Kobelt 6555 User manual

Kobelt Manufacturing Co. Ltd.
6555 Analog 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 Configuration Key........................................................................................................... 7
3Installation ....................................................................................................................8
3.1 Receipt....................................................................................................................................... 8
3.2 Mechanical ................................................................................................................................ 8
3.3 Electrical .................................................................................................................................... 8
3.4 Functional Test .......................................................................................................................... 9
4Maintenance .................................................................................................................9
4.1 Preventative Maintenance ........................................................................................................ 9
4.2 Calibration ................................................................................................................................. 9
4.3 Lubrication............................................................................................................................... 10
4.4 Recommended Spare Parts and Kits........................................................................................ 10
5Warranty.....................................................................................................................11
6Appendix A: Installation Dimensions ............................................................................12
7Appendix B: Parts List ..................................................................................................13
8Appendix C: Installation Cut-out Template....................................................................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]
[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:
Equipment 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 6555 control head contains pinch points, which can
cause bodily harm. Ensure that hands and fingers
remain clear of the pinch points when performing work.

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2PRODUCT DESCRIPTION
2.1 OVERVIEW
The Kobelt 6555 analog control head provides potentiometer output proportional to the handle
positions. The handle also has three detent positions; one at TDC plus another two to correspond with
the clutch-in points.
Figure 1: Control head overview

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2.2 TECHNICAL DATA
Table 1: 6555 Technical Data
MODEL
6555 SERIES
Handle Travel:
oNeutral
oClutch engage
oFull throttle
0o Detented
+/-20oDetented
+/-75°
Power:
12VDC or 24VDC / 12 mA maximum
Output:
5kΩ/1 W potentiometers
Connection:
40 in [1m] pigtail, 22 AWG [0.5 mm2]
EMC immunity:
per IEC 60945
Environmental category:
ENV2 / Class A / Protected
Operating Temperature:
-13°F … 158°F [-25°C … 70°C]
Finish:
Polyester powder coat
Textured black
Product Weight:
7 lbs [3.2 kg]
2.3 MODEL CONFIGURATION KEY

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3INSTALLATION
3.1 RECEIPT
Kobelt offers the 6555 control head 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 control head must be mounted on a flat surface strong
and stiff enough to withstand the operating forces imposed during normal use without excessive flexing.
Choose a location that has sufficient room for the handle to swing to both extreme positions. Use the
template at the back of this manual to make the correct cut-out on the mounting surface.
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. Before securing the screws, ensure that the control head is
facing the correct direction by referencing the scales. This will ensure that the potentiometer output
increases towards the forward position.
3.3 ELECTRICAL
The standard control head has two 4 foot [1.0 m] long 3C/22AWG shielded cables for external
connections. Connect them to a 6505-2000, 6505-3000 or 6510 remote panel as required.
The potentiometers are wired as per the table below:
Table 2: 6555 Wire Connections –Potentiometers
65555 Potentiometers
Wire
#
Wire
Name
Colour
Gauge
Function
1
Vref
White
22AWG
power supply connection.
2
Signal
Red
22AWG
signal connection.
3
Com
Black
22AWG
ground connection.
The two LED boards for side illumination are connected together and are wired as follows:
Table 3: 6555 Wire Connections –LED boards
6555 LED boards
Wire
#
Wire
Name
Colour
Gauge
Function
1
power
Red
22AWG
power supply connection.
2
com
Black
22AWG
Common connection.

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3.4 FUNCTIONAL TEST
After installation, test that the potentiometers provide minimum reading at full astern. Ensure that the
friction adjustment is adequate to hold the handle position at all angles. Adjust if necessary (reference
fig 1).
Do not put the vessel into service until the control
head has been tested. The Functional Test should be
carried out while the vessel is safely secured.
4MAINTENANCE
4.1 PREVENTATIVE MAINTENANCE
•Monthly
oLubricate the detent track (reference section 4.2)
•Quarterly (4 times per year)
oEnsure that the friction adjustment is adequate.
•Every 2 years
oInspect detent plate. Replace if necessary (reference section 4.3)
•Every 5 years
oReplace potentiometers
4.2 CALIBRATION
When replacing the potentiometer or if the
setting has become disturbed, follow these steps
to center the output:
1. Remove the control head from the
console
2. Locate the potentiometer in need of
centering.
3. Connect a multimeter to the Pot+ (white
wire) and the Pot Wiper (red wire). Set
the meter to read resistance.
4. Position the handle in the center (neutral)
position.
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).
7. Compare the output between the wiper and Vref+ to wiper and Vref-. Adjust the shaft until the
two readings are equal.
Figure 2: Potentiometer centering

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8. Tighten the two locking set screws and reinstall the control head.
4.3 LUBRICATION
The track the detent runs along on the cam must be lubricated to prevent premature wear. Use a
grease with MoS2 additives for best results. The following greases are approved:
Table 4: Approved Lubricants
EP Grease Brand
CHEVRON DELO MOLY 5% EP2
MOBIL XHP-322
SHELL S3 V460
4.4 RECOMMENDED SPARE PARTS AND KITS
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 brake in service:
Table 5: Recommended Spare Parts
Part Number
Description
Qty
2012-0007
Detent Plunger
2
2542-0008
Friction Button
2
POT-5
Potentiometer
2
YPB-3232
Pinion Gear
2
When purchasing spare parts refer to Appendix B at the back of this manual for Kobelt component Part
Numbers.
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 6: 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
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.