KONRAD 662 Twin Prop User manual

GENERAL INSTALLATION MANUAL
600 Series Models
KONRAD, INC.
1421 HANLEY ROAD • HUDSON, WI 54016-9376 USA
Phone: [phone] • Toll Free: 1-800-927-3545 • Fax: [phone]
www.konradmarine.com

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 identification purposes only.
We are in no way implying that any of our parts are the original equipment manufacturer’s product.
600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE ii

Version 1.0
Part # 12-843
KONRAD, INC.
1421 HANLEY ROAD • HUDSON, WI 54016-9376 USA
Phone: [phone] • Toll Free: 1-800-927-3545 • Fax: [phone]
[email protected] • www.konradmarine.com
GENERAL INSTALLATION MANUAL
600 Series Models
*Core Content Originated by Randall J. Sofie, January 2007
*Adapted for 600 Series, June 2011
600 SERIES INSTALLATION MANUALSEPTEMBER 2011 PAGE iii

600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE iv

TABLE OF CONTENTS
620 Stern Drive Description ........................................................1
660 Stern Drive Description ........................................................2
680 Stern Drive Description ........................................................3
Stern Drive General Information .................................................4
General Operation ........................................................................4
Safety Notices ..............................................................................4
Tools Recommended For Installation .......................................5-6
Torque Specifications For Selected Fasteners ..............................7
Installation Guidelines .................................................................8
Figure A: 600 Series Cutout Template .........................................9
Figure B: 600 Series X-Dimension Guidelines .........................10
KONRAD 600 SERIES DRIVE INSTALLATION
Step 1: Transom Cutout ........................................................11-12
Step 2: Transom Assembly Installation ................................13-14
Step 3: Oil Reservoir Installation ..........................................15-17
Step 4: Trim/Lift Pump Installation ......................................18-21
Figure C: Trim System Electrical Drawing 12 Volt ...................22
Figure D: Trim System Electrical Drawing 24 Volt ...................23
Step 5: Stern Drive Installation .............................................24-29
Figure E: Alignment Specifications Chart .................................30
Step 6: Alignment Procedures ...............................................31-34
Step 7: Trim Cylinder Installation ........................................35-36
Figure F: Trim Assembly Diagram ............................................37
Figure G: Trim Assembly Individual Components ....................38
Step 8(a): 620 Propeller Installation ..........................................39
Step 8(b): 660 Propeller Installation ..........................................40
Step 8(c): 680 Propeller Installation ..........................................41
Step 9: Stern Drive Lubrication .................................................42
Step 10: Trim/Lift Control Module Installation ....................43-46
Step 11: Trim/Lift Pump Filling/Bleeding Procedure ...........47-48
Step 12: Setting Trim/Lift Limit & Sender Switch ...............49-50
Step 13: Manual Hydraulic Steering System Installation .....51-54
Figure H: Routing Diagram 30-462R ........................................55
Step 14: Power Steering System Installation ........................56-60
Figure I: Routing Diagram 30-390R ..........................................61
Figure J: Hoses for Assembly KM #30-390 ..............................62
Figure K: 30-264 Parts List ........................................................63
600 SERIES INSTALLATION MANUALSEPTEMBER 2011 - V1.0 PAGE v

Figure L: 30-272 Parts List ........................................................64
Step 15: Rubber Coupling Extension Shaft(s) ......................65-68
Step 16: U-Joint Extension Shaft Installation .......................69-70
Step 17: CV Extension Shaft Installation .............................71-72
Step 18: Drive Shaft Shroud Installation ...................................73
Figure M: Rear Mount/Tailpiece Cutout Template ....................74
Step 19: Rear Mount / Tailpiece Installation ........................75-77
TABLE OF CONTENTS (Continued)
600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE vi

600 SERIES INSTALLATION MANUALSEPTEMBER 2011 - V1.0 PAGE 1
Recreational
Performance
Maximum Recommendation:
1100 Nm (812 lb. ft.) of torque for
diesel or gas applications for planing
hulls of highly intermittent operation.
Maximum Operation:
300 hours per year and gross weight to
horsepower* less than 29 kg/kw (40 lbs/
hp). This classifi cation includes private,
non-commercial, non-charter, sport/
leisure activity craft. Standard warranty.
Military and
Government Service
Maximum Recommendation:
830 Nm (612 lb. ft.) of torque for diesel or
gas application for semi-displacement and
planing hulls of intermittent operation.
Maximum Operation:
800 hours per year and gross weight to
horsepower less than 29 kg/kw (40 lbs/
hp). This classifi cation includes light
commercial charter/sport activity craft,
patrol and crew boats. Standard warranty.
Medium Duty
Commercial Performance
Maximum Recommendation:
745 Nm (550 lb. ft.) of torque for diesel or
gas applications for semi-displacement and
planing hulls of intermittent operation with
some variations in engine rpm and power.
Maximum Operation:
2000 hours per year and gross weight
to horsepower less than 29 kg/kw (40
lbs/hp). This classification includes
charter and commercial craft. These
applications require factory approval.
620 Classifi cations
620 Stern Drive Description
The Konrad 620 stern drive is the hardest working stern
drive in the marine industry today. Designed for high-
use, endurance-type applications, the Konrad 620 is
recognized for its versatility and long-term durability.
It is not a “pleasure” drive. It’s a working drive that
can take you fi shing all day or patrol harbors 24/7. The
Konrad 620 is the only commercial-rated stern drive
available for diesel applications in the 350-475 hp
(261 - 354 kw) range.
The Konrad 620 stern drive is designed to
accommodate aluminum or stainless steel propellers
with three (3) to fi ve (5) blades. Propellers are chosen
depending on the application and performance criteria.
The maximum diameter propeller size for the Konrad
620 stern drive is 20 in. (50.8 cm).
NOTE: Factory approval is required for applications outside of the maximum ratings specified.
* Weight/power ratio does not apply for non-planing applications.

600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE 2
The Konrad 660 Twin Prop System reduces stress on
the gears by using dual, counter rotating propellers
providing an effi cient, durable drive with increased
control. This drive is designed for performance driven
applications with speeds up to 60 knots (70 mph).
The Konrad 660 stern drive features two, one
piece propeller shafts each which accommodate
a stainless steel propeller. The specially designed
propellers have a specifi c blade confi guration: 3
blades on the forward prop and 4 blades on the aft
prop. The propeller pitches are manipulated on
each application to meet the performance criteria.
The maximum diameter of the propellers in the
Konrad 660 is 16 in. (40.6 cm) for the forward
prop, and 15.25 in. (38.7 cm) for the aft prop.
660 Stern Drive Description
660 Classifi cations
Recreational
Performance
Maximum Recommendation:
1100 Nm (812 lb. ft.) of torque for
diesel or gas applications for planing
hulls of highly intermittent operation.
Maximum Operation:
300 hours per year and gross weight to
horsepower* less than 22 kg/kw (30 lbs/
hp). This classifi cation includes private,
non-commercial, non-charter, sport/
leisure activity craft. Standard warranty.
Military and
Government Service
Maximum Recommendation:
830 Nm (612 lb. ft.) of torque for diesel or
gas application for semi-displacement and
planing hulls of intermittent operation.
Maximum Operation:
500 hours per year and gross weight to
horsepower less than 22 kg/kw (30 lbs/
hp). This classifi cation includes light
commercial charter/sport activity craft,
patrol and crew boats. Standard warranty.
Medium Duty
Commercial Performance
Maximum Recommendation:
745 Nm (550 lb. ft.) of torque for diesel or
gas applications for semi-displacement and
planing hulls of intermittent operation with
some variations in engine rpm and power.
Maximum Operation:
1000 hours per year and gross weight
to horsepower less than 22 kg/kw (30
lbs/hp). This classification includes
charter and commercial craft. These
applications require factory approval.
NOTE: Factory approval is required for applications outside of the maximum ratings specified.
* Weight/power ratio does not apply for non-planing applications.

600 SERIES INSTALLATION MANUALSEPTEMBER 2011 - V1.0 PAGE 3
The Konrad 680 Twin Prop System is engineered with
the largest, strongest gears in the industry. It’s powerful
lower unit houses dual pinion gears which split the load
and enable the 680 to efficiently carry up to 7.7 metric
tons (17,000 lbs.) per drive. This model operates with
extreme efficiency in the 40 knot (40 mph) range.
The Konrad 680 stern drive features two, one piece
propeller shafts, each accommodating a specially
designed stainless steel propeller with a specific blade
configuration: 3 blades on the forward prop and 4 blades
on the aft prop. The propeller pitches are manipulated
on each application to meet the performance criteria.
The maximum diameter of the propellers is larger
in the Konrad 680: 20 in. (50.8 cm) for the forward
prop, and 17.25 in. (43.8 cm) for the aft prop.
680 Stern Drive Description
680 Classifications
Recreational
Performance
Maximum Recommendation:
1200 Nm (885 lb. ft.) of torque for
diesel or gas applications for planing
hulls of highly intermittent operation.
Maximum Operation:
300 hours per year and gross weight to
horsepower* less than 37 kg/kw (50 lbs/
hp). This classification includes private,
non-commercial, non-charter, sport/
leisure activity craft. Standard warranty.
Military and
Government Service
Maximum Recommendation:
904 Nm (667 lb. ft.) of torque for diesel or
gas application for semi-displacement and
planing hulls of intermittent operation.
Maximum Operation:
1000 hours per year and gross weight
to horsepower less than 37 kg/kw (50
lbs/hp). This classification includes light
commercial charter/sport activity craft,
patrol and crew boats. Standard warranty.
Medium Duty
Commercial Performance
Maximum Recommendation:
813 Nm (600 lb. ft.) of torque for diesel or
gas applications for semi-displacement and
planing hulls of intermittent operation with
some variations in engine rpm and power.
Maximum Operation:
2000 hours per year and gross weight
to horsepower less than 37 kg/kw (50
lbs/hp). This classification includes
charter and commercial craft. These
applications require factory approval.
NOTE: Factory approval is required for applications outside of the maximum ratings specified.
* Weight/power ratio does not apply for non-planing applications.

600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE 4
Stern Drive
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
modifications, or may not be possible at all. The
Konrad 620 and 680 stern drives are designed to
accommodate propellers (aluminum and stainless
steel) with a maximum diameter of 20 in (50.8
cm). The Konrad 660 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
reversing transmission. A coaxial planetary-style
reversing transmission is normally used in recre-
ational applications. A twin shaft vertically offset
standard reversing transmission (with coaxial ad-
ditions available) is normally used in commercial
applications. From this point the transmission is
connected via close couple or drive shaft (different
shafts are discussed in detail in Step 6 on pages 31
- 32 in this manual). The power is then transmitted
through a series of shafts and gears and then to the
propeller(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 safety
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-fitting 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 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.

600 SERIES INSTALLATION MANUALSEPTEMBER 2011 - V1.0 PAGE 5
Konrad has an installation tool kit available for purchase.
The following is a complete list of all items included in the kit.
Installation Tool Kit
30 – 190
NOTE: Additional tools may be required.
Tool box
3/8 in. Drill
13/64 in. Drill Bit (pilot for lag screws)
Jig Saw
Jig Saw Blades (2)
3/8 in. Drive Ratchet (quick release)
3/8 in. Drive 3 in. Extension
3/8 in. Drive 6 in. Wobble Extension
3/8 in. Drive to 1/4 in. Drive Reducer
1/4 in. Drive 1/4 in. Socket
3/8 in. Drive to 5/16 in. Socket
3/8 in. Drive 7/16 in. Socket
3/8 in. Drive 1/2 in. Deep Socket
3/8 in. Drive 1/2 in. Socket
3/8 in. Drive 9/16 in. Socket
3/8 in. Drive 5/8 in. Deep Socket
3/8 in. Drive 3/4 in. Socket
3/8 in. Drive 3/4 in. Deep Socket
3/8 in. Drive 5/16 in. Allen Head Socket
5/16 in. Combination Wrench
3/8 in. Combination Wrench
7/16 in. Combination Wrench
1/2 in. Combination Wrench
9/16 in. Combination Wrench
5/8 in. Combination Wrench
11/16 in. Combination Wrench
3/4 in. Combination Wrench
1-7/16 in. Combination Wrench
8 in. Adjustable Wrench
4 in. Flat Blade Screwdriver
6 in. Flat Blade Screwdriver
4 in. #2 Phillips Screwdriver
6 in. #3 Phillips Screwdriver
6 in. #2 Phillips Bit
6 in. #3 Phillips Bit
7 in. Vice Grips
6 in. Slip Joint Pliers
12 in. Flat Blade Pry Bar
15 in. Pry Bar
Diagonal Side Cutter
1-1/4 in. Putty Knife
Center Punch/Scratch
100 Grit Sandpaper (5) pcs.
Black Permanent Marker
2 lb. Hammer
Breathing Mask
Rasp File (Flat/Half Round)
Assortment of Cable Clamps (15)
Screws for Cable Clamps (15)
Pilot Drill 4/Cable Clamp Screws 3/32 in.
8 in. Cable Ties (15)
Horseshoe Magnet
Tools Recommended for Installation

600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE 6
Tools for 30-264 and 30-272
Rubber Coupling Drive Shaft (if applicable)
Tools Recommended for Installation (continued)
TO-066 Adapter, Torque Wrench 22 mm
TO-067 Adapter, Torque Wrench 7/8 in.
TO-068 Adapter, Torque Wrench 3/8 in.
GO-017, Dial Indicator with Magnetic Stand

600 SERIES INSTALLATION MANUALSEPTEMBER 2011 - V1.0 PAGE 7
Listed below are the torque specifications for selected fasteners. Additional torque specifications are listed
throughout this manual.
Torque Specifications for Selected Fasteners
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)
Power Trim Cylinder to Anchor Pin, Nuts (4)
Tighten until approx.
two (2) threads show.
Do not over tighten.
Lifting Bracket Top Cover Button Head Cap Screws (6) 20 lb. ft. (27 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. (109 Nm)
660 Forward Propeller Nut (1) 150 lb. ft. (203 Nm)
660 Aft Propeller Nut (1) 60 lb. ft. (81 Nm)
680 Forward Propeller Nut (1) 150 lb. ft. (203 Nm)
680 Aft Propeller Nut (1) 80 lb. ft. (109 Nm)

600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE 8
1) Ensure that the propeller height is performed
according to guidelines detailed in diagrams
12-835 (Figures A and B on pages 9 and 10 in
this manual). The height of the propeller(s)
is (are) critical to a successful application. If
the propeller centerline is too low, excessive
drag can occur based on transom assembly
location. Intermediate spacers are available
for special concerns.
2) Ensure that the water flow to the propeller
is clear and consistent without interruptions.
Protrusions on the hull surface create a neg-
ative pressure area and induce turbulence.
Turbulence can cause severe propeller inef-
ficiency and excessive torsional vibration.
There are to be no such protrusions within 2
meters forward of the propeller(s).
Common problems are:
• Water pickup
• Sonar transducers
• Retrofitted 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
Installation Guidelines
3) Ensure that the vessel center of gravity is
properly placed. Excessive weight forward
or aft can significantly affect performance
and the efficiency of the propeller.
4) Ensure that the stern drive is trimmed to
the correct level. While undertrimming can
cause premature u-joint wear, overtrimming
can cause propeller inefficiency, porpoising,
and premature gear wear.

600 SERIES INSTALLATION MANUALSEPTEMBER 2011 - V1.0 PAGE 9
Note: Drawing not to scale.
FIGURE A: 600 Series CUTOUT TEMPLATE
Note: Drawing not to scale.

600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE 10
FIGURE B: 600 Series X-DIMENSION GUIDELINES
Note: Drawing not to scale.

600 SERIES INSTALLATION MANUALSEPTEMBER 2011 - V1.0 PAGE 11
A
B
C D
1.1 Scribe an arc from points A and B to the bottom center of
the transom exterior. Scribe an arc from points C and D to
the top center of the transom exterior. Where the previous
mentioned arcs intersect, scribe a vertical line approxi-
mately 28 in. (71 cm) long. This will represent the center
line of the stern drive.
NOTE: For twin application, measure (to
the port and starboard) off the vessel verti-
cal center line over to the engine crank shaft
center line and scribe a vertical center line
parallel to the vessel vertical center line. See
the lower drawing of Figure B on page 10 in
this manual for explanation.
1.2 After establishing the x-dimension (see Figure B on page
10 in this manual), scribe a horizontal line at least 18 in.
(46 cm) long, perpendicular and centered on the existing
vertical line (scribed in Step 1.1).
NOTE: Specifi c characteristics of an installation may
change the recommended vertical drive position. Please
contact Konrad with any specifi c concerns.
ATTENTION: If you are installing the Konrad
“Rear Mount / Tail Piece” assembly, please go
to step 19 (page 75 - 77) in this manual.
Step 1: Transom Cutout
FIGURE 1B
FIGURE 1A

600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE 12
1.3 Place the cutout template (10-455) on the exterior of the
transom and position it so the scribed horizontal and ver-
tical match up with the scribed center lines on the tem-
plate.
1.4 Trace the cut out area and the eight (8) holes. Remove the
template.
1.5 Center punch the eight (8) holes traced in Step 1.4. Drill
the eight (8) holes through the transom using a 5/8 in. (16
mm) drill bit.
NOTE: Holes must be drilled perpendicular to the tran-
som face.
1.6 Using a reciprocating saw, cut out the area traced in Step
1.4. Use a file or rasp to touch up the cutout area.
NOTE: Cut must be made perpendicular to transom
face.
NOTE: For fiberglass transoms, it is recommended that
fiberglass epoxy resin be applied to the cut areas. Verify
that cutout area is correctly sized and shaped before
applying epoxy. Allow proper drying/setup time for epoxy
to cure.
Step 1: Transom Cutout (continued)
FIGURE 1C
FIGURE 1E
FIGURE 1D

600 SERIES INSTALLATION MANUALSEPTEMBER 2011 - V1.0 PAGE 13
2.1 Grease the transom assembly gasket with marine grade
grease (see Figure 2A).
NOTE: If the gimbal carrier assembly is not mounted
in the gimbal housing bore, it should be done at this time
(see Figure 2B).
NOTE: The gimbal carrier flange may differ from the
one pictured in Figure 2B per application.
1) Lightly grease the carrier assembly and o-ring,
then slide it into the gimbal housing bore.
2) Rotate the carrier assembly to achieve correct
orientation. The brass nipple should be at
approximately two o’clock.
3) Torque the three (3) fasteners to 70 lb. ft. (95 Nm).
NOTE: The gimbal carrier flange may differ from the
one pictured in Figure 2B per application.
2.2 Guide the transom assembly studs through the eight (8)
holes in the transom.
NOTE: The weight of the transom assembly is 67 lbs.
(30.4 kg). Use caution when lifting.
NOTE: Some installations/applications require an ex-
ternal adapter plate.
NOTE: Proper stud length varies due to hull thickness.
Stud length is also dictated by peripheral equipment that
mounts inside the hull (steering cylinder bracket, inner
transom plate, drive shaft shroud, etc.). Verify correct
stud length before continuing past this step.
Step 2: Transom Assembly Installation
FIGURE 2B
FIGURE 2C
FIGURE 2A

600 SERIES INSTALLATION MANUAL SEPTEMBER 2011 - V1.0PAGE 14
2.3 Place the inner transom backing plate (10-357) over the
eight (8) studs from the inside of the vessel.
NOTE: If an internal steering cylinder is going to be
used, the bracket can be mounted on the upper one (1) or
two (2) sets of horizontal studs depending on the steering
cylinder style used.
NOTE: The inner transom plate may require modification
or elimination depending on steering cylinder assembly
used.
NOTE: If an inner transom backing plate is not used, the
round washers (10-415) must be replaced with rectangular
washers (10-941).
2.4 Secure the transom assembly to the transom by using
eight (8) nylock nuts (10-334) and eight (8) flat washers
(10-415). Torque to 25-30 lb. ft. (34-41 Nm).
NOTE: Place inner transom backing plate continuity
cable between the washer and nylock nut of either of
the top two transom assembly studs before tightening (if
applicable).
NOTE: Connect the tiller arm continuity cable to the
inner transom backing plate by using the small phillips
head screw (if applicable).
NOTE: The two (2) oil lines in this photo will be ran and
attached in a later step.
Step 2: Transom Assembly Installation (continued)
FIGURE 2D
FIGURE 2E