”x 7.0”
[380 mm x 158 mm x 177 mm]
MOUNTING DIMENSIONS (L x W)
6.0” x 5.25” [152 mm x 133 mm]
4x 0.56” [14 mm] THRU-HOLES
PRODUCT WEIGHT
38 lbs [17.2 kg]
SHIPPING DIMENSIONS (L x W x H)
20.0” x 8.0” x 8.0”[508 mm x 203 mm x 203 mm]
Table 1: Technical Specifications

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4UNPACKING THE PRODUCT
When unpacking the box containing the 7012 Helm Pump, the box should include the
following additional items:
•1x 7012 Helm Pump
•1x 7012 Owner’s manual (this document)
•1x 7012 Cut-Out
If any of these items are missing or damaged, please contact Kobelt to arrange replacements.

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5INSTALLATION
5.1 MECHANICAL
The helm pumps are supplied with a short shaft or with a long shaft. The helm pumps can be
mounted through the console or behind the console, although the short shaft version would
normally be mounted in the thru-console mode.
When deciding which way to mount the pump, attention must be paid to the method of filling
the system. Now is a good time to install your fittings in the helm pump.
Allow space for the steering wheel.
When mounted thru-console, the filler plug is accessible, but when behind the console, it is
obscured. In the behind console mounting, either arrange access to the filler plug or adopt
some form of remote filling system. The remote filling system can either be a small tank or a
tube run up from the pump to a position convenient for topping up with oil.
Helm pump Model 7012 are best installed with the shaft on a horizontal plane.
5.1.1 Thru-console
A template is provided for the cut-out to allow the front half of the pump to protrude through
the console with the flange butting up against the back or front face of the console.
The pump should be secured to the console by four bolts through the bolt holes at the four
corners of the pump flange.
5.1.2 Behind console
A template is provided for the cut-out to allow the pump shaft through the console and for the
drilling of four holes to secure the pump to the back face of the console.
Four bolts and washers are required to screw into the tapped holes in the face of the pump.
If the variable flow facility of the helm pump is to be used, cut the hole for access to the
adjusting screw.
5.1.3 Expansion Tanks
Expansion Tanks are normally supplied by the shipyard. They can also be obtained from Kobelt
and, we recommend that approximately 1 Quart (or 1 Litre) minimum volume should be used
in this application. The vent line from the Expansion Tank to the Helm Pump should protrude
approximately 1" from the bottom of the Expansion Tank into the tank itself. This avoids dirt
and condensed water from entering the steering system. The vent plug must be arranged in
such a fashion that water spray and rain cannot enter the tank. (See Figure 2)
5.1.4 Installation with adaptor plate
An adaptor plate is optionally available to simplify mounting of the pump. This plate can be
installed on either side of the console. A template is provided to drill the necessary holes.
Two bolts with washers are required in this case to secure the pump to the bulkhead.

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Ordering number: 7012-0011A (cast bronze finish)
7012-0011B (black epoxy finish)
5.2 HYDRAULIC
For Manual Systems, it is recommended to use ISO #32 Hydraulic Oil. We do not recommend
using any other type of fluid. The hydraulic oil used should be new and clear of all foreign
matters.
During installation it is of utmost importance to keep dirt and foreign matters out of the system.
Cleanliness is extremely important.
•We do not recommend the use of Teflon tape for pipe sealing. This often rolls over
the edge of the fitting and is cut off on installation; it then floats in the system. It is
recommended that liquid Teflon sealant or its equivalent is used. It is easier to
ensure that none of this type of sealant gets into the system.
•Copper or Stainless-Steel tubing is preferred for the piping material. The tubing
should be of large inside diameter to avoid excessive friction in the hydraulic system,
especially in cold weather environments.
Depending on the number of stations, the length of runs and the size of the Helm
Pump, the piping must be chosen accordingly.
We recommend the minimum diameter of 1/2" tubing, but on the long runs 3/4"
tubing is recommended. When installing this tubing, it is very important to have a
steady rise in the lines towards the highest point in the steering system. It is very
difficult to bleed the tubing system with a rise and fall pattern, because air gets
trapped in the elevated pockets.
•It is also recommended that an expansion tank is installed on the uppermost station,
to provide an additional reservoir of oil. This expansion tank must have a vented
plug. The plug, however, must be arranged in such a fashion that water cannot enter
the steering system. All other filler plugs on the steering stations must be of a non-
vented type. If an expansion tank is not used, the uppermost steering station must
have a vented filler plug on the Helm Pump.
This is to allow the oil to expand during a hot day and contract when the
temperature declines.
5.2.1 Non-Vented and Vented
If no Header Tank is installed, a Vented Plug is required at the highest pump. This can be done
by drilling a small hole into the side of the plug.