KONRAD 620B Installation Manual Download

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KONRAD 600B SERIES INSTALLATION GUIDE

JANUARY 2019 - V4.0

PAGE 54

FWD

PORT

STAR.

A/L

B/R

GEROTOR (HELM) UNIT

LOCK VALVE

PLEASE CORRESPOND YOUR LENGTHS TO THE NUMBERS ON THE DIAGRAM

AFT

ELBOW ADAPTERS (2)

BOTTOM THRU FITTING ON TRANSOM ASSEMBLY

TOP THRU FITTING ON TRANSOM ASSEMBLY

STEERING CYLINDER

FITTING OUT AT ANGLE

FITTING OUT OF TOP

TOP THRU FITTING ON TRANSOM ASSEMBLY

BOTTOM THRU FITTING ON TRANSOM ASSEMBLY

STEERING CYLINDER

FITTING OUT AT ANGLE

TEE FITTINGS (2)

JUMPER HOSES (2)

PTO PUMP

COOLER

ENGINE

B/R-RIGHT (STARBOARD) CYLINDER LINE

A/L-LEFT (PORT) CYLINDER LINE

P-HIGH PRESSURE PUMP

T-LOW PRESSURE RETURN

SIDE VIEW OF HELM UNIT & PORTS

A/L

B/R

TOP

BOTTOM

CUMMINS TO PROVIDE PTO PARTS: 4931665-QTY. 1-ADAPTER 3900637-QTY. 2-SCREW 4896897-QTY. 1-GASKET

KONRAD TO PROVIDE GEAR PUMP.

KONRAD RESERVOIR

KONRAD TO PROVIDE OIL COOLER. BUILDER/END USER TO INCORPORATE COOLER INLINE WITH 2" I.D. COOLING LINES ON ENGINE.

FITTING OUT OF TOP

31-074R

DRAWING NO.

NEXT ASS'Y

DRAWING NUMBER

Konrad

.020

.XX

.010

.XXX

.005

DRAWN BY: SC

APP.BY:

SCALE:

ROUTING DIAGRAM

31-074R

MAT'L:

TOLERANCE

TITLE:

DATE:

WEIGHT:

9/9/15

1:1

DATE

SYM

REVISION

DO NOT SCALE DRAWING

THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN IS CONFIDENTIAL AND PROPRIETARY PROPERTY AND MUST NOT BE USED, REPRODUCED, OR ITS CONTENT DISCLOSED, IN WHOLE OR IN PART, WITHOUT PRIOR WRITTEN CONSENT OF KONRAD MARINE.

Steering System Routing Diagram 31-074R (single drive)

Summary of Contents for 620B

Page 1: ...STALLATION GUIDE Models 620B 660B 680B Remote and Direct Mount Version 4 0 KONRAD MARINE INC 1421 HANLEY ROAD HUDSON WI 54016 9376 USA Phone 715 386 4203 Toll Free 1 800 927 3545 Fax 715 386 4219 www konradmarine com ...

Page 2: ...ed 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 occ...

Page 3: ...ON Version 4 0 Part 13 648 Core Content Originated by Randall J Sofie 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 715 386 4203 Toll Free 1 800 927 3545 Fax 715 386 4219 www konradmarine com ...

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

Page 5: ... 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...

Page 6: ...ngine 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 preca...

Page 7: ...rea and induce turbulence Turbulence can cause severe propeller inefficiency 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 Retrofitted surfaces which are not properly faired or smoothed Any hull shape which does not provide smooth transition In heavy applications...

Page 8: ...IES INSTALLATION GUIDE JANUARY 2019 V4 0 PAGE 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 ...

Page 9: ...KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 V4 0 PAGE 9 Figure B 600B Series X Dimension Guidlines ...

Page 10: ...3 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...

Page 11: ...4 liters Make sure the drive is completely filled 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 own...

Page 12: ... by sliding the inner transom straps 13 675 round flat 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 Tigh...

Page 13: ...et 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 w...

Page 14: ...e flat surface on the top of the gimbal housing Slide the gauge towards the back of the tailpiece until it is flush with the tailpiece Adjust the engine mounts until the gauge slides over the alignment shaft while sitting flush against the tailpiece housing and the top of the gauge is up against the flat on the upper portion of the gimbal housing 2 8 When the correct alignment is made the alignmen...

Page 15: ...he 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 Careful...

Page 16: ...r 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 w...

Page 17: ...10 into top cap 13 421 3 14 Remove cap 13 012 from fitting 11 702 Place blue Loctite on oil vent hose fitting 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 flat washers and hand tighten Install two 2 M6 X 18mm S H C S 13 696 into the forward upper side ...

Page 18: ...anifold 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 fittings 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 fittings on the trim manifold As seen in image to the right NOTE Apply blue Loctite to all the hose fittings on final install 4 4 Moun...

Page 19: ...t 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 ...

Page 20: ...arts 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 fitting side of hose Remote Mount application only route other end of the hose to one side of the brass T fitting 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...

Page 21: ...n a 1qt 946 L bottle 13 090 or 2 5 gallon 9 46 L bottle 13 091 6 7 Apply blue Loctite to the center fitting on the transom assembly Install oil supply hose with the adapter fitting onto transom fitting and tighten Route other end of hose to the final location on the T fitting NOTE Oil hose should be cut to length for easiest downward flow to both the drive and the gimbal carrier 6 6 Connect the op...

Page 22: ...ould be mounted in an accessible and logical position away from bilge fluid contact It must also be labeled clearly Wiring from the batteries to the trim pump must meet the specifications listed in the chart below Length 12 Volt 24 Volt 0 30 Feet 0 9 1 Meters 4 AWG 25 mm2 6 AWG 16 mm2 NOTE Battery or batteries must be disconnected while all electrical connections are being made or serviced NOTE Re...

Page 23: ...g three 3 H H C S and lock washers Remove the top portion of the trim pump assembly bracket 7 3 Attach the positive trim pump power feed from the fuse or breaker unit to one of the solenoid bolts on the link bar side NOTE coat terminal with corrosion protectant 7 4 Attach the negative power feed to the trim pump ground bolt NOTE coat terminal with corrosion protectant Step 7 Trim Control Wiring In...

Page 24: ...ump assembly bracket and con nect them to the appropriate terminals of the 6 position horizontal terminal strip NOTE The black wires are routed to terminal 2 The yellow wire for the trim is routed to terminal 4 The yellow wire for the rudder is routed to terminal 3 The red wires are routed to terminal 5 NOTE Numbering for the terminals starts on the left side with number 1 and goes to the right NO...

Page 25: ...incides with orientation 7 11 Connect the appropriate wire harness connector to the trim control module 7 12 Connect the large wire harness connector from trim control module to the large connector at the trim pump 7 13 Connect the small three pin connector at the trim pump with the one from the wire harness 7 14 Route wire harness to helm area to the mount ing location of the trim gauge Wire the ...

Page 26: ...KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 V4 0 PAGE 26 Single Drive Single Helm Step 7 Trim Control Wiring Installation continued ...

Page 27: ...3 457 B A B A C C B A B A C C B A C C B A C B A C B A C C B A C B A C B A NOTE CONDUCTORS WIRES NOT SUPPLIED BY KONRAD MARINE BK BK BK K M P N 10 528 4 POSITION TERMINAL STRIP K M P N 11 070 6 POSITION TERMINAL STRIP K M P N 11 069 BK 4 4 3 3 2 2 1 1 6 5 4 3 2 1 6 5 4 3 2 1 RD BK BK RD K M P N 11 065 K M P N 13 438 MOMENTARY ON OFF ON TOGGLE SWITCH TRIM OVER RIDE YL PR PK RD RD BK BK RD BK GR TN B...

Page 28: ...13 457 B A B A C C B A B A C C B A C C B A C B A C B A C C B A C B A C B A NOTE CONDUCTORS WIRES NOT SUPPLIED BY KONRAD MARINE BK BK BK K M P N 10 691 4 POSITION TERMINAL STRIP K M P N 11 070 6 POSITION TERMINAL STRIP K M P N 11 069 BK 4 4 3 3 2 2 1 1 6 5 4 3 2 1 6 5 4 3 2 1 RD BK BK RD K M P N 11 065 K M P N 13 438 MOMENTARY ON OFF ON TOGGLE SWITCH TRIM OVER RIDE YL PR PK RD RD BK BK RD BK GR TN ...

Page 29: ...KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 V4 0 PAGE 29 Single Drive Dual Helm Step 7 Trim Control Wiring Installation continued ...

Page 30: ...CONDARY K M P N 13 679 18 13 7 12 6 1 18 17 16 15 C A B C A B A C B A B C A B C C B A 3 HARNESS K M P N 31 054 HOT POSITIVE 8 32VDC NEGATIVE GROUND THROTTLE TRIM 3 DN THROTTLE TRIM 2 DN THROTTLE TRIM 3 UP THROTTLE TRIM 2 UP WT TN GY GR THROTTLE TRIM 3 DN THROTTLE TRIM 3 UP THROTTLE TRIM 2 DN THROTTLE TRIM 2 UP GR GY TN WT NOTES FOR HARNESS K M P N 31 054 1 ALL WIRES ARE PIGTAILED AND TO BE ROUTED ...

Page 31: ...M P N 13 679 18 13 7 12 6 1 18 17 16 15 C A B C A B A C B A B C A B C C B A 3 HARNESS K M P N 31 054 HOT POSITIVE 8 32VDC NEGATIVE GROUND THROTTLE TRIM 3 DN THROTTLE TRIM 2 DN THROTTLE TRIM 3 UP THROTTLE TRIM 2 UP WT TN GY GR THROTTLE TRIM 3 DN THROTTLE TRIM 3 UP THROTTLE TRIM 2 DN THROTTLE TRIM 2 UP GR GY TN WT NOTES FOR HARNESS K M P N 31 054 1 ALL WIRES ARE PIGTAILED AND TO BE ROUTED CONNECTED ...

Page 32: ...KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 V4 0 PAGE 32 Twin Drives Single Helm Step 7 Trim Control Wiring Installation continued ...

Page 33: ... 1M K M P N 31 059 40 12 2M K M P N 31 060 C A A A B B B B B A A A B OR BK HARNESS K M P N 31 051 B A B A C C B A B A C C B A C C B A C B A C B A C B A C B A B A C B A NOTE CONDUCTORS WIRES NOT SUPPLIED BY KONRAD MARINE BK BK BK K M P N 10 528 4 POSITION TERMINAL STRIP K M P N 11 070 6 POSITION TERMINAL STRIP K M P N 11 069 BK 4 4 3 3 2 2 1 1 6 5 4 3 2 1 6 5 4 3 2 1 RD BK K M P N 11 065 K M P N 13...

Page 34: ... 1M K M P N 31 059 40 12 2M K M P N 31 060 C A A A B B B B B A A A B OR BK HARNESS K M P N 31 051 B A B A C C B A B A C C B A C C B A C B A C B A C B A C B A B A C B A NOTE CONDUCTORS WIRES NOT SUPPLIED BY KONRAD MARINE BK BK BK K M P N 10 691 4 POSITION TERMINAL STRIP K M P N 11 070 6 POSITION TERMINAL STRIP K M P N 11 069 BK 4 4 3 3 2 2 1 1 6 5 4 3 2 1 6 5 4 3 2 1 RD BK K M P N 11 065 K M P N 13...

Page 35: ...KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 V4 0 PAGE 35 Twin Drives Dual Helm Step 7 Trim Control Wiring Installation continued ...

Page 36: ... 40 12 2M K M P N 31 060 CONNECTING HARNESS 6 1 8M K M P N 31 061 10 3M K M P N 31 057 14 4 3M K M P N 31 062 CONNECTING HARNESS FROM TRIM PUMP 2 MODULE 2 13 697 KEYSWICH PANEL ILLUMINATION THROTTLE TRIM 1 UP THROTTLE TRIM 1 DN THROTTLE TRIM 2 UP THROTTLE TRIM 2 DN HOT POSITIVE 8 32VDC C C C C C C RD BK RD BK A B C C B A C B A B C A B A C B A C 22 21 19 20 THROTTLE TRIM 2 UP THROTTLE TRIM 1 DN THR...

Page 37: ...40 12 2M K M P N 31 060 CONNECTING HARNESS 6 1 8M K M P N 31 061 10 3M K M P N 31 057 14 4 3M K M P N 31 062 CONNECTING HARNESS FROM TRIM PUMP 2 MODULE 2 13 697 KEYSWICH PANEL ILLUMINATION THROTTLE TRIM 1 UP THROTTLE TRIM 1 DN THROTTLE TRIM 2 UP THROTTLE TRIM 2 DN HOT POSITIVE 8 32VDC C C C C C C RD BK RD BK A B C C B A C B A B C A B A C B A C 22 21 19 20 THROTTLE TRIM 2 UP THROTTLE TRIM 1 DN THRO...

Page 38: ...KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 V4 0 PAGE 38 Triple Drives Single Helm Step 7 Trim Control Wiring Installation continued ...

Page 39: ...1 057 20 6 1M K M P N 31 058 30 9 1M K M P N 31 059 40 12 2M K M P N 31 060 CONNECTING HARNESS 6 1 8M K M P N 31 061 10 3M K M P N 31 057 14 4 3M K M P N 31 062 1 2 4 5 6 7 8 9 12 10 28 27 25 26 24 23 21 22 19 20 K M P N 10 528 POWER RELAY DN K M P N 10 430 THROTTLE TRIM 3 UP B 18 17 16 15 C A B C A B A C B A B C A B C C B A B A C 3 CONNECTING HARNESS FROM TRIM PUMP 2 MODULE 2 13 697 CONNECTING HA...

Page 40: ... 057 20 6 1M K M P N 31 058 30 9 1M K M P N 31 059 40 12 2M K M P N 31 060 CONNECTING HARNESS 6 1 8M K M P N 31 061 10 3M K M P N 31 057 14 4 3M K M P N 31 062 1 2 4 5 6 7 8 9 12 10 28 27 25 26 24 23 21 22 19 20 K M P N 10 691 POWER RELAY DN K M P N 10 690 THROTTLE TRIM 3 UP B 18 17 16 15 C A B C A B A C B A B C A B C C B A B A C 3 CONNECTING HARNESS FROM TRIM PUMP 2 MODULE 2 13 697 CONNECTING HAR...

Page 41: ...KONRAD 600B SERIES INSTALLATION GUIDE JANUARY 2019 V4 0 PAGE 41 Triple Drives Dual Helm Step 7 Trim Control Wiring Installation continued ...

Page 42: ...NNECTING HARNESS 6 1 8M K M P N 31 061 10 3M K M P N 31 057 14 4 3M K M P N 31 062 CONNECTING HARNESS K M P N 31 108 THROTTLE TRIM 2 UP THROTTLE TRIM 3 UP 32 31 YL PR OR PK WT TN GY BK RD 18 12 6 13 7 1 1 7 13 18 12 6 THROTTLE TRIM 1 DN THROTTLE TRIM 1 UP PANEL ILLUMINATION KEYSWITCH HOT POSITIVE 8 32VDC NEGATIVE GROUND THROTTLE TRIM 3 DN THROTTLE TRIM 2 DN DIGITAL DISPLAY K M P N 13 544 30 29 HOT...

Page 43: ...NNECTING HARNESS 6 1 8M K M P N 31 061 10 3M K M P N 31 057 14 4 3M K M P N 31 062 CONNECTING HARNESS K M P N 31 108 THROTTLE TRIM 2 UP THROTTLE TRIM 3 UP 32 31 YL PR OR PK WT TN GY BK RD 18 12 6 13 7 1 1 7 13 18 12 6 THROTTLE TRIM 1 DN THROTTLE TRIM 1 UP PANEL ILLUMINATION KEYSWITCH HOT POSITIVE 8 32VDC NEGATIVE GROUND THROTTLE TRIM 3 DN THROTTLE TRIM 2 DN DIGITAL DISPLAY K M P N 13 544 30 29 HOT...

Page 44: ... III is not used it is recom mended that the trim cylinders be purged of any fluid since they are shipped new from Konrad with this fluid in them 8 2 Remove the down line hose from the trim pump and place in a container to catch any purged fluid The up line should already be attached from Trim Pump Installation earlier in this manual Hold one finger over the down line port of the trim pump to prev...

Page 45: ...r bottle goes below the minimum level 8 5 Cycle the drive all the way to the down posi tion and then all the way to the up position Repeat this step three to four 3 4 times to purge any remaining air out of the system NOTE Re check the fluid level of the reservoir Add fluid if necessary NOTE Check the entire trim system inboard and outboard the transom for leaks before proceeding 8 4 With the driv...

Page 46: ...nit 9 3 Once the trim control unit is installed in the desired location the wire harness pigtail for the trim control can be connected to power and the unit cali brated NOTE Battery or batteries must be disconnected while all electrical connections are being made NOTE See Trim System Electrical Drawing for your specific vessel configuration 9 4 Secure any loose and excess wire harness 9 5 Once pow...

Page 47: ...r arrow key to adjust the number of drives 1 3 and press the enter key when the correct number is shown in the square box 9 9 The Module Configuration screen will be set up from the factory Do Not Attempt to Program Location of the modules are critical since they are pro gramed to a specific drive location on the vessel 9 10 The Calibration screen is where the drives trim and rudder position is se...

Page 48: ...g as shown to the right This distance should be 8 684 inches or 220 57 mm 9 11 Once the trim and rudder calibration has been set the home screen will show both The trim loca tion is on top and the rudder location is below on the bottom The picture to the right is what a single drive with the default screen will look like To access the alternate display press the down arrow on the directional butto...

Page 49: ...Is displayed under the trim read out when there is a problem with the trim sensor Common issues are Damaged sensor or wiring Loose wires at the trim pump Lost connection to the sensor NOTE This warning is only displayed on the stan dard screen shown in the picture to the right The optional screen display will not show this warning RS Fail Is displayed under the trim read out when there is a proble...

Page 50: ...the trim gauge will change over to a red oil warning light and an image of an oil bottle will appear Check the oil level in the drive and reservoir then refill the oil to the appropriate level to avoid serious damage to the drive unit Step 9 Trim Gauge Installation and Programming continued To change the display to the optional one shown in the picture to the right press the directional key pad do...

Page 51: ... How many drives will be used How is the vessel used Does the vessel turn frequently such as in a river What type of drives are used twin prop or single Will there be multiple helm stations What engines are being used and do they offer a power steering pump option The following pages will contain examples and routing diagrams of our most popular steering systems avail able for the 600B series driv...

Page 52: ... E R FITTING OUT OF BOTTOM FITTING OUT AT ANGLE R L P T BOTTOM VIEW OF HELM UNIT PORTS ELECTRIC POWER STEERING PUMP 31 031R DRAWING NO NEXT ASS Y DRAWING NUMBER Konrad X 020 XX 010 XXX 005 DRAWN BY SC APP BY SCALE ROUTING DIAGRAM 31 031R MAT L TOLERANCE TITLE DATE WEIGHT 10 9 15 1 1 DATE SYM REVISION DR DO NOT SCALE DRAWING C COPYRIGHT 2004 KONRAD MARINE ALL RIGHTS RESERVED THIS DOCUMENT AND THE I...

Page 53: ... ON TRANSOM ASSEMBLY FITTING OUT OF TOP FITTING OUT AT ANGLE STEERING CYLINDER TOP THRU FITTING ON TRANSOM ASSEMBLY BOTTOM THRU FITTING ON TRANSOM ASSEMBLY ELBOW ADAPTERS 2 8 7 AFT STAR PORT 31 031R DRAWING NO NEXT ASS Y DRAWING NUMBER Konrad X 020 XX 010 XXX 005 DRAWN BY SC APP BY SCALE ROUTING DIAGRAM 31 031R MAT L TOLERANCE TITLE DATE WEIGHT 10 5 15 1 1 DATE SYM REVISION DR DO NOT SCALE DRAWING...

Page 54: ... SIDE VIEW OF HELM UNIT PORTS T A L P B R TOP BOTTOM CUMMINS TO PROVIDE PTO PARTS 4931665 QTY 1 ADAPTER 3900637 QTY 2 SCREW 4896897 QTY 1 GASKET KONRAD TO PROVIDE GEAR PUMP 9 10 KONRAD RESERVOIR KONRAD TO PROVIDE OIL COOLER BUILDER END USER TO INCORPORATE COOLER INLINE WITH 2 I D COOLING LINES ON ENGINE FITTING OUT OF TOP 31 074R DRAWING NO NEXT ASS Y DRAWING NUMBER Konrad X 020 XX 010 XXX 005 DRA...

Page 55: ...W PRESSURE RETURN SIDE VIEW OF HELM UNIT PORTS T A L P B R TOP BOTTOM ENGINE 2 9 10 KONRAD RESERVOIR KONRAD TO PROVIDE OIL COOLER BUILDER END USER TO INCORPORATE COOLER INLINE WITH 2 I D COOLING LINES ON ENGINE CUMMINS TO PROVIDE PTO PARTS 4931665 QTY 1 ADAPTER 3900637 QTY 2 SCREW 4896897 QTY 1 GASKET KONRAD TO PROVIDE GEAR PUMP 31 074R DRAWING NO NEXT ASS Y DRAWING NUMBER Konrad X 020 XX 010 XXX ...

Page 56: ...TTING ON TRANSOM ASSEMBLY BOTTOM THRU FITTING ON TRANSOM ASSEMBLY STAR PORT DRAWING NO NEXT ASS Y DRAWING NUMBER Konrad X 020 XX 010 XXX 005 DRAWN BY SC APP BY SCALE ROUTING DIAGRAM MAT L TOLERANCE TITLE DATE WEIGHT 10 5 15 1 1 DATE SYM REVISION DR DO NOT SCALE DRAWING C COPYRIGHT 2004 KONRAD MARINE ALL RIGHTS RESERVED THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN IS CONFIDENTIAL AND PROPRIET...

Page 57: ...SEMBLY BOTTOM THRU FITTING ON TRANSOM ASSEMBLY STAR PORT POWER ASSIST UNIT R C2 C1 H2 H1 3 4 6 DRAWING NO NEXT ASS Y DRAWING NUMBER Konrad X 020 XX 010 XXX 005 DRAWN BY SC APP BY SCALE ROUTING DIAGRAM MAT L TOLERANCE TITLE DATE WEIGHT 10 6 15 1 1 DATE SYM REVISION DR DO NOT SCALE DRAWING C COPYRIGHT 2004 KONRAD MARINE ALL RIGHTS RESERVED THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN IS CONFID...

Page 58: ... A L T SIDE VIEW OF HELM UNIT PORTS B R RIGHT STARBOARD CYLINDER LINE P HIGH PRESSURE PUMP A L LEFT PORT CYLINDER LINE T LOW PRESSURE RETURN CUSTOMER TO PROVIDE PUMP RESERVOIR AND COOLER ON ENGINE W CONNECTING HOSES 31 080R DRAWING NO NEXT ASS Y DRAWING NUMBER Konrad X 020 XX 010 XXX 005 DRAWN BY SC APP BY SCALE ROUTING DIAGRAM 31 080R MAT L TOLERANCE TITLE DATE WEIGHT 10 6 15 1 1 DATE SYM REVISIO...

Page 59: ...RU FITTING ON TRANSOM ASSEMBLY ELBOW ADAPTERS 2 8 7 AFT STAR PORT T LOW PRESSURE RETURN A L LEFT PORT CYLINDER LINE P HIGH PRESSURE PUMP B R RIGHT STARBOARD CYLINDER LINE SIDE VIEW OF HELM UNIT PORTS T A L P B R TOP BOTTOM 31 080R DRAWING NO NEXT ASS Y DRAWING NUMBER Konrad X 020 XX 010 XXX 005 DRAWN BY SC APP BY SCALE ROUTING DIAGRAM 31 080R MAT L TOLERANCE TITLE DATE WEIGHT 10 6 15 1 1 DATE SYM ...

Page 60: ...We suggest using tool TO 186 to bolt onto the flange faces of the transmission and the gimbal housing to make measuring the distances easier If aligning without Konrad tool TO 186 then skip ahead to the NOTES and alignment specifications chart 2 Place one of the alignment sticks onto the gimbal flange with the beveled edge facing away from the gimbal flange and fasten using two 13 625 H H C S 3 Ta...

Page 61: ...between points A B and C D are within 030 inches or 762mm of each other See alignment specifications chart in the following pages 6 Rotate the flanges until the sticks are horizontal and remeasure points A B C D A D and C B Adjust the engine mounts until the measured distances between the points A B and C D is within 030 inches or 762 mm of each other Step 11 Drive Shaft Alignment Procedures conti...

Page 62: ...vertical offset see picture below x x tan a y 3 0 in or x x tan a y 7 62 cm 4 Fix magnetic base arm and dial indicator assembly GO 017 to transmission output flange 5 Rotate transmission flange indicating the face of the alignment flange All facial measurements must be within 010 in 25 mm 6 Rotate transmission flange indicating the circumference of the alignment flange All measurements must be wit...

Page 63: ...ut flange and gimbal car rier input flange must be concentric within the manufacturer s recommended specifications 2 Fix magnetic base arm and dial indicator assembly GO 017 to transmission output flange 3 Rotate transmission flange indicating the face of the alignment flange All facial measurements must be within manufacturer s requirements 4 Rotate transmission flange indicating the circumferenc...

Page 64: ...pe Direct Rear Mount Tailpiece 30 998 Fixed Close Couple N A N A Fixed N A TO 189 N A N A Tail Piece Coaxial N A Constant Velocity CV 31 044 9 5 55 in 25 4 140 cm Max 2 Max Offset 2 0625 in 1 59 mm N A GO 017 TO 186 TO 187 85 lbs ft 115 Nm Yes Output Flange 30 999 U Joint Carden 13 430 9 60 in 23 152 cm 030 in 762 mm Compound Offset between 5 x 1 1 in 25 4 mm Yoke Orientation GO 017 TO 186 TO 187 ...

Page 65: ... procedure from Step 11 in this manual before proceeding 12 2 If applicable bolt transmission output flange adapter on to the transmission output flange Apply Loctite to the fasteners before tightening Torque fasteners correctly according to their size 12 3 Bolt u joint shaft onto gimbal carrier flange Apply Loctite to the four 4 fasteners before tightening Torque to 89 lb ft 121 Nm NOTE Ensure pi...

Page 66: ... Apply Loctite to the four 4 fasteners before tightening Torque to 89 lb ft 121 Nm NOTE Ensure pilot is correctly sized and fully engaged if applicable NOTE Ensure that the shaft is installed within the working limitations of the slip compensating spline 12 5 Grease u joints and extension joint before operation of the shaft occurs Step 12 U Joint Extension Shaft Installation continued ...

Page 67: ...cifications Chart previously in this manual and the alignment procedure from Step 11 in this manual before proceeding 13 2 Connect CV adapter flange to gimbal carrier flange Apply Loctite to threads of fasteners Torque fasteners to 85 lb ft 115 Nm 13 3 Connect CV adapter flange to transmission output flange Apply Loctite to threads of fasteners Torque fasteners correctly according to their size ...

Page 68: ...ange on the transmission using the six 6 S H C S and the three 3 2 hole washer plates provided Repeat this for the gimbal carrier flange Apply Loctite to the threads of the fasteners and torque to 85 lb ft 115 Nm NOTE In some cases only four 4 of the six 6 fasteners can be installed Inspect adapter flanges prior to shaft installation In this case insert a plastic plug provided with shaft hardware ...

Page 69: ...nut using a 1 7 16 socket tool to 80 lb ft 109 Nm When approaching 80 lb ft 109 Nm make sure that the tabs on the tabbed retaining washer at least 2 out of 6 line up with the grooves in the splined washer hub NOTE A block of wood can be placed between the propeller and the lower drive housing to prevent the propeller from spinning while torquing the propeller nut 14 5a Bend over the tabs using app...

Page 70: ...100 lb ft 136 Nm using hex wrench TO 121 14 5b Slide aft thrust hub onto aft prop shaft so the tapers meet Some grease can be used on tapers to hold in place 14 6b Grease splined area and the threads of the aft propeller shaft 14 7b Place the aft propeller on the propeller shaft until it seats against thrust hub 14 8b Torque the aft propeller nut to 60 lb ft 81 Nm using 17 16 socket wrench Descrip...

Page 71: ...ard thrust hub onto forward prop shaft so the tapers meet Some grease can be used on tapers to hold in place 14 2c Grease splined area and the threads of the forward propeller shaft 14 3c Place the forward propeller on the propeller shaft until it seats against thrust hub 14 4c Torque the forward propeller nut to 100 lb ft 136 Nm using hex wrench TO 129 Step 14 c 680B Propeller Installation Descri...

Page 72: ... cable from transom stud to engine or transmission Also check for continuity from prop shaft of sterndrive to the gimbal assembly gimbal housing trim cylinder and steering cylinder Steering A Confirm proper fluid level B Verify proper bleeding procedure was done C Check all hose routing and connection points for leaks D Verify of turns lock to lock E Verify correct rudder indicator position when c...

Page 73: ...lines for any leaks at connection points and also proper routing of hoses Confirm proper orientation of bellows and check for secure connection on drive and gimbal assembly Tighten hose clamps Check for continuity from prop shaft of sterndrive all the way to the gimbal assembly including the gimbal housing trim cylinders and steering cylinders Check stern drive for side to side play The movement s...

Page 74: ...US Light on module should blink rapidly when operating properly If the light blinks at a slow rate about every 3 seconds check to ensure that no CAN lines are disconnected Displays Primary 13 544 Secondary 13 679 only used in dual helm applications Part numbers are scribed on back of displays Receives CAN messages from Module Secondary display does not have any internal memory and gets it s signal...

Page 75: ...s referred to as J1939 twisted pair or distributed system Each CAN line is made up of a backbone trunk Y connectors and differential twisted pair wires leading from the Y connector to the module Backbone Trunk The backbone of a CAN line runs from one terminating resistor to the other terminating resistor linking all modules together creating a path of communication throughout the entire boat Y Con...

Page 76: ... continued Each Y Connector is connected together creating the backbone of the CAN line The X or backbone connection wire will have a blue colored female triangular wedge lock Y Connector continued Each Y Connector has a rounded post connection point for all modules used on the truck The O or module connection wire will have an orange colored female round wedge lock Backbone Wire The backbone wire...

Page 77: ...re displayed under the digital trim angle readout on the standard screen only Closs Communication error between the module and display once in operation RS Fail Rudder sensor signal failure TS Fail Trim sensor signal failure Dual Displays Secondary display 13 679 screen turns all blue in color and reads Communication loss with control module Make sure that the primary display is turned on If the p...

Page 78: ...en both terminating resistors have been located follow the steps outlined below to check each terminating resistor for the proper ohms value 2 Remove the terminating resistor from the Y connector Resistors 3 Remove the blue wedge lock from the resistor using a screw driver or pick Using an ohm meter measure across the two pins of the resistor A good terminating resistor will have readings of 119 6...

Page 79: ...emeasure the ohms in the CAN line If the reading is 119 to 120 ohms then the line is broken ahead of the point where the terminat ing resistor is placed repeat step 4 6 If the measured reading is 59 9 or 60 ohms the break in the CAN line is in the part of the can line that was unplugged X X 7 Once the area of the brake is identified measure each wire through the connectors Measure pin A to pin A a...

Page 80: ... for the sensor that you are checking The trim sensor will be in position 4 and the rudder sensor will be in position 3 A voltage reading of 0 is bad Voltages should be between 1 and 5 2 When testing voltages if the voltages jump instead of showing an even smooth change It is possible that the sen sor shaft is out of position This is especially common when the drive has been recently removed or a ...

Page 81: ...NNEL AND OR CARGO WEIGHT VESSEL TOTAL RUNNING WEIGHT PROP MFG NUMBER OF BLADES DIAMETER PITCH PROP MATERIAL AL or SS 1 2 3 4 5 6 7 8 Please circle the unit of measure KG or LBS you are using for entries with weights KONRAD APPLICATION TRIAL DATA FORM CONDITION DESCRIPTIONS DEALER or DISTRIBUTOR COMPANY NAME DEALER or DISTRIBUTOR CONTACT NAME DEALER or DISTRIBUTOR EMAIL PROJECT NAME NUMBER CLIENT N...

Page 82: ... GPS WOT RPM Knots GPS Speeds at Varying RPM TRIM POSITION TRIAL DATA FOR MAX VELOCITY AT VARIOUS CONDITIONS OUTLINED IN CHART 1 MAXIMUM VELOCITY READINGS ORIGINAL HEADING 0 o KONRAD APPLICATION TRIAL DATA FORM VELOCITY MAX KTS ENGINE EXHAUST TEMP C o AND LOAD ENGINE BOOST PRESSURE kPa CONDITION See Chart 1 for Description OPPOSITE HEADING 180 o TIME TO PLANE SEC RPM ENGINE VELOCITY MAX KTS RPM EN...

Page 83: ... CRUISE VELOCITY AT VARIOUS CONDITIONS OUTLINED IN CHART 1 CRUISE VELOCITY READINGS MINIMUM 3 READINGS 200 RPM INCREMENTS ORIGINAL HEADING 0 o KONRAD APPLICATION TRIAL DATA FORM ENGINE EXHAUST TEMP C o AND LOAD ENGINE BOOST PRESSURE kPa CONDITION See Chart 1 for Description OPPOSITE HEADING 180 o TIME TO PLANE SEC RPM ENGINE RPM Knots GPS Speeds at Varying RPM TRIM POSITION VELOCITY CRUISE KTS VEL...

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Page 85: ...KONRAD MARINE INC 1421 HANLEY ROAD HUDSON WI 54016 9376 USA Phone 715 386 4203 Toll Free 1 800 927 3545 Fax 715 386 4219 www konradmarine com ...

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KONRAD 620B, Installation Manual

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