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TABLE OF CONTENTS

600B SERIES MAINTENANCE MANUAL

TABLE OF CONTENTS

JULY 2016 - V1.0

1 - KONRAD 600B SERIES STERNDRIVES

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications for Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sterndrive Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specified Gear Oil and Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sterndrive Removal

A. 620B/680B all dates and 660B build dates January 26, 2016 or after. . . . . . . .
B. 660B build dates before January 26, 2016. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sterndrive Installation

C. 620B/680B all dates and 660B build dates January 26, 2016 or after. . . . . . . .
D. 660B build dates before January 26, 2016 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 - KONRAD 600B SERIES GENERAL MAINTENANCE

Sterndrive Gear Lube

Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fluids

Trim/Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propeller and Hardware

Model 620B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 660B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Содержание Series 600B

Страница 1: ...NOTICE TO INSTALLER After completing installation this Maintenance Manual should be placed with the Sterndrive for the Owner s future use Series 600B Maintenance Manual...

Страница 2: ...s 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...

Страница 3: ...MAINTENANCE MANUAL 600B Series Models Core Content Originated by Randall J Sofie October 2007 Adapted for 600 Series November 2011 Adapted for 600 B Series July 2016 600 B SERIES MAINTENANCE MANUAL J...

Страница 4: ......

Страница 5: ...ll dates and 660B build dates January 26 2016 or after B 660B build dates before January 26 2016 Sterndrive Installation C 620B 680B all dates and 660B build dates January 26 2016 or after D 660B buil...

Страница 6: ...NTENANCE Bellows Universal Joints Propeller Shaft Bearing Carrier Seal Replacement Model 620B Model 660B Model 680B Electrical Drawings Trim Lift Electrical Drawing 12 Volt Trim Lift Electrical Drawin...

Страница 7: ...nstallation 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...

Страница 8: ...t whether a lower upper or complete requires a ten 10 hour break in running period Please use the following guidelines during the first ten 10 hours to assure optimum performance from your new Konrad...

Страница 9: ...Center Pin Cover Hex Head Cap Screw 2 35 lb ft 47 5 Nm Gimbal Ring Center Pin Retaining Hex Head Cap Screw 1 50 lb ft 67 8 Nm Trim Sender Cover Button Head Cap Screws 2 13 lb in 147 Ncm Trim Sender Ho...

Страница 10: ...th trim and steering cylinders 115 lbs 52 2 kg Trim pump 13 lbs 5 9 kg Upper housing and Intermediate 151 lbs 68 5 kg Lower housing assembly 67 lbs 30 4 kg Total Dry Weight 346 lbs 156 9 kg Standard 6...

Страница 11: ...proper tightness Every 120 Days Every 6 months Once a year Propeller Shaft Saltwater Use Lubricate shaft check shaft seals for leaking and damage check propeller hardware torque Every 60 days Every 6...

Страница 12: ...ication configurations such as spacers by 1 3 quarts 95 2 84 liters Make sure the drive is completely filled to the top and purged of air prior to operating KVD Transmisson Dextron III automatic trans...

Страница 13: ...ll cap 13 251 3A Disconnect the steering cylinder s 30 986 from the drive leg by removing the aft cotter pins 13 368 washers 12 352 and the clevis pins 13 341 from the steering cylinder Repeat the pro...

Страница 14: ...remove cover 7A Remove the pivot pin retaining H H C S 13 560 from the front of the intermediate section of the drive Slide the pivot pin 13 561 downward and remove from the gimbal ring 8A Remove the...

Страница 15: ...the gimbal ring bushings are in place Carefully slide the alignment pin and end yoke into the bellows and into the splines of the drive shaft carrier or transmission tailpiece Reinstall the u joint b...

Страница 16: ...steering tabs 7B Remove the lifting ring and install the plug 10 010 and gasket 10 285 Remove the cap 13 251 on the oil supply line fitting and reinstall the oil supply line 30 997 from the transom u...

Страница 17: ...997 from the connector on the upper housing assembly 11 772 and install the 13 251 cap onto the supply line fitting Secure the oil supply line out of the way 3C Remove the steering lines 30 993 from b...

Страница 18: ...inuity cable 30 905 from the gimbal housing 8C Loosen the aft end of the bellows clamp 10 336 and slide the end of the bellows 10 230 off of the drive 9C Remove the two 2 H H C S 12 378 from the top r...

Страница 19: ...in 13 315 and remove the washer 12 352 and pin from both the port and starboard sides Secure the drive for lifting and removal 11C Remove the gimbal ring hinge pins 13 562 12C Slide the drive and gimb...

Страница 20: ...ce assembly WARNING Do not impact or apply force to the drive while engaging the input shaft as this will damage the gimbal carrier seal NOTE It may be necessary to rotate the splined end yoke shaft t...

Страница 21: ...ring through the trim cylinder rod ends and bushings Secure the clevis pin by sliding washer 12 352 over the clevis pin and place cotter pin 12 352 through the hole at the end of the clevis pin and b...

Страница 22: ...openings facing forward and placing blue Loctite 243 onto the two S H C S 13 600 10D Install the outer housing covers and place blue Loctite 243 onto the two 2 B H C S 13 572 and tighten 11D Install...

Страница 23: ...te 243 onto the S H C S before placing them through the flat washers and hand tightening Install the two 2 M6 X 14mm S H C S 12 951 into the forward upper side of the cover Install the two 2 M6 X 25mm...

Страница 24: ...the sterndrive by removing the socket head cap screws 12 951 3 Pour in gear oil until it reaches just below the top cap 4 Wait fifteen 15 minutes Rotate the propeller five or six 5 6 times in both di...

Страница 25: ...the back of the upper housing cover and remove the cover from the upper housing 3 Remove the top vent plug 10 010 located on the top cap 13 421 4 Remove the bottom fill drain plug 10 155 Allow lubric...

Страница 26: ...unit Before further use the area where the leak occurs should be identified and corrected Then refill the unit with new lubricant IMPORTANT Always check oil level when the drive is cool and engine is...

Страница 27: ...ce it in a container to catch any purged fluid Hold one 1 finger over the down line port of the trim lift pump to prevent the intake of air Trim the drive all the way up using the toggle switch on the...

Страница 28: ...e Control must be in NEUTRAL the engine turned off and ignition key removed from switch before removing and or installing propeller Model 620B Individual Components Description Quantity Part Number A...

Страница 29: ...d retaining washer tabs using Konrad Tool TO 063 2 Place a block of wood between the propeller and cavitation plate 3 Remove propeller nut 4 Remove additional propeller hardware see diagram on previou...

Страница 30: ...NEUTRAL the engine turned off and ignition key removed from switch before removing and or installing propeller Mod0B Individual Components Description Quantity Part Number A Forward Prop Shaft 1 12 50...

Страница 31: ...aft propeller repeat steps to remove the forward propeller 2 Place a block of wood between the propeller and cavitation plate 3 Remove aft propeller nut with 17 16 socket and breaker bar for forward p...

Страница 32: ...UTRAL the engine turned off and ignition key removed from switch before removing and or installing propeller Model 680B Individual Components Description Quantity Part Number A Forward Prop Shaft 1 12...

Страница 33: ...ft propeller repeat steps to remove the forward propeller 2 Place a block of wood between the propeller and cavitation plate 3 Remove aft propeller nut with 113 16 socket and breaker bar for forward p...

Страница 34: ...Part Zinc Part superceded by aluminum Aluminum Part 1 Anode Cylinder 2 11 277 12 472 2 Screw 4 11 278 3 Plate Inhibitor 2 10 433 12 475 4 Anode 600 Upper 1 13 025 13 640 5 Plate Inhibitor 1 10 432 12...

Страница 35: ...Description Quantity Part Zinc Part superceded by aluminum Aluminum Part 1 Anode Cylinder 2 11 277 12 472 2 Screw 4 11 278 3 Anode 600 Upper 1 13 025 13 640 4 Anode 1 12 820 13 666 Complete Assembly...

Страница 36: ...c Part superceded by aluminum Aluminum Part 1 Anode Cylinder 2 11 277 12 472 2 Screw 4 11 278 3 Plate Inhibitor 2 10 433 12 475 4 Anode 600 Upper 1 13 025 13 640 Complete Assembly Kit for 680 Part 31...

Страница 37: ...600B SERIES MAINTENANCE MANUAL JULY 2016 V1 0 PAGE 31 Anodes Placement on Sterndrive Chapter 2 General Maintenance continued 1 2 4 3 5...

Страница 38: ...art Aluminum Part 2 Plate Inhibitor 2 if applicable 10 433 12 475 3 Anode 600 Upper 2 if applicable 13 025 13 640 5 Steering Cylinder Anode 2 if applicable 11 277 12 472 Model 620B Placement of Anodes...

Страница 39: ...der External 30 995 Steering Cylinder External 30 993 4 per drive 2 per cylinder Oil Supply Hose 30 997 Trim Pump to Transom 31 037 1 per drive 6 per drive Oil Reservoir to Transom Direct Mount Oil Re...

Страница 40: ...BS DO NOT SCALE DRAWING C COPYRIGHT 2004 KONRAD MARINE ALL RIGHTS RESERVED THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN IS CONFIDENTIAL AND PROPRIETARY PROPERTY AND MUST NOT BE USED REPRODUCED O...

Страница 41: ...DRAWN XXX 005 XX 010 X 020 Konrad DRAWING NUMBER NEXT ASS Y THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN IS CONFIDENTIAL AND PROPRIETARY PROPERTY AND MUST NOT BE USED REPRODUCED OR ITS CONTENT...

Страница 42: ...removal and installation of bellows Remove U joint bellows from gimbal housing by loosening the two 2 hose clamps 10 336 Position ground clips on bellows Position u joint bellows with TOP mark facing...

Страница 43: ...H YOKE 7 10 365 SHAFT END YO 6 10 518 RING SNAP 5 10 373 CROSS BEAR 4 12 840 CAP SCREW H 3 12 768 WASHER TAB 2 12 586 O RING 1 12 766 YOKE END ITEM NO PART NO DESCRIPTION 30 831M DRAWING NO NEXT ASS Y...

Страница 44: ...ndition inspect for evidence of interference with bearing caps hitting center socket Cleaning and Inspection 1 Clean all parts except the bearing in fresh solvent Blow dry with compressed air IMPORTAN...

Страница 45: ...ve second bearing 4 Remove yoke Installation Universal Joint Shaft Reassembly Lube Specifications Use only non lithium soap base or equivalent E P grease with an operating temperature of three hundred...

Страница 46: ...eplacement Model 620B Individual Components 620B Item Description Quantity Part 1 Cover Nut 1 12 783 2 Washer 1 12 784 3 Key 1 10 017 4 O Ring 1 12 796 5 Ring Load 1 12 798 6 Carrier Bearing 1 12 797...

Страница 47: ...S MAINTENANCE MANUAL JULY 2016 V1 0 PAGE 41 12 797 10 017 12 784 12 783 12 799 12 796 10 394 13 641 12 798 10 269 10 509 10 360 10 363 13 641 Model 620B Prop Shaft Parts Chapter 3 Complex Maintenance...

Страница 48: ...houlder Apply red Loctite 263 to outside of second seal 13 641 and grease inner seal surface Press into carrier unit with the raised numbers printed on the seal facing downward using the opposite shor...

Страница 49: ...1 12 525 6 Seal Fishline Cutter 1 12 517 7 Nut Retaining Fwd 1 12 513 8 O Ring TP Carrier 1 12 527 9 Carrier TP 1 12 510 10 Needle Bearing Fwd 1 12 522 11 Seal Inner Fwd 1 12 526 12 Seal Fishline Cut...

Страница 50: ...AINTENANCE MANUAL JULY 2016 V1 0 PAGE 44 12 510 12 513 12 521 12 515 12 527 12 522 12 526 12 518 12 838 12 954 12 517 12 839 12 525 12 520 Model 660B Prop Shaft Parts 12 502 Chapter 3 Complex Maintena...

Страница 51: ...TO 028 NOTE Be careful not to damage surface of thrust cap on the opposite end of the propeller shaft Protect with some sort of cloth 2 Clean propeller shaft assembly 12 502 thoroughly 3 Apply red Loc...

Страница 52: ...b ft 271 Nm of torque 5 Check rolling torque of lower unit as described in the Konrad Technical Manual 6 Slide carrier 12 510 into lower housing be sure to align dowel pins on carrier to retaining nut...

Страница 53: ...706 3 Shim Set Aft Bearing 1 12 714 4 Bearing 1 12 721 5 O Ring 1 12 722 6 Roller Bearing Fwd 1 12 723 7 Seal Inner Fwd Prop Shaft 1 13 547 8 Seal Outer Fwd Prop Shaft 1 13 547 9 Cover Nut Fwd 1 10 24...

Страница 54: ...ERIES MAINTENANCE MANUAL JULY 2016 V1 0 PAGE 48 Model 680B Prop Shaft Parts 12 706 12 714 12 722 12 723 13 547 12 721 12 242 12 955 12 925 12 952 13 641 13 641 12 705 Chapter 3 Complex Maintenance con...

Страница 55: ...shaft assembly 12 705 thoroughly 3 Apply red Loctite 263 to outside of first seal 13 641 and grease inner seal surface Press into propeller shaft with the raised numbers printed on the seal facing up...

Страница 56: ...s described in the Konrad Technical Manual 6 Grease outer diameter of carrier and install carrier unit 12 706 into lower housing aligning dowel pins on carrier to retaining nut 10 242 7 Lubricate thre...

Страница 57: ...AIR WIRE BK RD TWISTED PAIR WIRE 1 2 3 4 5 6 1 2 3 4 5 6 1 1 2 2 3 3 4 4 BK 6 POSITION TERMINAL STRIP K M P N 11 069 4 POSITION TERMINAL STRIP K M P N 11 070 K M P N 10 528 BK BK BK NOTE CONDUCTORS WI...

Страница 58: ...7 HARNESS K M P N 31 051 PR YL GY BK RD BL TN PK GR BK OR HOT POSITIVE 8 32V THROTTLE TRIM 1 DN THROTTLE TRIM 1 UP PANEL ILLUMINATION KEYSWITCH SEAL PLUG K M P N 13 445 SEAL PLUG K M P N 13 445 NEGATI...

Страница 59: ...L STRIP K M P N 11 070 K M P N 10 528 BK BK B K NOTE CONDUCTORS WIRES NOT SUPPLIED BY KONRAD MARINE A B C A B A B C A B C A B C A B C A B C C A B C C A B A B C C A B A B HARNESS K M P N 31 051 PR YL G...

Страница 60: ...ROM 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 32V SEAL PLUG K M P N 13 445 SEAL PLUG K M P N 13...

Страница 61: ...CONNECTING HARNESS K M P N 31 071 1 2 4 5 6 7 8 9 12 10 21 22 19 20 17 16 18 15 27 28 K M P N 10 528 POWER RELAY DN K M P N 10 430 THROTTLE TRIM 3 UP B 24 23 25 26 C A B C A B A C B A B C A B C C B A...

Страница 62: ...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 GR BK RD 18 12 6 13 7 1 1 7 13 18 12 6 THROTTLE TRIM 1 DN THROTTLE TRIM 1 UP PANEL ILLU...

Страница 63: ...9 4 POSITION TERMINAL STRIP K M P N 11 070 K M P N 10 691 BK BK BK NOTE CONDUCTORS WIRES NOT SUPPLIED BY KONRAD MARINE A B C A B C A B C A B C A B C A B C A B C C A B C C A B A B C C A B A B Y CONNECT...

Страница 64: ...NNECTOR K M P N 13 457 HARNESS K M P N 31 051 PR YL GY BK RD BL TN PK GR BK OR HOT POSITIVE 8 32V THROTTLE TRIM 1 DN THROTTLE TRIM 1 UP PANEL ILLUMINATION KEYSWITCH SEAL PLUG K M P N 13 445 SEAL PLUG...

Страница 65: ...KONRAD MARINE A B C A B A B C A B C A B C A B C A B C C A B C C A B A B C C A B A B HARNESS K M P N 31 051 PR YL GY BK RD BL TN PK GR BK OR NOTES FOR CONNECTOR 2 1 ALL WIRES ARE PIGTAILED AND TO BE R...

Страница 66: ...1 10 K M P N 31 057 14 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 PO...

Страница 67: ...GROUND HOT POSITIVE 8 32V OIL RESERVOIR BOTTLE SWITCH CONNECT TO NEGATIVE GROUND SIDE OF 24VDC CIRCUIT CONNECT TO POSITIVE SIDE OF 24VDC CIRCUIT 50 AMP NOTE CONDUCTOR WIRES NOT SUPPLIED BY KONRAD MAR...

Страница 68: ...2 13 697 CONNECTING HARNESS FROM TRIM PUMP 3 MODULE 3 13 698 B CONNECTING HARNESS 6 K M P N 31 061 10 K M P N 31 057 14 K M P N 31 062 CONNECTING HARNESS 6 K M P N 31 061 THROTTLE TRIM 2 UP THROTTLE T...

Страница 69: ...roll to the number of drives your vessel has Once the correct number is shown on the screen press the key below the word ENTER 3 Press the key below the word HOME to go back to the main menu Scroll do...

Страница 70: ...rive number 1 by default is the drive on the starboard side then proceeds towards the port side Note If the sensor reading jumps around it maybe out of position Check to ensure the sensor wires and in...

Страница 71: ...ignment gauge against the 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...

Страница 72: ...sing 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 f...

Страница 73: ...C B Adjust the engine mounts until the measured distance 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...

Страница 74: ...it is easier to hold the horizontal measurement at zero NOTES 1 Transmission output flange and gimbal carrier input flange must be parallel within 030 inches or 762 mm 2 Transmission output flange an...

Страница 75: ...Fasteners Thread Lock Compound Transmission Type Stern Drive Carrier Type Constant Velocity CV 31 044 12 7 55 in 32 3 140 cm Max 2 Max Offset 2 0625 in 1 59 mm N A GO 017 or TO 186 or TO 187 85 ft lbs...

Страница 76: ......

Страница 77: ...1421 Hanley Road Sales 715 386 4203 Hudson Wisconsin 54016 9376 USA Toll Free 800 927 3545 Fax 715 386 4219 Website www konradmarine com E mail sales konradmarine com...

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