Kobelt 6506 Instruction Manual
Kobelt Manufacturing Co. Ltd.
6506 Side Mounted Propulsion Control
Lever
Owner’s Operation, Installation &
Maintenance Manual
6506 Control Lever Kobelt Manufacturing Co. Ltd.
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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 Overview.....................................................................................................................6
2.2 Technical Data ............................................................................................................6
2.3 Model Configuration Key ...........................................................................................7
3Installation............................................................................................................ 7
3.1 Receipt........................................................................................................................7
3.2 Mechanical .................................................................................................................7
3.3 Electrical .....................................................................................................................8
4Commissioning ...................................................................................................... 9
4.1 Electrical Check...........................................................................................................9
4.2 Functional Test ...........................................................................................................9
5Operation.............................................................................................................. 9
6Maintenance ......................................................................................................... 9
6.1 Preventative Maintenance.........................................................................................9
6.2 Calibration ................................................................................................................10
6.3 Lubrication................................................................................................................10
6.4 Recommended Spare Parts......................................................................................11
Troubleshooting ............................................................................................................. 12
7Warranty............................................................................................................. 13
8Appendix A: Installation Dimensions .................................................................... 14
9Appendix B: Parts List .......................................................................................... 15
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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:
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
Disconnect Power: Turn off power at distribution panel before
beginning installation to protect installer from electrical hazards.
Voltage and Current Compatibility: Confirm that the power source
is compatible with the maximum voltage and current ratings of is
product variant. Failure to do so could result in damage or fire.
Pinch Points: The internal mechanism contains gearing which may
pinch fingers when operated with the cover off.
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2PRODUCT DESCRIPTION
2.1 OVERVIEW
The Kobelt 6506 side mounted
control Lever provides 5 kohm
potentiometer output that is
proportional to the lever position.
This output is used by Kobelt’s
Mighty Mariner or 6525 controller to
control engine throttle, clutch
engagement or propellor pitch. The
handle has three detent positions;
one at neutral plus another two to
correspond with clutch activation
points in both ahead and astern. The
detents and handle friction are user
adjustable.
The 6506 is supplied with a gasket for
either indoor or outdoor installations
and the handle is splined to permit
user selectable handle orientation.
2.2 TECHNICAL DATA
Table 1: 6506 Technical Data
MODEL
6506 SERIES
Handle Travel:
oNeutral
oClutch engage
oFull throttle
0o Detented
+/-20oDetented
+/-74°
Output:
5kΩ/1 W potentiometer
Connection:
40 in [1m] pigtail, 18 AWG [0.75 mm2]
EMC immunity:
per IEC 60945
Environmental category:
ENV5 / Class C / Exposed
IP Rating1:
IP56 (above console)
Operating Temperature:
-13°F … 158°F [-25°C … 70°C]
Vibration Resistance:
0.7 g
Finish:
Polyester powder coat
Textured black
Product Weight:
5.7 lbs [2.6 kg]
1) Requirements to achieve IP56: Minimum 3/16” [5mm] thick steel dash, or equivalent. Requires 4x installation
screws to be sealed. IP rating only applies to units manufactured after March 2022
Figure 1: 6506 Overview Diagram
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2.3 MODEL CONFIGURATION KEY
3INSTALLATION
3.1 RECEIPT
Kobelt offers the 6506 control lever in several
configurations (reference section 2.3). Upon receipt of
the device ensure that the model number and serial
number are noted on the table in page 2 of this manual.
The serial number can be found in the location noted at
right. This model number will determine what spare
parts are applicable.
3.2 MECHANICAL
The 6506 Control Lever should be mounted:
•In a central location at each station on-board
the vessel
•With sufficient room for the handle to swing
fully to both extreme conditions
•Within 3 feet [0.9 m] of the remote selector panel
•With the external electrical cables protected from potential damage
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The lever must be mounted on a flat surface with a maximum roughness of ra = 125 micro-
inches [500 m]. The mounting surface must have the following minimum thickness to
prevent excessive flexing:
Steel consoles: 0.19 inches [4.8 mm]
Aluminum consoles: 0.27 inches [6.8 mm]
The Lever is equipped with (4) four mounting holes for #10 [M5]. Use #10 or M5 sealing
screws or bonded sealing washers to prevent water ingress below the dash. Tighten the
fasteners to 23 in-lbs [4 Nm] with an anaerobic thread locker such as Loctite 243.
3.3 ELECTRICAL
The Control Lever has 4 foot [1.0 m] long 3C/18 cables for external connections. Connect
them to a 6505-2000 or 6505-3000 remote panel as required.
The product’s 3C/18 electrical cables contains the following wires and related functions:
Table 2: 6506 Wire Connections –Potentiometer 1
6506 - Potentiometer 1
Wire #
Wire Name
Colour
Gauge
Function
1
Vref
White
18AWG
power supply connection.
2
Signal
Green
18AWG
signal connection.
3
Com
Black
18AWG
1 ground connection.
Figure 2: 6506 Internal Wiring Diagram
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The operating direction of the Control Lever handle is CW rotation for ahead throttle
command.
4COMMISSIONING
4.1 ELECTRICAL CHECK
Ensure that the rear cover is installed and secured before powering
up the 6506.
Confirm that the electrical connections to the 6506 have been made correctly and correspond
to the requirements of your system installation.
4.2 FUNCTIONAL TEST
The Functional Test should be carried out while the vessel is still at
dock and before it is taken out to sea after installation has been
completed.
A complete functional test should be performed on the system that the Control Lever has
been installed within before entering operational use.
5OPERATION
The Kobelt 6506 Control Lever contains one or two potentiometers. Operating the Control
Lever causes the vessel to engage in the ahead direction when rotated CW. When the lever is
released it stays at the set position and does not spring back to centre.
The operation of the lever can be reversed by swapping the black and white wires at the
remote panel.
6MAINTENANCE
6.1 PREVENTATIVE MAINTENANCE
•Quarterly (4 times per year)
oLubricate the detent track (reference section 6.3)
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oEnsure that the friction drag is adequate.
•Every 2 years
oInspect detent plate. Replace if necessary.
oReplace shaft seal
6.2 CALIBRATION
When replacing the potentiometer
or if the setting has become
disturbed, follow these steps to
center the output:
1. Position the handle in
the center (neutral)
position.
2. Remove the control head
back cover.
3. Locate the
potentiometer in need of
centering.
4. Connect a multimeter to
the Pot –(white wire)
and the Pot Wiper (green
wire). Set the meter to
read resistance.
5. Loosen the two locking
set screws on the pinion
gear with a 1/16-inch
Allen key.
6. Using a short flat head
screwdriver, rotate the
potentiometer shaft until the meter reads half of the rated output (2500 ohms for
a 5K potentiometer).
a. Note: compare the output between the wiper and Vref+ to wiper and
Vref-. Adjust the shaft to balance.
7. Tighten the two locking set screws and replace the cover.
6.3 LUBRICATION
The track the detent runs along on the detent plate must be lubricated to prevent premature
wear. Use a grease with MoS2 additives for best results. The following greases are approved:
Table 3: Approved Lubricants
EP Grease Brand
Figure 3: Potentiometer centering
6506 Control Lever Kobelt Manufacturing Co. Ltd.
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CHEVRON DELO MOLY 5% EP2
MOBIL XHP-322
SHELL S3 V460
6.4 RECOMMENDED SPARE PARTS
The spare parts kept on hand will depend on the severity of the service. The User should
monitor the condition of their control head to predict necessary spare parts and ensure they
are on hand when needed. As a minimum Kobelt recommends keeping the following parts
for each control head in service:
Table 4: Recommended Spare Parts
Part Number
Description
Qty
2009-0011
Detent Plunger
1
2542-0008
Friction Button
1
POT-5
Potentiometer
1
YPB-3232
Pinion Gear
1
When purchasing spare parts refer to Appendix B at the back of this manual for Kobelt
component Part Numbers.
It is recommended that any required service work on a Kobelt unit
be performed by a factory authorized service representative. Please
contact the nearest Kobelt authorized distributor for assistance.
The table below itemizes which spare part numbers change with the various configuration
options. Please reference this table to ensure you receive the correct parts.
Table 5: Configuration Part Numbers
Configuration Part Numbers
Potentiometer Code
Potentiometer
Resistance
(blank)
POT-1
1 kohm
-H
POT-5
5 kohm
-J
POT-10
10 kohm
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TROUBLESHOOTING
If you encounter problems with the operation of your product, please refer to the trouble-
shooting suggestions before contacting Kobelt for assistance. If the steps below do not
resolve your issue, please reach out either Kobelt directly or our Dealers in your area.
Table 6: Common Solutions
Problem
(Issue encountered)
Cause
(What it means)
Corrective Action
(What to do)
Control Lever action is
reversed.
Wiring is backwards.
Swap the POT+ and POT- output
wires to their respective
potentiometer and system
connections.
Control Lever does
not influence vessel
propulsion.
The rest of the system
isn’t hooked up correctly.
Check system wiring.
Confirm wiring to Control Lever.
Broken potentiometer or
contact.
Use a multi-meter to monitor the
resistance of the wiring between
potentiometer contacts.
Check for normal operation of the
potentiometer by measuring the
connection while moving the
Control Lever.
Check potentiometer directions.
Replace any damaged
potentiometers.
Wiring is wrong.
Check wiring.
Refer to system design drawing for
proper wiring.
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7WARRANTY
Kobelt Manufacturing Co. Ltd. (“Kobelt”) warrants the Products and Parts manufactured by
Kobelt to be free from defects in workmanship or material and that said products are
designed mechanically and functionally to perform to specifications.
This warranty is effective providing:
•The equipment is used within the intended operating conditions and in accordance with
Kobelt recommendations
•The equipment is installed according to equipment diagrams, specifications and
recommendations which Kobelt has provided
This warranty becomes invalid if the factory supplied serial number has been removed or
altered on the product. This warranty does not cover cosmetic damage or damage caused by
an act of God, accident, misuse, abuse, negligence or modification of any part of the product.
This warranty does not cover damage due to improper operation or maintenance, connection
to inappropriate equipment or attempted repair by anyone other than an authorized Kobelt
representative.
Upon identification 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 FOB the Kobelt factory
provided that any such defective part is returned by the Buyer with freight and applicable
forwarding charges prepaid by the Buyer. Kobelt’s sole obligation to the Applicant will be to
repair or replace the defective part with same or similar product, to a maximum value of the
list price of the product or part. The Kobelt warranty does not cover labour charges, travel or
any other associated expenses.
All Products and Parts manufactured by Kobelt, are subject to a warranty against
manufacturer’s defects in materials or workmanship for a period of two (2) years from the
date of purchase.
Kobelt will be responsible for all Products or Parts sold by Kobelt but manufactured by 3rd
party manufacturing companies. However, these products and parts are subject to applicable
3rd party warranties and may not be the same as the Kobelt warranty.
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8APPENDIX A: INSTALLATION DIMENSIONS
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9APPENDIX B: PARTS LIST
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ITEM QTY. PART NUMBER DESCRIPTION
1 1 6506-0001-BT FRONT HOUSING, TEXTURE BLACK
2 1 6506-0003-K HANDLE; CHROME FINISH
3 1 6506-0005 CAM
4 1 6506-0006 SHAFT; FFU LEVER HANDLE
5 1 YP-3264-3 SPUR GEAR - DELRIN; 32DP/64T - STYLE A / .79 BORE
6 1 YPB-3232 SPUR GEAR - DELRIN, 32T, 32DP, 1/4IN ID, B-STYLE
7 1 POT-5 POTENTIOMETER; 22MM, 5K, 1 TURN
8 1 6639-0001 SHIM WASHER, 10MM X 2MM, AISI 304
9 1 1023-0214 WASHER, .622 X .445 X .030 IN, STEEL
10 1 6009-0006 TERMINAL BLOCK, 140 SERIES, 6 POS, 15A, 250V
11 1 1024-0812 SLOTTED SPRING PIN, 3/16IN DIAX 7/8IN
12 6 1010-0806 SCREW, RND HD PHL, 10-24 X 3/8, 18-8 SS
13 2 1012-0604 MACHINE SCREW - PAN HD PHIL;, 6-32 X 1/4, 18-8
14 2 1016-1204 SET SCREW - SKT; CP PT, 3/8 UNC X 1/4, 18-8
15 1 1201-0002 COMPRESSION SPRING; 1/4 DIA X 3/8 LG
16 1 1201-0003 SPRING, COMPRESSION, 0.25 DIA X .50 LG
17 1 2542-0008 FRICTION PLUG
18 1 2009-0011 DETENT PLUNGER
19 1 6506-0002 COVER - 6506 SIDE MOUNT CONTROL
20 1 1016-1004 SCREW, SET, SKT, 1/4-20 x 1/4, 18-8 SS
21 1 6506-0004 BRACKET - 6506 SIDE MOUNT CONTROL
22 1 6001-0247 CABLE GLAND WITH NUT, M16, 5-10 MM, POLYAMIDE
23 1 6001-0248-W-M16 WASHER, SEALING, M16, POLYETHYLENE
24 6 6009-6451 FORK TERMINAL, 22-18 AWG, #6 STUD
25 2 1012-0606 SCREW, PAN HD, PHL DRIVE, 6-32 x 3/8IN, 18-8 SS
26 3 6014-0022B WIRE, STRANDED, TYPE MW, 22 AWG, BLK
27 3 6014-0022G WIRE, STRANDED, TYPE MW, 22 AWG, GRN
28 3 6014-0022W WIRE, STRANDED, TYPE MW, 22 AWG, WHT
29 1 6525W-CT-RL CABLE; 3C/18AWG / SHLD / 600V / 105C / GRY
30 4 6009-6230 CABLE TIE 0.1IN X 4IN 18LB BLACK
31 1 1101-0014 O-RING, 2-014, 1/2IN X 1/16IN, NBR70
32 2 6009-7465 HEAT SHRINK 2:1 1/8IN 120C BLK
33 1 6506-0010 GASKET
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(Intentionally Blank)
Heiko Epkens
Digitallysigned by Heiko Epkens
Date:2022.10.28 14:49:55 -07'00'
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