KONRAD 620 User manual

NOTICE TO INSTALLER
After completing installation this
Maintenance Manual should be
placed with the Stern Drive for
the Owner’s future use.
Series 600
Maintenance Manual

All rights reserved. Reproduction or use, without express permission, of editorial or pictorial con-
tent, 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 con-
tained 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.
600 SERIES MAINTENANCE MANUALPAGE ii JULY 2017 - V3.6

Version 3.6
Part # 12-842
MAINTENANCE MANUAL
600 Series Models
*Core Content Originated by Randall J. Soe, October 2007
*Adapted for 600 Series, November 2011
600 SERIES MAINTENANCE MANUALJULY 2017 - V3.6 PAGE iii

TABLE OF CONTENTS
600 SERIES MAINTENANCE MANUAL
TABLE OF CONTENTS JULY 2017 - V3.6
1 - KONRAD 600 SERIES STERN DRIVES
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specications for Fasteners . . . . . . . . . . . . . . . . . . . .
Stern Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stern Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - KONRAD 600 SERIES GENERAL MAINTENANCE
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants
Specied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fluids
Trim/Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller and Hardware
Model 620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 660 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 680 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
3
5
5
7
8
9
10
11
12
13
13
13
14
15
15
15
16
17
17
17

600 SERIES MAINTENANCE MANUAL
TABLE OF CONTENTS JULY 2017 - V3.6
3 - KONRAD 600 SERIES COMPLEX MAINTENANCE
Electrical Drawings
Trim/Lift Electrical Drawing (12 Volt) . . . . . . . . . . . . . . . . . . . . . . . . .
Trim/Lift Electrical Drawing (24 Volt) . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Trim/Lift Sender Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuity Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Bearing Carrier Seal Replacement
Model 620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 660 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 680 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
(continued)
18
19
20
21
25
26
29
31
37
39
42
46
50

600 SERIES MAINTENANCE MANUALJULY 2017 - V3.6 PAGE 1
General Information
The Konrad 600 Series stern drives are designed to accommodate engines that generate up to 1200 Nm
(885 lb. ft.) of torque. Maximum torque ratings are drive model and application dependent.
There is a sixteen degree (16°) trim range to optimize vessel performance while underway. 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 600 Series stern drives are designed for applications where the vessel transom angle is 14
degrees (14°). Applications that do not meet this criteria may require extra equipment or modications,
or may not be possible at all. The Konrad 620 and 680 stern drives are designed to accommodate
propellers (aluminum or stainless steel) with a maximum diameter of 20 in (50.8 cm). The Konrad 660
can accommodate propellers (aluminum or stainless steel) with a maximum diameter of 16 in. (40.6 cm).
Safety Notices
Read and understand all of the safety precautions and warnings before performing any installation 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 safety guideline. Working conditions vary greatly, consequently safety
measures will vary upon your individual circumstances. Always use caution. Make sure the work area
surrounding the product is safe. Be aware of hazardous conditions that can exist.
ALWAYS wear protective eyeglasses 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 supported 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 drive components. Make
sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct
capacity.
ALWAYS use tools that are in good condition. Make sure you understand how to use them before doing
any service work.
ALWAYS use the same fastener part number (or equivalent) when replacing fasteners.
DO NOT use a fastener of lesser quality if replacements are necessary.
ADDITIONAL SAFETY PRECAUTIONS ARE INCLUDED IN THE PROCEDURES WHEN
APPLICABLE.
Chapter 1 - Stern Drive

600 SERIES MAINTENANCE MANUAL JULY 2017 - V3.6
PAGE 2
Operation
The engine produces power (clockwise or counterclockwise) that is transmitted through a reversing
transmission. A coaxial planetary-style reversing transmission is normally used in recreational applications.
A twin shaft vertically offset standard reversing transmission (with coaxial additions available) is normally
used in commercial applications. From this point the transmission is connected via close couple or drive
shaft. The power is then transmitted through a series of shafts and gears and then to the propeller(s).
WARNING: If a u-joint style drive shaft is used, the drive shaft angle may not exceed one-half degree
(1/2º). If the angle exceeds one-half degree (1/2º), any warranty offered with your application is
void.
Break-In Procedure
Make sure the stern drive and gimbal carrier are properly lled with gear oil prior to operation.
Any new Konrad stern drive unit, whether a lower, upper or complete, requires a ten (10) hour break-in
running period. Please use the following guidelines during the rst ten (10) hours to assure optimum
performance from your new Konrad stern drive.
1. Avoid full throttle starts.
2. Avoid straining or heavy loading of the stern drive.
3. To achieve even wear patterns on your new drive gear sets, operate at intermittent
throttle levels throughout the entire break-in period.
4. DO NOT exceed seventy-ve percent (75%) of full throttle during the rst ve (5) hours.
5. During the next ve (5) hours of the break-in period, operate periodically at full throttle.
6. The stern drive should be shifted into forward gear a minimum of ten (10) times during
the rst ten (10) hours with moderate (but not excessive) RPM’s after each shift.
7. Change the gear oil when the break-in period is complete.
NOTE: When the initial oil change is done, small metal particles may be found in the break-in oil. Do
not be alarmed. This is typical during break-in and will decrease as you run the drive.
Chapter 1 - Stern Drive (continued)

600 SERIES MAINTENANCE MANUALJULY 2017 - V3.6 PAGE 3
Torque Specications for Fasteners
Listed below are the torque specications for those fasteners that have a specied torque value. Securely
tighten all other fasteners. Internal drive component torque specications are stated in the Konrad
Series 600 Technical Manual.
Description Torque Value
Drive Shaft Flange to Transmission
Output Flange Shaft Nuts/Bolts (if applicable) 70 lb. ft. (95 Nm)
Transom Assembly / Gimbal Housing
Studs to Inner Transom Plate Nuts (8) 25 - 30 lb. ft. (34 - 41 Nm)
Drive Shaft Housing to Gear Housing Nuts and Bolts (8) 35 lb. ft. (47 Nm)
Trim Cylinder to Anchor Pin, Nuts (4)
(Rubber Bushings Only)
Tighten until outer washer
(10-444) is bottomed out
on anchor pin..
Trim Cylinder to Anchor Pin, Nuts (4)
(Hardened Bushings Only) 30-35 lb ft. (41-47 Nm)
Lifting Bracket Top Cover Socket Head Cap Screws (5) 80 lb. in. (9 Nm)
Hinge Pins for Upper Housing Ears (2) 65 lb. ft. (88 Nm)
Gimbal Carrier Bolts (S.H.C.S.) (3) (if applicable) 70 lb. ft. (95 Nm)
620 Propeller Nut (1) 80 lb. ft. (108 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. (108 Nm)
Chapter 1 - Stern Drive (continued)

600 SERIES MAINTENANCE MANUAL JULY 2017 - V3.6
PAGE 4
Chapter 1 - Stern Drive (continued)
620
Stern Drive
Item Description
620
Weight
Trim cylinders with anchor pins
Trim cylinders with anchor pins
26 lbs
11.8 kg
11.8 kg
Trim pump
Trim pump
13 lbs
5.9 kg
5.9 kg
Upper housing assembly
Upper housing assembly
118 lbs
53.5 kg
53.5 kg
Lower housing assembly
Lower housing assembly
84 lbs
38.1 kg
38.1 kg
Transom assembly
Transom assembly
(with inner transom plate)
67 lbs
30.4 kg
30.4 kg
Total Dry Weight 308 lbs 130.7 kg
-
Upper and Lower Only 202 lbs 91.6 kg
Standard 620 Propellers Propeller Weight
3 Blade, Stainless Steel, 18.5” Diameter
24 lbs
10.9 kg
4 Blade, Stainless Steel, 18.5” Diameter
28 lbs
12.7 kg
5 Blade, Stainless Steel, 18.5” Diameter
30 lbs 13.6 kg
660
Stern Drive
Item Description
660
Weight
Trim cylinders with anchor pins
Trim cylinders with anchor pins
26 lbs
11.8 kg
11.8 kg
Trim pump
Trim pump
13 lbs
5.9 kg
5.9 kg
Upper housing assembly
Upper housing assembly
118 lbs
53.5 kg
53.5 kg
Lower housing assembly
Lower housing assembly
67 lbs
30.4 kg
30.4 kg
Transom assembly
Transom assembly
(with inner transom plate)
67 lbs
30.4 kg
30.4 kg
Total Dry Weight 291 lbs 132.0 kg
- Upper and Lower Only 185 lbs 83.9 kg
Standard 660 Propellers Propeller Weight
3 Blade, Stainless Steel, 16” Diameter
14 lbs
6.4 kg
4 Blade, Stainless Steel, 15.25” Diameter
15 lbs
6.8 kg
680
Stern Drive
Item Description
680
Weight
Trim cylinders with anchor pins
Trim cylinders with anchor pins
26 lbs
11.8 kg
11.8 kg
Trim pump
Trim pump
13 lbs
5.9 kg
5.9 kg
Upper housing assembly
Upper housing assembly
118 lbs
53.5 kg
53.5 kg
Lower housing assembly
Lower housing assembly
115 lbs
52.2 kg
52.2 kg
Transom assembly
Transom assembly
(with inner transom plate)
67 lbs
30.4 kg
30.4 kg
Total Dry Weight 339 lbs 153.8 kg
- Upper and Lower Only 233 lbs 105.7 kg
Standard 680 Propellers Propeller Weight
3 Blade, Stainless Steel, FWD, 18.5” Diameter
21 lbs
9.5 kg
4 Blade, Stainless Steel, AFT, 17.25” Diameter
26 lbs
11.8 kg
600
Series Stern Drive
Weight
Descriptions
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