KONRAD Series 600B User manual

600B SERIES INSTALLATION GUIDE
Models 620B, 660B, 680B, Remote and Direct Mount
Version 4.0
KONRAD MARINE, INC.
1421 HANLEY ROAD • HUDSON, WI 54016-9376 USA
Phone: [phone] • Toll Free: 1-800-927-3545 • Fax: [phone]
www.konradmarine.com

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 2
All rights reserved. Reproduction or use, without express permission, of editorial or pictorial content, in any manner,
is prohibited. No patent liability is assumed with respect to the use of the information contained herein. While every
precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or
omission. Neither is any liability assumed for damages resulting from use of the information contained herein.
All instructions and diagrams have been checked for accuracy and ease of application; however, success and safety in
working with tools depend to a great extent upon individual accuracy, skill and caution. For this reason, the publishers are
not able to guarantee the result of any procedure contained herein. Nor can they assume responsibility for any damage to
property or injury to persons occasioned from the procedures. Persons engaging in the procedure do so entirely at their own
risk.
*Original equipment manufacturer’s names, drawings, colors and part numbers are used for identication purposes only.
We are in no way implying that any of our parts are the original equipment manufacturer’s product.

KONRAD 600B SERIES INSTALLATION GUIDEJANUARY 2019 - V4.0 PAGE 3
600B Series Models
GENERAL INSTALLATION
Version 4.0
Part # 13-648
*Core Content Originated by Randall J. Soe, January 2007
*Adapted for 600 Series - RS, CS, JH, June 2011
*Adapted for 600B Series - MS, JH, AG Sept. 2015
KONRAD, INC.
1421 HANLEY ROAD • HUDSON, WI 54016-9376 USA
Phone: [phone] • Toll Free: 1-800-927-3545 • Fax: [phone]
www.konradmarine.com

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 4

KONRAD 600B SERIES INSTALLATION GUIDEJANUARY 2019 - V4.0 PAGE 5
TABLE OF CONTENTS
Stern Drive General Information .................................................6
General Operation........................................................................6
Safety Notices ..............................................................................6
Installation Guidelines .................................................................7
Figure A: 600B Series Cutout Template ......................................8
Figure B: 600B Series X-Dimension Guidelines.........................9
Torque Specications For Selected Fasteners............................10
Specied Lubricants................................................................... 11
KONRAD 600B SERIES DRIVE INSTALLATION
Step 1: Transom Cutout and Installation....................................12
Step 2: Direct Mount/Tailpiece Installation..........................13-14
Step 3: Drive Leg Installation...............................................15-17
Step 4: Trim Pump Installation ..................................................18
Step 5: MerCathode Installation ................................................19
Step 6: Oil Reservoir Installation..........................................20-21
Step 7: Trim/Lift Control Wiring Installation .......................22-43
Step 8:Trim/Lift Pump Filling/Bleeding Procedure..............44-45
Step 9: Trim Gauge Installation and Programming ..............46-50
Step 10: Power Steering System Installation.............................51
Steering System Routing Diagrams
31-031R Single............................................................52
31-031R Twin ..............................................................53
31-074R Single............................................................54
31-074R Twin ..............................................................55
31-078R Single............................................................56
31-079R Single............................................................57
31-080R Single............................................................58
31-080R Twin ..............................................................59
Step 11: Drive Shaft Alignment Procedures .........................60-64
Step 12: U-Joint Extension Shaft Installation.......................65-66
Step 13: CV Extension Shaft Installation .............................67-68
Step 14: Propeller Installation...............................................69-71
(a): 620B Propeller Installation......................................69
(b): 660B Propeller Installation .....................................70
(c): 680B Propeller Installation......................................71
Step 15: Installation Review .................................................72-73
Inside Vessel Checklist.................................................72
Outside Vessel Checklist..............................................73
Trim System Component Overview and Trouble Shooting..74-80
Application Sea Trial Data Forms...............................81-83

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 6
Stern Drive
General Information
The Konrad 600B Series stern drives are
designed to accommodate engines that generate
up to 1200 Nm (885 lb. ft.) of torque at maximum
rated RPM. Maximum torque ratings are drive
model and application dependent.
There is a sixteen degree (16°) trim range to
optimize vessel performance while underway.
To achieve optimal wear it is recommended that
the stern drive be operated between the +20to -20
degree trim range while under power.
There is an additional 30 degrees (30°) of lift
range that may only be used in an emergency or
when the stern drive is being serviced or transported.
The Konrad 600B Series stern drives are
designed for applications where the vessel transom
angle is 13 degrees (13°). Applications that do not
meet this criteria may require extra equipment or
modications, or may not be possible at all. The
Konrad 620B and 680B stern drives are designed
to accommodate propellers (aluminum and
stainless steel) with a maximum diameter of 20 in.
(50.8 cm). The Konrad 660B can accommodate
propellers (aluminum and stainless steel) with a
maximum diameter of 16 in. (40.6 cm).
General Operation
The engine produces power (clockwise or
counterclockwise) that is transmitted through a re-
versing transmission. A coaxial planetary-style re-
versing transmission is normally used. The trans-
mission is connected to the stern drive via close
couple or drive shaft. The power is then transmit-
ted through a series of shafts and gears to the pro-
peller(s).
Safety Notices
Read and understand all of the safety precau-
tions and warnings before performing any installa-
tion or repair.
This list contains the general safety precautions
and warnings that MUST be followed to provide
personal safety. This list is only a suggested safe-
ty guideline. Working conditions vary greatly and
safety measures will vary upon your individual cir-
cumstances.
ALWAYS USE CAUTION. Make sure the
work area surrounding the product is safe. Be
aware of hazardous conditions that can exist.
ALWAYS wear protective eyewear and
protective footwear when working.
DO NOT wear loose-tting or torn clothing.
Remove all jewelry when working.
DO NOT work on anything that is support-
ed only by lifting jacks or a hoist.
ALWAYS use blocks or proper stands to
support the product before performing any
service work.
TO AVOID PERSONAL INJURY, use
a hoist or get assistance when lifting stern
drive components. Make sure all lifting de-
vices such as chains, hooks or slings are in
good condition and are of the correct lifting
capacity.

KONRAD 600B SERIES INSTALLATION GUIDEJANUARY 2019 - V4.0 PAGE 7
1) Ensure that the transom is at within 1/16”
(2.0 mm) around mounting area and is prop-
erly supported to handle the thrust of the en-
gine and drive combination for the vessel.
2) Ensure that the propeller height is established
according to the vessel application as deter-
mined by the Konrad Application Engineer.
The height of the propeller is critical to a suc-
cessful application. If the propeller centerline
is too low, excessive drag can occur based
on transom assembly location. Intermediate
spacers are available if needed.
3) Ensure water ow to the propeller is clear and
consistent without interruptions. Protrusions
on the hull surface create a negative pressure
area and induce turbulence. Turbulence can
cause severe propeller ineciency and ex-
cessive torsional vibration. There are to be
no such protrusions within 2.5 meters for-
ward of the propeller(s).
Common causes of interruptions are:
• Water pickup
• Sonar transducers
• Retrotted surfaces which are not
properly faired or smoothed
• Any hull shape which does not
provide smooth transition
• In heavy applications, the bow can
produce turbulence if the attitude
of the vessel is weighted forward
• Improper listing of the vessel due
to weight distribution
4) Ensure that the vessel center of gravity is
properly placed. Excessive weight forward
or aft can signicantly aect performance
and the eciency of the propeller.
5) Ensure that the stern drive is trimmed to the
correct level. While under-trimming can
cause premature u-joint wear, over-trim-
ming can cause propeller ineciency, por-
poising, and premature gear wear.
Installation Guidelines

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 8
Note: Drawing not to scale.
Figure A: 600B Series Cutout Template
The installer is responsible to ensure
that the transom is properly supported
for the thrust of the system

KONRAD 600B SERIES INSTALLATION GUIDEJANUARY 2019 - V4.0 PAGE 9
Figure B: 600B Series X-Dimension Guidlines

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 10
Description Torque Value
Transom Assembly / Gimbal Housing
Studs to Inner Transom Plate Nuts (6) 50 lb. ft. (67.8 Nm)
Gimbal Ring Center Pivot Pin Cover Hex Head Cap Screws 35 lb. ft. (47.5 Nm)
Gimbal Ring Center Pivot Pin Retaining Hex Head Cap Screw 50 lb. ft. (67.8 Nm)
Trim Sender Cover Button Head Cap Screws 13 lb. in. (147 N cm)
Trim Sender Housing Cap Screws 8 lb. ft. (10.8 Nm)
Trim Sender Socket Head Cap Screws 8 lb. ft. (10.8 Nm)
Lifting Bracket Top Cover Button Head Cap Screws (5) 20 lb. ft. (27 Nm)
Gimbal Carrier Compression Ring Socket Head Cap Screws
Tail piece Compression Ring Hex Head Cap Screws
45 lb. ft. (61 Nm)
35 lb. ft. (47.5 Nm)
620 Propeller Nut (1) 80 lb. ft. (109 Nm)
660 Forward Propeller Nut (1) 100 lb. ft. (136 Nm)
660 Aft Propeller Nut (1) 60 lb. ft. (81 Nm)
680 Forward Propeller Nut (1) 100 lb. ft. (136 Nm)
680 Aft Propeller Nut (1) 80 lb. ft. (109 Nm)
Torque Specications for Selected Fasteners

KONRAD 600B SERIES INSTALLATION GUIDEJANUARY 2019 - V4.0 PAGE 11
Specied Lubricants
Gear / Drive Oil
Konrad 75W90 Full Synthetic Oil Part number
1 Quart (.95 Liters) (13-090)
2.5 Gallon (9.5 Liters) (13-091)
55 Gallon (208 Liters) (13-092)
Lubricant Capacity 600B Series (standard conguration) **
Complete Sterndrive, 620B model - approximately eighteen (18) quarts (17 Liters).
Complete Sterndrive, 660B model - approximately sixteen (16.5) quarts (15.1 Liters).
Complete Sterndrive, 680B model - approximately eighteen (18) quarts (17 Liters).
** Oil capacities will vary depending on application congurations, such as spacers, by 1-3 quarts
(.95-2.84 liters)
Make sure the drive is completely lled to the top and line from reservoir is purged of air prior to
operating.
KVD Transmisson
Mobiltrans HD30 Drive-train Oil SAE 30 Part number
1 Gallon (3.79 Liters) (13-758)
Approved Alternative - Shell Spirax S4 CX 30
Fluid capacity
Fluid capacity will vary depending on the location, transmission model, and length of cooler hoses.
Refer to the Velvet Drive owners manual for instructions on how to check the uid level.
Trim / Lift pump
Dexron III automatic transmission uid Part number
1 Quart (.95 Liters) (10-585)
Fluid capacity
Trim Pump Reservoir - approximately (1) quart (.95 Liters)
Steering system
Dexron III automatic transmission uid Part number
1 Quart (.95 Liters) (10-585)
Fluid capacity
Capacity will vary depending on the type of steering system used and hose length.

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 12
1.1 Locate the Cutout Template (13-548) that is
packaged along with the manuals in the drive
shipment. Place the cut out on the transom of
the vessel following the mounting height guidelines
established for the vessel’s application.
1.2 Carefully drill and cut out the transom
of the vessel according to the template.
Clean the area and prep for installing the tran-
som assembly.
1.3 Apply marine grease to the gasket
around the transom assembly. Carefully lift the
transom assembly into place, guide the eight (8)
studs through the drilled holes and secure by
sliding the inner transom straps (13-675), round
at washers (10-584) and nylock nuts (13-623)
over the studs on the sides. Place the two (2)
square backing plates (10-941) onto the top and
bottom center studs, secure using the remaining
nylock nuts (13-623).
1.4 Attach one end of the continuity ca-
ble (31-094) to one of the transom studs, and
secure. The other end will be connected to the
engine ground.
1.5 Tighten the nuts evenly in a star pattern
until the nal torque of 50 lb. ft. (67.8 Nm) is
reached.
1.6 Remove the two (2) H.H.C.S. and
washers from both the bottom and top plates on
the gimbal ring, then remove the plates.
NOTE: Be careful to keep the top center pin
bushing in place for installing the drive later.
NOTE: If the application uses a drive shaft,
proceed to Step 3: Drive Leg Installation.
Step 1: Transom Installation

KONRAD 600B SERIES INSTALLATION GUIDEJANUARY 2019 - V4.0 PAGE 13
Step 2: Direct Mount / Tailpiece installation
2.1 Remove the tailpiece compression ring and
oring from the transmission tailpiece by removing
the ve (5) H.H.C.S. and washers.
2.2 Position the tailpiece compression ring and
oring onto the gimbal housing by sliding the ring
and gasket from the bottom of the gimbal housing
upward under the trim hoses and into position.
2.3 With the transmission and tailpiece mounted
on the engine, position the tailpiece to slide
through the gimbal housing. Hold the tailpiece
compression ring and oring so it will slide onto the
tailpiece housing while positioning the engine and
transmission into place.
2.4 Apply red Loctite to the (5) H.H.C.S. that
were removed in Step 2.1. Start the bolts by hand
and tighten in a star pattern at 5 lb ft (6.8 Nm)
increments until 35 lb ft (47.5 Nm) is obtained.

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 14
2.5 Tool TO-189 is used to align the engine,
transmission and tailpiece with the gimbal housing.
NOTE: These steps must be completed prior
to installing the stern drive.
2.6 Slide the tailpiece alignment shaft (TO-
189-A) all the way into the tailpiece output.
2.7 Hold the top portion of the alignment gauge
against the at surface on the top of the gimbal
housing. Slide the gauge towards the back of the
tailpiece until it is ush with the tailpiece.
Adjust the engine mounts until the gauge slides
over the alignment shaft while sitting ush against
the tailpiece housing, and the top of the gauge is up
against the at on the upper portion of the gimbal
housing.
2.8 When the correct alignment is made, the
alignment pin will be centered in the alignment
gauge as shown in the picture to the right.
Step 2: Direct Mount / Tailpiece installation (continued)
alignment
gauge tailpiece
alignment
shaft

KONRAD 600B SERIES INSTALLATION GUIDEJANUARY 2019 - V4.0 PAGE 15
3.2 Prepare the Konrad drive leg for installation by
securing it upright. (A lifting ring is included with the
drive and is located in the packet with the manuals).
You may install the lifting ring by removing the plug on
top of the drive’s top cap and threading it into place.
NOTE: Stern drive is shipped full of oil, secure drive
upright before removing plug and installing lift ring.
3.1 Install the u-joint bellows (10-230) on the output
ange of the gimbal bearing carrier assembly. Position
the bellows with the “TOP” mark facing upward.
Install the grounding clip on the bellows making con-
tact with the gimbal bearing. Tighten the forward
clamp.
3.3 Locate the alignment pin shipped with the man-
ual packet. Apply marine grease to the pin, end yoke
splines, and o-ring. Install one end of the pin into the
end of the yoke assembly. Use the other end of the pin
to help guide the end yoke into the splines of the gimbal
housing.
3.5 Slide the drive toward the transom assembly,
aligning the center of the gimbal ring with the drive’s
intermediate pivot point. Carefully sliding the u-joint
end yoke into the bellows and at the same time ro-
tate the u-joint to help align with the gimbal housing
splines.
WARNING! Do not impact or apply force to the
drive while engaging the input shaft as this will
damage the gimbal carrier seal.
Install the grounding clip on the bellows so it makes
contact with the bearing carrier. Tighten the aft clamp.
Step 3: Drive Leg Installation
3.4 Remove the center pivot pin and retaining bolt
from the intermediate section of the drive, to be rein-
stalled later.

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 16
3.6 Apply marine grease onto center pin and
reinstall the center pivot pin (13-561) into the lower
gimbal ring and into the intermediate section the
drive.
Note: Use the slot on the bottom of the pin to align
the hole for the retaining bolt at the bottom of the
intermediate housing.
3.7 Put red Loctite on the H.H.C.S. (13-560)
and install into the intermediate section (as shown
in picture to the right). Tighten into the center pivot
pin at 50 lb.ft. (67.8 Nm).
3.8 Reinstall the bottom cover (13-320), lock
washers (13-670), and the H.H.C.S. (13-310). Ap-
ply blue Loctite and tighten the H.H.C.S. to 35 lb.ft
(47.5 Nm).
3.9 Remove the screw from the top starboard
side of the intermediate and attach the continuity
cable from the transom assembly.
Step 3: Drive Leg Installation (continued)
3.10 Reinstall the top cover plate with rudder
indicator sensor (if equipped) facing forward align-
ing the sensor and wiring with the slot on the top
portion of the pivot pin.
3.11 Apply blue Loctite to the H.H.C.S (12-378)
and reinstall into the washers (13-670), and top
plate, then tighten into the gimbal ring.
NOTE: There is a small indicator on the shaft of
the sensor indicating the side that must align with
the wiring, and the slot in the shaft. (See arrow in
picture)

KONRAD 600B SERIES INSTALLATION GUIDEJANUARY 2019 - V4.0 PAGE 17
3.12 Install the steering rams onto the drive
by placing the two (2) bushings (13-319) on the
steering ram eyelet. Place the steering ram between
the steering tabs on the drive. Clevis pin (13-341),
slides through the top steering tab and downward
through the steering rod and out the bottom tab.
Install at washer (12-352), and secure with cotter
pin (13-368) by sliding through the hole at the bot-
tom of clevis pin and bending the legs of the cotter
pin back around the outside of the clevis pin.
Repeat this process for both port and starboard
sides.
3.13 Remove lifting ring from drive and reinstall
gasket (10-285) and plug (10-010) into top cap (13-
421).
3.14 Remove cap (13-012) from tting (11-702).
Place blue Loctite on oil vent hose tting (11-702),
and install oil supply hose (31-130) from the gim-
bal housing and tighten.
3.15 Install the cover onto the upper housing.
Place blue Loctite onto the S.H.C.S. before placing
them through the at washers and hand tighten.
Install two (2) M6 X 18mm S.H.C.S (13-696) into
the forward upper side of the cover. Install two (2)
M6 X 18mm S.H.C.S (13-696) into each forward
bottom side hole in the cover.
3.16 Install two (2) M6 X 18mm S.H.C.S. (13-
696) with blue Loctite and washers (12-335) on the
aft side of the cover and tighten.
3.17 Install splash deector (13-403), using the
four (4) H.H.C.S. and washers supplied with the de-
ector plate into the lower gimbal housing. Apply
red Loctite to the bolts and tighten to 35 lb.ft. (47.5
Nm)
See photo to right.
Step 3: Drive Leg Installation (continued)

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 18
Step 4: Trim Pump Installation
4.1 Apply blue Loctite to each of the transom
trim ttings (13-575), then attach one end of each
of the four (4) trim hoses (13-702) to the four (4)
transom ttings (13-575).
NOTE: Six (6) total trim hoses are included with
each drive. (4) 13-702 for transom to manifold and
(2) 13-703 for trim pump to manifold.
4.2 Mount the trim system manifold in the
desired location, and attach the opposite ends of the
trim hoses (13-702) to the four (4) ttings.
NOTE: Trim hose lengths are 24 inches (60cm)
each)
4.3 Install one end of the remaining two (2) trim
hoses (13-703) to the bottom ttings on the trim
manifold. As seen in image to the right.
NOTE: Apply blue Loctite to all the hose ttings
on nal install.
4.4 Mount the trim pump in the desired location
within 24 inches (60cm) of the trim system mani-
fold, and install the remaining hose ends onto the
pump ttings.
UP UP
DOWN
DOWN
13-702 13-703
UP

KONRAD 600B SERIES INSTALLATION GUIDEJANUARY 2019 - V4.0 PAGE 19
Step 5: MerCathode Installation
The transom can be equipt with a Mercury MerCathode kit. The reference electrode and anode assembly can be
mounted on the transom/gimbal housing assembly by removing the plugs mounted on the lower portion.
5.1 Mount the MerCathode controller to the inside of the transom or other vertical surface and is within
reach of the wire leads.
5.2 Connect the red /purple wire assembly (with fuse) between the controller and battery positive (+) terminal.
Check the fuse for proper installation.
5.3 Connect the black wire assembly to the controller and the battery negative (-) terminals.
5.4 Connect the anode lead (orange) to the controller terminal marked “A”.
5.5 Connect the electrode lead (brown) to the controller terminal marked “R”.
5.6 Secure all connections and apply a thin coat of liquid neoprene sealant (Mercury Marine part # 92-25711
3) to all exposed terminals and fasteners
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or
can damage the electrical system. Always disconnect the negative(-) battery cable rst and connect it last.
CAUTION!
NOTE: Prevent galvanic corrosion resulting from inadequate electrical power to the MerCathode system.
Avoid using switches in the system and ensure current is always available from the battery.

KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 - V4.0PAGE 20
Step 6: Oil Reservoir Installation
6.1 The oil reservoir assembly (30-992) that is
shipped with each drive consists of a 4 qt (3.79 L)
bottle with molded mounting brackets, low oil level
sensor and a vented cap.
5.2 Locate and mark the desired mounting
location for the oil reservoir on the transom keeping
within 12-18 inches (30-45.7 cm) of the trim pump
assembly. This is a gravity fed system and must be
mounted above the oil input line to the drive.
Make sure there is enough clearance to ll the bottle
with oil, and it is clear of any steering or other
moving parts that maybe installed later.
6.4 Connect the oil supply line hose to the bot-
tom of the reservoir.
Direct Mount application: go to Step 5.7 for installa-
tion of tting side of hose.
Remote Mount application only: route other end
of the hose to one side of the brass “T” tting and
secure both ends with a hose clamp.
6.3 Mount the bottle with a minimum of
four (4) of the appropriate fasteners, (using
more fasteners for rough water applications).
6.2 Locate and mark the desired mounting
location for the oil reservoir on the transom keeping
within 12-18 inches (30-45.7 cm) of the trim pump
assembly. This is a gravity fed system and must be
mounted above the oil input line to the drive.
Make sure there is enough clearance to ll the bottle
with oil, and it is clear of any steering or other
moving parts that maybe installed later.