Kobelt 7012 Series Owner'S Operation, Installation & Maintenance Manual Download Page 1 | Manualshive

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June 2020

(Rev A)

HELM PUMP

7012

Owner’s Operation, Installation &

Maintenance Manual

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Summary of Contents for 7012 Series

Page 1: ...June 2020 Rev A HELM PUMP 7012 Owner s Operation Installation Maintenance Manual ...

Page 2: ...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 ...

Page 3: ...al Specifications 7 4 Unpacking the Product 8 5 Installation 9 5 1 Mechanical 9 5 2 Hydraulic 10 6 Commissioning 12 6 1 Hydraulic Fill Bleed 12 6 2 Calibration and Adjustment 13 7 Operation 14 8 Maintenance 15 8 1 Preventative Maintenance 15 8 2 Recommended Spare Parts 15 9 Troubleshooting 16 10 Warranty 17 11 Appendix A Installation Dimensions 18 12 Appendix B Parts List 20 13 Appendix C Typical ...

Page 4: ...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 produ...

Page 5: ...nforms 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 completin...

Page 6: ...ernal 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 ...

Page 7: ... 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 MOUNTI...

Page 8: ...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 ...

Page 9: ... 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 va...

Page 10: ...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 w...

Page 11: ...t Manufacturing Co Ltd Rev A MNL 7012 11 of 32 Installers should familiarize themselves with the equipment and their instructions Operators should fully understand how the system works Figure 2 Expansion Tank Installation ...

Page 12: ...n turned slowly this side of the system should now be reasonably free of air 11 Continue to turn the wheel until the cylinder moves to the hard over position 12 There should at this point be a significant resistance to further turning 13 Now turn the wheel in the opposite direction There may be at this point a blow back of air up the tubing into the pump which can expel oil with some force from th...

Page 13: ...ditives that are harmful to oil seals used in steering systems All hydraulic lines in the steering system must be thoroughly cleaned prior to filling the system Ensure all hydraulic lines are secured and fittings are tight 6 2 CALIBRATION AND ADJUSTMENT The Kobelt Model 7012 helm pumps outputs are adjustable These Helm Pump have a variable output This enables the pump to be set at the optimum numb...

Page 14: ... of the steering cylinder As the cylinder moves oil from other end of the steering cylinder is push backed up to the opposite side of the helm pump This called a two line system When you stop turning the steering wheel the hydraulic oil in both lines is locked by the rudder lock valve sometimes called a non return valve The rudder will stay in place and not move until you start turn the steering w...

Page 15: ...ts and nuts are tight for their functions Every two years o Sample and analyze the oil in the steering lines o Check for corrosion and excessive wear at all moving parts that could cause problem in normal operation 8 2 RECOMMENDED SPARE PARTS As a minimum Kobelt recommends the following spare parts are on hand Table 2 Recommended Spares RECOMMENDED SPARES QTY ITEM KOBELT PART 1 REPAIR KIT FOR HELM...

Page 16: ...our issue please reach out either Kobelt directly or our Dealers in your area Table 3 Common Troubleshooting Problems Problem Issue encountered Cause What it means Corrective Action What to do Helm pump doesn t turn actuator in correct direction The tube connection from helm pump to cylinder is backward Switch PORT and STBD connection at helm pump or at the cylinder Cylinder movement is not smooth...

Page 17: ...cation of a potential issue or defect with a Kobelt Product or Part the Warranty Applicant Applicant must immediately contact Kobelt and describe the issue in writing by letter fax email or other electronic conveyance Kobelt will then assess the cause of the defect and determine warranty applicability and appropriate remediation If any part is found to be defective Kobelt will replace said part FO...

Page 18: ...Helm pump 7012 Kobelt Manufacturing Co Ltd Rev A MNL 7012 18 of 32 11 APPENDIX A INSTALLATION DIMENSIONS Figure 2 Installation Dimensions Short Shaft ...

Page 19: ...Helm pump 7012 Kobelt Manufacturing Co Ltd Rev A MNL 7012 19 of 32 Figure 4 Installation Dimensions Long Shaft ...

Page 20: ...Helm pump 7012 Kobelt Manufacturing Co Ltd Rev A MNL 7012 20 of 32 12 APPENDIX B PARTS LIST Figure 5 Parts Diagram ...

Page 21: ...BLY 7012 LVC 4 FRONT SEAL RETAINER SUB ASSEMBLY 7012 5005 5 REAR HOUSING 7012 0002 6 BEARING THRUST 7012 51110 7 BEARING THRUST 7012 51115 8 SQUARE KEY 7005 0019 9 FITTING ADAPTER 7039 0144 10 FITTING HEX HEAD PLUG 7039 1342 11 PLUG 7039 3044 12 HEX HEAD SCREW 1001 1216 13 SOCKET HEAD SCREW 1002 0810 14 SOCKET HEAD SCREW 1002 1032 15 SOCKET HEAD SCREW 1002 1112 16 FLAT HEAD SCREW 1009 0806 17 WASH...

Page 22: ...Helm pump 7012 Kobelt Manufacturing Co Ltd Rev A MNL 7012 22 of 32 ...

Page 23: ...SCREW 7012 0023 5 O RING 1101 0012 6 O RING 1101 0017 7 FILLER PLUG 7005 0028 8 DOWEL PIN 7012 0029 9 BALL BEARING 7005 6006 10 ADJUSTMENT BLOCK SUB ASSEMBLY 7012 0007 SA Front housing of the pump is spring loaded Opening and closing of front housing for repair or maintenance need extra caution At the time of installation leave the adjustment screw item 4 all the way out at minimum displacement po...

Page 24: ...Helm pump 7012 Kobelt Manufacturing Co Ltd Rev A MNL 7012 24 of 32 ...

Page 25: ...uring Co Ltd Rev A MNL 7012 25 of 32 Part No 7012 0007 ITEM DESCRIPTION 1 THRUST BEARING RETAINER 7012 0007 2 SHOULDER BOLT 7012 0022 3 ADJUSTMENT LINK 7012 0009 4 ADJUSTING BLOCK 7012 0010 5 PIN 7012 0021 6 RETAINING RING 1029 1031 ...

Page 26: ...Helm pump 7012 Kobelt Manufacturing Co Ltd Rev A MNL 7012 26 of 32 ...

Page 27: ... No 7012 5002 S 7012 5002 L ITEM DESCRIPTION 1 SHAFT 7012 0015 7012 0016 2 PISTON 7012 0012 3 SPRING 1201 0168 4 SPRING SEAT 7012 0032 5 PIN 1024 2030C 6 ROTOR 7012 0005 7 O RING 1101 0026 8 PISTON CHECK VALVE 7012 5003 9 PINTLE 7012 0013 10 SOCKET HEAD CAP SCREW 1002 1112 ...

Page 28: ...Helm pump 7012 Kobelt Manufacturing Co Ltd Rev A MNL 7012 28 of 32 13 APPENDIX C TYPICAL SYSTEM ARRANGEMENT Figure 6 Typical System Arrangement ...

Page 29: ...Helm pump 7012 Kobelt Manufacturing Co Ltd Rev A MNL 7012 29 of 32 14 APPENDIX D SHAFT SEAL REPLACEMENT Model No 7012 5005 ITEM DESCRIPTION 1 FRONT SEAL RETAINER 7012 0003 2 SHAFT SEAL 7005 11130 ...

Page 30: ... of 32 15 APPENDIX E LOCK VALVE SUB ASSEMBLY Model No 7012 LVC ITEM DESCRIPTION 1 LOCK VALVE BODY 7012 0006 2 SHUTTLE 7012 0014 3 BALL SEAT 7012 0026 4 BALL 1301 0116 5 SPRING SEAT 7012 0031 6 SPRING 1201 0167 7 PIN 7012 0024 8 PLUG 7012 0025 9 O RING 1101 0021 ...

Page 31: ...Helm pump 7012 Kobelt Manufacturing Co Ltd Rev A MNL 7012 31 of 32 Page Intentionally Left Blank ...

Page 32: ...et Surrey British Columbia Canada V3W 0A6 Sales Tel 1 604 572 3935 Fax 1 604 590 8313 Email sales kobelt com Website www kobelt com Made in Canada Printed in Canada Keivan Ashouei Digitally signed by Keivan Ashouei Date 2020 08 31 11 16 02 07 00 ...

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