KONRAD 520, 560, 540 General Installation Manual

Download

500 Series Models

GENERAL INSTALLATION MANUAL

1421 HANLEY ROAD • HUDSON, WI 54016-9376 USA

Phone: 715-386-4203 • Toll Free: 1-800-927-3545 • Fax: 715-386-4219

KONRAD, INC.

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 identication purposes only.

We are in no way implying that any of our parts are the original equipment manufacturer’s product.

500 SERIES INSTALLATION MANUAL JULY 2016PAGE II

500 Series Models

GENERAL INSTALLATION MANUAL

Version 3

Part # 11-660

*Written/Narrated by Randall J. Soe, January 2007

*Modied by Randall J. Soe, January 2010

1421 HANLEY ROAD • HUDSON, WI 54016-9376 USA

Phone: 715-386-4203 • Toll Free: 1-800-927-3545 • Fax: 715-386-4219

sales@konradmarine.com • www.konradmarine.com

KONRAD, INC.

500 SERIES INSTALLATION MANUALJULY 2016 PAGE III

TABLE OF CONTENTS

520 Stern Drive Description ........................................................1

540 Stern Drive Description ........................................................2

560 Stern Drive Description ........................................................3

Stern Drive General Information .................................................4

General Operation ........................................................................ 4

Safety Notices ..............................................................................4

Tools Recommended For Installation .......................................5-6

Torque Specications For Selected Fasteners .............................. 7

Installation Guidelines .................................................................8

Figure A: 500 Series Cutout Template ......................................... 9

Figure B: 500 Series X-Dimension Guidelines .........................10

KONRAD 500 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 .............................................24-27

Figure E: Alignment Specications Chart .................................28

Step 6: Alignment Procedures ...............................................29-32

Step 7: Trim Cylinder Installation.........................................33-34

Figure F: Trim Assembly Diagram ............................................ 35

Figure G: Trim Assembly Individual Components .................... 36

Step 8(a): 520 / 540 Propeller Installation .................................37

Step 8(b): 560 Propeller Installation .......................................... 38

Step 9: Stern Drive Lubrication ............................................39-41

Step 10: Trim/Lift Control Module Installation ....................42-45

Step 11: Trim/Lift Pump Filling/Bleeding Procedure ...........46-47

Step 12: Setting Trim/Lift Limit & Sender Switch ...............48-49

Step 13: Manual Hydraulic Steering System Installation .....50-53

Figure H: Routing Diagram 30-462R ........................................54

Step 14: Power Steering System Installation ........................55-59

Figure I: Routing Diagram 30-390R .......................................... 60

Figure J: Hoses for Assembly KM #30-390 ..............................61

Figure K: 30-264 Parts List ........................................................62

Figure L: 30-274 Parts List ........................................................ 63

500 SERIES INSTALLATION MANUALJULY 2016 PAGE V

TABLE OF CONTENTS (Continued)

Step 15: Rubber Coupling Extension Shaft(s) ......................64-67

Step 16: U-Joint Extension Shaft Installation .......................68-69

Step 17: CV Extension Shaft Installation .............................70-71

Step 18: Drive Shaft Shroud Installation ...................................72

Figure M: Rear Mount/Tailpiece Cutout Template .................... 73

Step 19: Rear Mount / Tailpiece Installation ........................74-76

Step 20:Installation Review ..................................................77-78

Application Trial Data Forms ...............................................79-81

500 SERIES INSTALLATION MANUAL JULY 2016PAGE VI

520 Stern Drive Description

The Konrad 520 stern drive is the hardest working stern drive in the marine industry today. Designed for highuse, endurance-type applications, the Konrad 520 is recognized for its versatility and long-term durability. It is not a “pleasure” drive. It’s a working drive that

can take you shing all day or patrol harbors 24/7. The

Konrad 520 is the only commercial-rated stern drive available for diesel applications in the 180-440 hp (134 - 328 kw) range.

The Konrad 520 stern drive is designed to accommodate aluminum or stainless steel propellers

with three (3) to ve (5) blades. Propellers are chosen

depending on the application and performance criteria. The maximum diameter propeller size for the Konrad 520 stern drive is 20 in. (50.8 cm).

520 Classications

Recreational Performance

Maximum Recommendation: 1000 Nm (738 lb. ft.) of torque for diesel or gas applications. Maximum operation: 250 hours per year for planing type hulls of highly intermittent operation. Gross weight to horsepower less than

15.2 kg/kw (25 lbs./hp). This classification includes private, non-commercial, noncharter, sport/leisure activity craft. Long range pleasure cruisers, sport fishing charters and commercial service craft are NOT in this service classification. Standard warranty.

Commercial/Military

Performance

Maximum recommendation: 755 Nm (557 lb. ft.) of torque for semi displacement and planing hulls of intermittent operation. Maximum operation: 1000 hours per year and gross weight to horsepower less than 21.3 kg/kw (35

lbs./hp). This classication includes light

commercial charter/sport activity craft, patrol and crew boats. Standard warranty.

Medium Duty Performance

Maximum operation: 678 Nm (500 lb. ft.) of torque for semidisplacement and displacement monohulls of intermittent operation with some variations in engine rpm and power.

This classication includes charter and

commercial craft. Note: These applications must be approved by the factory. Standard warranty.

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 1

540 Stern Drive Description

The Konrad 540 is specically designed for high speed

applications, both diesel and gasoline. This versatile stern drive is manufactured in two variations: Standard and High Performance. The High Performance model includes a lower hydrodynamic nose cone, and both versions have a lightweight design to deliver superior hole-shot and on-plane performance. The Konrad 540 allows mariners to apply greater power levels, while still delivering performance and reliability.

The Konrad 540 stern drive is designed to accommodate aluminum or stainless steel propellers with three (3) to six (6) blades. Propellers are chosen depending on the application and performance criteria. The maximum diameter propeller size for the Konrad 540 stern drive is 16 in. (40.6 cm).

540 Classications

Recreational Performance

Maximum recommendation: 1000 Nm (738 lb. ft.) of torque for diesel or gas applications. Maximum operation: 250 hours per year for planing type hulls of highly intermittent operation. Gross weight to horsepower less than 12.2 kg/kw (20 lbs./hp). This classication includes private, non-commercial, non-charter, sport/ leisure activity craft. Long range pleasure cruisers, sport shing charters and commercial service craft are NOT in this ser-

vice classication. Standard warranty.

Commercial Performance

Maximum recommendation: 755 Nm (557 lb. ft.) of torque for diesel or gas applications. Maximum operation: 500 hours per year for planing type hulls of highly intermittent operation. Gross weight to horsepower less than

12.2 kg/kw (20 lbs./hp). This clas-

sication includes light commercial

charter/sport activity craft, patrol and intercept boats. Standard warranty.

High Performance

Maximum operation: 100 hours/year for racing applications at highly intermittent operation. Gross weight to horsepower less than 12.2 kg/kw (20 lbs./hp). No warranty.

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 2

560 Stern Drive Description

The Konrad 560 Twin Prop System is engineered to reduce stress on the gears using dual propeller technology, providing a reliable, durable stern drive unit. With counter rotating propellers, the 560 reduces

propeller roll, which increases efciency and control.

The Konrad 560 stern drive features two, one piece propeller shafts that accommodate two stainless steel propellers. The specially designed

propellers have one blade conguration: 3 blades

on the forward prop and 4 blades on the rear prop. The propeller pitches are manipulated on each application to meet the performance criteria. The maximum diameter of the propellers in the Konrad 560 is 16 in. (40.6 cm) for the forward prop, and 15.25 in. (38.7 cm) for the rear prop.

560 Classications

Recreational Performance

vice classication. Standard warranty.

Commercial Performance

12.2 kg/kw (20 lbs./hp). This clas-

sication includes light commercial

charter/sport activity craft, patrol and intercept boats. Standard warranty.

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 3

Stern Drive

Safety Notices

General Information

The Konrad 500 Series stern drives are designed to accommodate engines that generate up to 738 lb. ft. (1000 Nm) of torque.

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 500 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 520 stern drive is designed to accommodate propellers (aluminum and stainless steel) with a maximum diameter of 20 in (50.8 cm). The Konrad 540 and 560 can accommodate propellers (aluminum and stainless steel) with a maximum diameter of 16 in. (40.6 cm).

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 and 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 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 supported

only by lifting jacks or a hoist.

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 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 (different shafts are discussed in detail in Step 6 on pages 29

- 32 in this manual). The power is then transmitted through a series of shafts and gears and then to the propeller(s).

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 devices such as chains, hooks or slings are in good condition and are of the correct lifting capacity.

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 4

Tools Recommended for Installation

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

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 5

Tools Recommended for Installation (continued)

Tools for 30-264 and 30-272

Rubber Coupling Drive Shaft (if applicable)

TO-066 Adapter, Torque Wrench 12 mm

TO-067 Adapter, Torque Wrench 22 mm.

TO-068 Adapter, Torque Wrench 24 mm.

GO-017, Dial Indicator with Magnetic Stand

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 6

Torque Specications for Selected Fasteners

Listed below are the torque specifications for selected fasteners. Additional torque specifications are listed throughout this manual.

Description Torque Value

Drive Shaft Flange to Transmission Output Flange Shaft Nuts/Bolts (if applicable)

Transom Assembly / Gimbal Housing Studs to Inner Transom Plate Nuts (8)

Drive Shaft Housing to Gear Housing Nuts and Bolts (8) 35 lb. ft. (47 Nm)

Power Trim Cylinder to Anchor Pin, Nuts (4)

Lifting Bracket Top Cover (and Emergency Tiller Arm if applicable) (6) 20 lb. ft. (27 Nm)

Stern Drive Unit to Bell Housing, Nuts (6) 55 lb. ft. (75 Nm)

Gimbal Carrier Bolts (S.H.C.S.) (3) (if applicable) 70 lb. ft. (95 Nm)

520 Propeller Nut (1) 80 lb. ft. (109 Nm)

540 Propeller Nut (1) 55 lb. ft. (75 Nm)

70 lb. ft. (95 Nm)

25-30 lb. ft. (34-41 Nm)

Tighten until approx.

two (2) threads show.

Do not over tighten.

560 Forward Propeller Nut (1) 100 lb.ft. (136 Nm)

560 Rear Propeller Nut (1) 60 ft.lb. (81 Nm)

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 7

Installation Guidelines

1) Ensure that the propeller height is performed

according to guidelines detailed in diagrams 10-410 (Figures A and B on pages 9 and 10 in this manual). The height of the propeller is 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 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 inef-

ciency and excessive torsional vibration.

Common problems 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

3) Ensure that the vessel center of gravity is properly placed. Excessive weight forward

or aft can signicantly affect performance and the efciency 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 inefciency, porpoising,

and premature gear wear.

500 SERIES INSTALLATION MANUAL JANUARY 2010PAGE 8

FIGURE A: 500 Series CUTOUT TEMPLATE

in.

Note: Drawing not to scale.

500 SERIES INSTALLATION MANUALJANUARY 2010 PAGE 9

FIGURE B: 500 Series X-DIMENSION GUIDELINES

Note: Drawings not to scale.

500 SERIES INSTALLATION MANUAL JANUARY 2010PAGE 10

Step 1: Transom Cutout

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 approximately 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 vertical 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.

FIGURE 1A

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: Specic characteristics of an installation may

change the recommended vertical drive position. Please

contact Konrad with any specic concerns.

ATTENTION: If you are installing the Konrad “Rear Mount / Tail Piece” assembly, please go

to step 19 (page 73 - 74) in this manual.

FIGURE 1B

500 SERIES INSTALLATION MANUALJANUARY 2010 PAGE 11

Step 1: Transom Cutout (continued)

1.3 Place the cutout template (10-455) on the exterior of the transom and position it so the scribed horizontal and vertical match up with the scribed center lines on the template.

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.

FIGURE 1A

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 le or rasp to touch up the cutout area.

NOTE: Cut must be made perpendicular to transom

face.

NOTE: For berglass transoms, it is recommended that

berglass 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.

FIGURE 1B

FIGURE 1C

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 12

Step 2: Transom Assembly Installation

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 ange 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.

NOTE: The gimbal carrier ange may differ from the

one pictured in Figure 2B per application.

Torque the three (3) fasteners to 70 lb. ft. (95 Nm).

FIGURE 2A

FIGURE 2B

2.2 Guide the transom assembly studs through the eight (8) holes in the transom.

NOTE: The weight of the transom assembly is 81 lbs.

(36.7 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.

FIGURE 2C

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 13

Step 2: Transom Assembly Installation (continued)

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 modication

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) at 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.

FIGURE 2D

FIGURE 2E

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 14

Step 3: Oil Reservoir Installation

Provided the stern drive and gimbal carrier (if applicable) are purged, the oil level can be checked at the remote oil reservoir. The bottle should be visible upon opening the engine compartment cover. There are two (2) different styles of reservoirs, one (1) reservoir is used per drive. The one (1) pt. (.47 l) reservoir assembly (with a rectangular bottle) has a part number of 30-

179. The part number of the bottle only is 10-431. The one (1)

qt. (.95 l) reservoir assembly (with a cylindrical bottle) has a part number of 30-295. The part number of the bottle only is 30941 (See Figure 3A). Manufacturer will have predetermined the correct reservoir.

3.1 This is a gravity feed system. Position the oil reservoir bottle and bracket on the transom, keeping it as high as possible. The oil bottle must be above the line input to the stern drive and gimbal carrier (if applicable). When considering the position make sure that there is enough

clearance to ll the bottle with oil. Keep in mind that the bottle may be removed from the bracket to be lled, however, it must be secured again after lling is complete

(see Figure 3B).

FIGURE 3A

NOTE: Pay attention to the placement of the bottle

bracket to ensure that they will clear the steering cylinder ram or other moving parts that will potentially be mounted

in later steps.

NOTE: The connecting oil hoses must be fastened to the

transom within 6 in. (15 cm) of the oil bottle and every 6

in. (15 cm) afterward (see Figure 3C). Oil hoses must not

be kinked or looped such that it impedes gravity feed.

3.2 For berglass hulls, mount the bottle bracket with two

(2) lag screws. For aluminum hulls, attach bottle bracket to hull by welding or using a mounting plate (see Figure 3B).

FIGURE 3B

FIGURE 3C

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 15

Step 3: Oil Reservoir Installation (continued)

3.3 Connect the long hose (1/4 in. that feeds the brass “T”

tting) to the bottom of the reservoir bottle with a hose

clamp.

NOTE: Ensure the bottle is mounted 4 ft. (122 cm) or

less from the carrier assembly and stern drive, and 4 ft.

(122 cm) or less from the trim pump.

3.4 Connect the 3/8 in. hose from the brass “T” to the gimbal carrier nipple. Secure hose clamp.

FIGURE 3D

3.5 Connect the 3/8 in. hose (attached to gimbal housing) to

the brass “T” tting.

NOTE: Oil hose should be cut to length for easiest

downward ow.

To Stern

Drive

FIGURE 3E

To Gimbal

Carrier

FIGURE 3F

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 16

Step 3: Oil Reservoir Installation (continued)

3.6 For tailpiece application, a gimbal carrier is not utilized. Connect oil bottle to long 1/4 in. hose. Connect 3/8 in. hose which is attached to the gimbal housing to brass reducer coupling, located on 1/4 in. hose.

3.7 Fill oil bottle to “ll” line with Konrad 75W90 synthetic

gear lube.

NOTE: In accordance with MSDS regulations and

requirements, the stern drive is shipped full of the above

mentioned lubricant. Prior to operation, verify that the

entire system is completely purged of air and lled with

lubricant. If a different gear oil is chosen for your application, it is recommending that the stern drive is

drained and relled. This may void manufacturer’s warranty. Purge oil line to the stern drive by manually

opening connecting valve located on the outside port face of bell housing (outboard side of transom). Open valve

until solid oil ow occurs. Rell oil bottle at proper level

indicated on bottle.

FIGURE 3G

3.8 Purge the air out of the oil line feeding the stern drive by depressing the check valve nipple, located on the bell

housing face, until a solid stream of oil comes out. Rell

reservoir bottle to the appropriate level.

FIGURE 3H

FIGURE 3I

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 17

Step 4: Trim/Lift Pump Installation

Wire style and gauge shall meet requirements of local, state and national codes.

4.1 Trim pump circuit requires inline fuse/breaker (on the positive lead) of the following values:

1) 12 Volt = 100 Amperes (see Figure 4A)

2) 24 Volt = 50 Amperes (see Figure 4B)

This item should be mounted in an accessible and logical

position away from bilge uid contact. It must also be

labeled clearly.

NOTE: Battery, or batteries, must be disconnected while

all electrical connections are being made or serviced (see Figure 4C).

FIGURE 4A

FIGURE 4B

NOTE: Refer to the Trim System Electrical Drawings

(Figure C and Figure D on pages 22 and 23 in this manual) for further documentation on this and proceeding instructions.

4.2 Mount trim pump in a location which is:

1) As elevated as possible and away from bilge

uid contact.

2) Is within reach of transom assembly wiring

approximately 36 in. (91.4 cm).

3) Is within reach of oil bottle wiring

approximately 48 in. (122 cm).

4) Is within reach of transom assembly hydraulic

hoses, 32 in. or 48 in. (81.3 cm or 122 cm). Measure to determine length.

NOTE: For berglass hulls, it is recommended that a

pilot hole be drilled prior to lag screw installation.

NOTE: For metal hulls, attach by either welding or us-

ing a mounting plate.

FIGURE 4C

FIGURE 4D

NOTE: The two (2) hydraulic hoses in this photo will be

attached in later steps.

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 18

Step 4: Trim/Lift Pump Installation (continued)

4.3 Remove the cover of the trim/lift pump assembly by removing the front three (3) bolts and lock washers.

4.4 Remove the three (3) rear bolts and lock washers and remove the top portion of the trim/lift pump assembly bracket.

FIGURE 4E

4.5 Attach the positive trim/lift pump power feed (from the breaker/fuse unit) to one of the solenoid bolts on the linkbar side.

NOTE: Coat terminal with corrosion protectant.

4.6 Attach the negative trim/lift pump power feed to the ground bolt.

NOTE: Coat terminal with corrosion protectant.

FIGURE 4F

FIGURE 4G

FIGURE 4H

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 19

Step 4: Trim/Lift Pump Installation (continued)

4.7 Reattach the top portion of the trim/lift pump assembly bracket.

4.8 Route the four (4) wires from the transom assembly to the trim/lift pump. Fasten to the transom or hull every 6 in. (15 cm).

FIGURE 4I

4.9 Route the two (2) wires (color coded black and grey) from the oil reservoir to the trim/lift pump. Fasten to the transom or hull every 6 in. (15 cm). Attach the wires by running them through the upper hole of the trim/lift pump assembly bracket. Connect them to the two (2) terminals on the terminal strip labeled “Oil”.

NOTE: Coat the terminals with corrosion protectant.

4.10 Attach the wires by running them through the upper hole of the trim/lift pump assembly. Connect them to the appropriate terminals of the terminal strip.

NOTE: The two (2) wires coming from the port side

switch (color coded blue and purple) on the transom

assembly go to the terminals labeled “Port”. The two (2)

wires coming from the starboard side switch (color coded red and black) go to the terminals labeled “Star”.

FIGURE 4J

FIGURE 4K

FIGURE 4L

NOTE: Coat the terminals with corrosion protectant.

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 20

Step 4: Trim/Lift Pump Installation (continued)

4.11 Reattach the trim/lift pump assembly cover plate.

4.12 Route the two (2) hydraulic hoses from the transom assembly to the trim/lift pump. Fasten to the transom or hull every 6 in. (15 cm). Connect the “up” line to the trim/ lift pump. Hook the line up according to the “up” label on the line and on the port marked “up” on the trim/lift pump. Ensure not to cross thread. Tighten till snug.

FIGURE 4M

NOTE: The “down” line will be hooked up later during

the bleeding process (Step 11 on page 46 in this manual).

NOTE: Be sure to avoid potential moving objects (such

as the steering ram or drive shaft if applicable) when

routing the trim/lift pump hydraulic lines.

4.13 Connect the appropriate length wire harness (predetermined) to the trim/lift pump pigtail. Run the harness across the transom (to the starboard side of the vessel) and up through the bilge compartment, or raceway, towards the helm control station. Use wire ties and cable fasteners as necessary. Run the harness up to the helm station and to the location of the trim/lift pump control plate, on the instrument/switch panel (which will be mounted at a later time, Step 10 on pages 42 - 45 in this manual).

NOTE: Wire harness comes in 5 lengths: 3 ft./.91 m

(30-183), 10 ft./3 m (30-182), 20 ft./6.1 m (30-181), 30 ft./9.1 m (30-227), 40 ft./12.2 m (30-228).

FIGURE 4N

FIGURE 4O

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 21

KONRAD MARINE INC

TRIM SYSTEM ELECTRICAL DRAWING

LIFT C ONTROL AS SEMBLY

FIGURE C: TRIM SYSTEM ELECTRICAL DRAWING (12 VOLT)

S WIT CH

TRI M/LIFT LIM IT

K.M. P/N 30-959

BKBK BK BK GY BK

OIL RESERVOIR

K.M. P/N 30-992

BOTTLE + SWI TC H

UNIT

K.M. P/N 30-959

TRI M/LIFT SE NDIN G

5 6 TE RMIN AL S TRIP 1

1 2 3 4

(12

POWER

RE LAY

CH AN GE OV ER

TE RMIN AL S TRIP 2

RE LAY (UP)

PU MP MOT OR

GR BL

POWER

RE LAY (DN)

K.M. P/N 30-200

TRI M/LIFT PUM P A SSEMB LY

NOT E:COND UCTORS (W IRES) NO T S UPP LIED BY KO NRA D MAR INE

CONNECT TO NEGATIVE/

Upd ated 2015

JANUARY 2003

DR AWI NG BY R .J.S.

AMP )

CIRCUIT

OF 12 VDC CIR CUIT (100

GR OUND SID E O F 12VDC

CONNECT TO POSITIVE SIDE

10' K.M. P/N 30-182

20' K.M. P/N 30-181

30' K.M. P/N 30-227

40' K.M. P/N 30-228

CONN ECTIN G H ARNES S

VOLT)

GAU GE SENDE R (RED)

HOT/PO SIT IVE (PU RPLE)

GR OUND /NEGATIVE (BL ACK )

LOW OIL IND ICATI ON (GR AY)

LIFT AB LE (WHIT E)

TR IM AB LE (ORA NGE)

TRI M/LIFT UP S OLENOID (BL UE)

TRI M/LIFT DOW N SO LE NOI D (GREEN)

SAME COLOR (AS CA LLED OU T IN T HE CON NECTI NG HARN ESS).

PURPLE, GR=GREEN, OR=ORANG E, WT=WHITE, GY=GRAY

NOT E:OTHER WIRES ARE LABLED AS: BK=BL AC K, BL=BL UE, RD =RED, PR=

NOT E:ALL WI RES PASSI NG T HROUG H 8-PIN CONNECTORS REMAIN THE

NOT E:ALL GROUN D/NEGATIVE WIRES ARE BLACK

POSI TIV E SID E OF

CONN ECT TO (12VDC)

POSI TIV E SID E OF

INS TRUM ENT PA NEL

CONN ECT TO (12VDC)

INSTRUMENT PANEL CIRCUIT

IL LUMIN ATIO N CIR CUI T

BLPR

GAU GE

"RED " L.E.D.

"GREEN" L.E.D.

MOMENTARY ACTION

"RED " L.E.D.

NOT E:S.P.D.T. SWITCHES HA VE

K.M. P/N 30-199

TRI M/

FIGURE D: TRIM SYSTEM ELECTRICAL DRAWING (24 VOLT)

KONRAD MARINE INC

TRIM SYSTEM ELECTRICAL DRAWING

LIFT C ONTROL AS SEMBLY

S WIT CH

TRI M/LIFT LIM IT

K.M. P/N 30-959

BKBK BK BK GY BK

OIL RESERVOIR

K.M. P/N 30-992

BOTTLE + SWI TCH

UNIT

K.M. P/N 30-959

TRI M/LIFT SE NDIN G

5 6 TERM INAL STR IP 1

1 2 3 4

(24

POWER

RE LAY

CH AN GE O V ER

TE RMIN AL S TRIP 2

RE LAY (UP)

PU MP MOT OR

GR BL

POWER

RE LAY (DN)

K.M. P/N 30-054

TRI M/LIFT PUM P A SSEMB LY

NOT E:COND UCTORS (WIR ES) NO T S UPP LIED BY KO NRA D MAR INE

GR OUND SID E O F 24VDC

CONNECT TO NEGATIVE/

UPDATED 2015

JANUARY 2003

DR AWI NG BY R .J.S.

CIRCUIT

CONNECT TO POSITIVE SIDE

OF 24 VDC CIR CUIT (50 A MP)

10' K.M. P/N 30-182

20' K.M. P/N 30-181

30' K.M. P/N 30-227

40' K.M. P/N 30-228

CONN ECTIN G H ARNES S

VOLT)

GAU GE SENDE R (RED )

HOT/PO SIT IVE (PU RPLE)

GR OUND /NEGATIVE (BL ACK )

LOW OIL IND ICATI ON (GR AY)

LIFT AB LE (WHIT E)

TR IM AB LE (ORA NGE)

TRI M/LIFT UP S OLENOID (BL UE)

TRI M/LIFT DOW N SO LEN OI D (GREEN)

SAME COLOR (AS CA LLED OU T IN T HE CON NECTI NG HARN ESS).

PURPLE, GR=GREEN, OR=ORANG E, WT=WHITE, GY=GRAY

NOT E:OTHER WIRES ARE LABLED AS: BK=BL AC K, BL=BL UE, RD =RED, PR=

NOT E:ALL WI RES PASSI NG T HROUG H 8-PIN CONNECTORS REMAIN THE

NOT E:ALL GROUN D/NEGATIVE WIRES ARE BLACK

POSI TIV E SID E OF

CONN ECT TO (24VDC)

POSI TIV E SID E OF

INS TUMEN T PA NEL

CONN ECT TO (24VDC)

INS TUME NT P ANEL CIR CUIT

IL LUMIN ATIO N C IRCUI T

BLPR

GAU GE

"RED " L.E.D.

"GREEN" L.E.D.

MOMENTARY ACTION

"RED " L.E.D.

NOT E:S.P.D.T. SWITCHES HA VE

K.M. P/N 30-180

TRI M/

Step 5: Stern Drive Installation

NOTE: If this is a direct couple tailpiece application, do

not install the stern drive at this time. Return to this step

after completing Step 6A on page 29 in this manual.

5.1 Rig the Konrad drive for lifting. Secure the stern drive to the lifting device with a nylon strap.

NOTE: Optional lifting bracket (12-388) is available to

assist in the lifting process (see Figure 5A).

520 Stern Drive Weight is 188 lbs. (85.3 kg) 540 Stern Drive Weight is 153 lbs. (69.4 kg) 560 Stern Drive Weight is 167 lbs. (75.7 kg)

NOTE: An overhead lifting device is the preferred meth-

od of lifting the Konrad drive. A lifting cart or forklift may

be used as an alternate lifting device.

5.2 Remove the six (6) nuts (10-334) and six (6) washers (10-415) from the bell housing studs (10-250). (These nuts and washers are on the studs when shipped from Konrad).

FIGURE 5A

FIGURE 5B

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 24

Step 5: Stern Drive Installation (continued)

5.3 Using marine grade grease, grease both sides of the gasket (10-305) and slide it over the six (6) studs on the bell housing. Slide it forward until it makes full contact with the bell housing face.

NOTE: Observe proper orientation of gasket.

FIGURE 5C

5.4 Grease the o-rings (10-306) (see Figure 5D) and (10-493) (see Figure 5E).

FIGURE 5D

FIGURE 5E

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 25

Step 5: Stern Drive Installation (continued)

5.5 Grease the splined end yoke shaft (10-365).

5.6 Grease one end of the engagement pin (10-494) (see Figure 5G). Insert greased end into the end of the splined end yoke shaft (see Figure 5H). Three quarters (3/4) of the engagement pin should remain beyond the end of the splined end yoke shaft.

FIGURE 5F

FIGURE 5G

FIGURE 5H

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 26

Step 5: Stern Drive Installation (continued)

5.7 Slide drive onto transom assembly. The splined end yoke shaft and u-joint assembly must be held up and guided into the gimbal carrier or tailpiece assembly.

NOTE: It may be necessary to rotate the splined end

yoke shaft (this can be achieved by sliding the propeller

onto the splined propeller shaft and rotating it back and

forth or re-orientating input yoke using a screwdriver as pictured in Figure 5I) or yoke assembly so the splines line up for the drive to be fully seated against the transom assembly.

NOTE: If the stern drive does not engage easily, pull

stern drive back, reset engagement pin and reattempt 5.7.

WARNING! Do not impact or apply force to the drive

while engaging the input shaft as this will damage the gimbal carrier seal.

FIGURE 5I

5.8 Fasten the stern drive to the transom assembly using the six (6) nuts and six (6) washers provided. Torque to 55 lb. ft. (74 Nm).

NOTE: Be sure to put the continuity cable ring on the

upper starboard stud before putting the washer and nut on.

An alternate method of stern drive installation is to remove

the gimbal carrier assembly (non-tailpiece applications) from the gimbal housing (inside of the vessel). This can be done by removing the three (3) S.H.C.S. (10-385). Hold up the splined end yoke shaft and guide it into gimbal carrier as the carrier is reinstalled. Torque the three (3) S.H.C.S. (10-385) to 70 lb. ft. (95 Nm).

FIGURE 5J

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 27

(Rear Mount

Tailpiece)

(Rubber)

Driveshaft

w/Rubber

Couplings

(w/slip joint)

Driveshaft

w/Rubber

Couplings

(w/slip joint)

Constant

Velocity (CV)

NOTE:

FIGURE E: ALIGNMENT SPECIFICATIONS CHART

Stern Drive

Carrier Type

Type

Transmission

Compound

Thread Lock

Torque

(Fasteners)

Tools

Suggested

Coupling

Orientation

N/A

Coaxial

Tail Piece

3-Lobe

30-301

Output

Flange

Yes

95 Nm

70 ft. lbs.

11-284

GO-017

Yes

(See

Step 15)

3-Lobe

Output

Yes

70 ft. lbs.

GO-017

Yes

(See

30-301

Flange

95 Nm

TO-096

Step 15)

3-Lobe

Output

Yes

70 ft. lbs.

11-284

GO-017

Yes

(See

30-301

Flange

95 Nm

Step 15)

30-303

Output

Flange

Yes

115 Nm

85 ft. lbs.

N/A GO-017

30-303

Output

Flange

Yes

121 Nm

89 ft. lbs.

GO-017

Yoke

Orientation

Compensation

Parallelism Concentricity Axial Slip

Fixed

(Range)

Part # Length

Alignment Speciﬁcations Chart for Transmission to Stern Drive Coupling

Type

Direct

Coupling

N/A N/A Fixed N/A TO-094 N/A N/A

(Close

Couple)

30-449

N/A

< .003 in.

Fixed

(Close

30-286

30-287

Direct

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 28

< .076 mm

Couple)

30-464

1 in.

25.4 mm

< .010 in.

< .254 mm

< .010 in.

< .254 mm

9 - 15 in.

23 - 38 cm

30-264

Short

1 in.

25.4 mm

< .010 in.

< .254 mm

< .010 in.

< .254 mm

15 - 48 in.

38 - 122 cm

30-272

Long

1/16 in.

Max 2° Max Offset 2°

>9.5 - <55 in.

11-797

1 in.

1.59 mm

Offset

Compound

< .010 in.

>9.5 - <60 in.

25.4 - 140 cm

30-391

30-043

U-Joint

25.4 mm

between

.5°< x <1°

< .254 mm

24 - 152 cm

Carden

In most cases, the use of a u-joint shaft is not recommended, please contact Konrad for approval prior to installation.

Step 6: Alignment Procedures

NOTE: General vessel installation plans should be di-

rected at near straight shaft angles. The shaft’s maximum

misalignment tolerances should be reserved for temporary movement of components while the vessel is underway.

A) Direct Couple Rear Mount

with Tailpiece

1) Attach transmission to engine.

2) Attach tailpiece unit to transmission.

3) Slide o-ring on to tailpiece.

4) Lightly grease o-ring.

5) Position engine into vessel.

6) Slide tailpiece into gimbal housing bore.

7) Fasten tail piece assembly to tail piece

mounting plate.

8) Use Tool TO-094 for alignment. Shaft must

slide easily into tailpiece spline until fully engaged to the limiting shoulder surface.

FIGURE 6A

NOTE: See Step 19 for complete detailed instructions.

B) Direct Rubber Coupling

1) Rubber coupling must be oriented for transmis-

sion output rotation in forward mode in Steps 15 on pages 64 - 67 in this manual.

2) Install engine transmission and shaft to gimbal

carrier trilobe ange. Do not tighten any bolts.

3) Transmission output ange must be indicated

to the gimbal carrier outside diameter (and face) within .003 in. (.076 mm). Adjust engine mounts accordingly.

4) Tighten all fasteners to specied torque of

70 lb. ft. (95 Nm).

as stated

FIGURE 6B

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 29

Step 6: Alignment Procedures (continued)

C) Rubber Coupling Extension Shafts

1) Remove frost plug (10-485).

2) Fasten alignment ange (11-284) to gimbal

carrier.

3) Fix magnetic base, arm and dial indicator

assembly (GO-017) to transmission output

ange. Complete assembly must be rigidly

fastened.

4) Rotate transmission ange indicating the

face of the alignment ange. All facial

measurements must be within .010 in. (.25 mm).

5) Rotate transmission ange indicating the

circumference of the alignment ange. All

measurements must be within .010 in. (.25 mm).

6) Remove alignment ange and install frost plug.

7) Install rubber coupling drive shaft assembly

according to Step 15 on pages 64 - 67 in this manual.

8) For longer extension shafts, an extension piece

should be attached to the transmission ange. The dial indicator base can be xed to this

extension piece allowing the indicator to reach

the alignment ange. The extension piece, dial

indicator base and arm must all be rigidly fastened.

Part # 30-264

NOTE: Drawing shows drive in clockwise position

Part # 30-272

NOTE: Drawing shows drive in counterclockwise position

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 30

Step 6: Alignment Procedures (continued)

D) U-Joint Extension Shaft

NOTE: It is recommended to hold either the horizontal or

vertical offset at zero and achieve the offset in one plane. In most cases it is easier to hold the horizontal measurement at zero. In most cases, the use of a u-joint shaft is not

recommended, please contact Konrad for approval prior to installation.

1) Transmission output ange and gimbal carrier

input ange must be parallel within .010 in.

(.25 mm).

2) Transmission output ange and gimbal carrier

input ange must have a compounded vertical

and horizontal offset angle (a) which is

1.0˚ > (a) > 0.5˚. This dimension is a function

of the length of the shaft.

3) To determine vertical offset (see Figure 6D)

(x): x = tan a (y - 3.376 in.) or (x): x = tan a (y - 8.575 cm)

4) Fix magnetic base, arm and dial indicator

assembly (GO-017) to transmission output

ange.

5) Rotate transmission ange indicating the face

of the alignment ange. All facial mea-

surements must be within .010 in. (.25 mm).

6) Rotate transmission ange indicating the cir-

cumference of the alignment ange. All mea-

surements must be within .010 in. (.25 mm). Offset measurements are according to calcula tion in section D3 above.

7) Refer to Step 16 on pages 68 - 69 in this manual

for u-joint extension shaft installation.

FIGURE 6C

FIGURE 6D

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 31

Step 6: Alignment Procedures (continued)

E) CV Extension Shaft

NOTE: The transmission output ange and gimbal

carrier input ange must be parallel within two de-

grees (2°) or manufacturer’s approval dependent on power and RPM levels.

1) A constant velocity joint is recommended over

a u-joint shaft because, unlike the u-joint, it has

no signicant impacts on the stern drive gear

sets.

2) The transmission output ange and gimbal car-

rier input ange must be concentric within the manufacturer’s recommended specications.

3) Fix magnetic base, arm and dial indicator

assembly (GO-017) to transmission output

ange.

4) Rotate transmission ange indicating the face

of the alignment ange. All facial measure-

ments must be within manufacturer’s require ments.

5) Rotate transmission ange indicating the

circumference of the alignment ange. All

measurements must be within the manufac turer’s requirements.

6) Refer to Step 17 on pages 70 - 71 in this manual

for CV extension shaft installation.

7) The axial distance must be within .0625 in.

(1.59 mm) of the shaft’s working length

(including the adapter anges).

FIGURE 6E

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 32

Step 7: Trim Cylinder Installation

7.1 Remove the nut (10-314), the outer retaining washer (10-

444), and the outer bushing (10-443) from the forward trim cylinder anchor pin (port and starboard side).

7.2 Locate the rear anchor pin assembly and remove all hardware and bushings. Slide the rear anchor pin through the anchor pin bore in the aft end of the upper housing.

FIGURE 7A

7.3 Following the order listed, place one washer (10-442), spacer (12-535), one washer (10-442) and bushing (10-

443) (tapered pointing away from drive) on to the port and starboard side of the rear trim cylinder anchor pin.

7.4 Slide the trim cylinders onto the anchor pins.

NOTE: If trim cylinders are at an inappropriate length

to t onto the anchor pins, the drive must be lifted up manually or the red caps (see Step 7.6 on page 34 in this

manual) must be removed and length must be adjusted.

CAUTION: Fluid may run or squirt out of the ports when

adjusting length.

FIGURE 7B

FIGURE 7C

NOTE: The end of the trim cylinder with the hydraulic

line inputs must be face up and closest the transom.

FIGURE 7D

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 33

Step 7: Trim Cylinder Installation (continued)

7.5 Place bushing (10-443), retaining washer (10-444) and nylock nut (10-314) on forward and aft anchor pins. Tighten the forward nuts to 20 lb ft (27 Nm). Tighten the aft nut so the retaining washer (10-444) bottoms out on the shoulder of the anchor pin. Make sure at least two or three (2-3) threads are showing beyond the end of the nuts.

NOTE: Install all four (4) nylock nuts (10-314) before

tightening nuts completely.

7.6 Remove the red caps from the trim cylinders if they have not been removed previously (see step 7.4 on page 33 in this manual). The trim cylinders have red plastic caps in the hydraulic line ports when they are shipped from Konrad.

FIGURE 7E

7.7 Hook up the four (4) trim lines (from the transom assembly to the trim cylinders) according to their tags. The line input on the trim cylinders closest to the transom is up.

NOTE: Ensure to not cross thread the hose’s ttings and

tighten down until snug. DO NOT overtighten. Check for leaks after the trim pump is bled (Step 11 on pages 46-47 in this manual).

FIGURE 7F

FIGURE 7G

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 34

FIGURE F: TRIM ASSEMBLY DIAGRAM

DOWN HYDRAULIC LINE

DOWN

PORT

UP HYDRAULIC LINE

Complete 30-002 Trim Assembly

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 35

FIGURE G: TRIM ASSEMBLY INDIVIDUAL COMPONENTS

Individual Components

Item #

1 Pin , Anchor 2 10-458

2 Washer 6 10-442

3 Bushing, Anchor Pin 8 10-443

4 Cylinder, Trim, Assembly OR 2 30-024

5 Washer 4 10-444

6 Nut 4 10-314

7 Hose, Oil (Black) 32 in. (81 cm) OR 1 10-490

9 Hose, Braided, Trim 4 11-078

Description Qty. Part #

Cylinder, Trim, Assembly (with stops) 2 30-265

Hose, Oil (Black) 48 in. (122 cm) 1 11-170

Hose, Oil (Gray) 32 in. (81 cm) OR 1 10-489

Hose, Oil (Gray) 48 in. (122 cm) 1 11-180

10 Spacer, Anchor Pin 2 12-535

13 Connector 1 10-331

14 Anode 2 11-277

15 Anode 2 10-434

Screw 4 11-278

Pump, Trim (Pump Only), 12 Volt OR Pump Assembly, Trim, 12 Volt

Pump, Trim (Pump Only), 24 Volt OR Pump Assembly, Trim, 24 Volt

10-430 30-200

10-690 30-054

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 36

Step 8(a): 520 & 540 Propeller Installation

8.1a Grease and slide thrust washer onto propeller shaft (model 520 only).

NOTE: Tapered end of thrust washer must

be towards the drive.

8.2a Grease splined area and the threads of the propeller shaft.

8.3a Place the propeller on the propeller shaft followed by the appropriate hardware (see below).

8.4a Torque the propeller nut to 80 lb. ft. (109 Nm) for the 520 model. When approaching 80 lb. ft. (109 Nm), 520 model only, 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.

8.5a Torque the propeller nut to 55 lb. ft. (75 Nm) for the 540 model only.

8.6a Bend over the tabs using appropriate tools, 520 model only.

Model 520

Description Qty Part #

A ............Prop shaft (L) OR .......... 1 ......... 10-360

Prop shaft (R) ................. 1 ......... 10-363

B ............ Forward thrust hub ......... 1 ......... 10-292

C ............ Propeller ......................... 1 ........ variable

D ............ Splined washer ............... 1 ......... 10-293

E ............Tab washer ..................... 1 ......... 10-295

F ............Propeller nut .................. 1 ......... 10-296

Model 540

Description Qty Part #

A ............ Prop shaft (L) OR ...........1.........10-677

Prop shaft (R) .................1.........10-596

B ............ Propeller .........................1........ variable

C ............ Prop hardware kit ...........1.........10-680

D ............ Propeller nut ................. 1/0 .......10-667

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 37

Step 8(b): 560 Propeller Installation

8.1b Slide forward thrust prop onto forward prop shaft so the tapers meet. Some grease can be used on tapers to hold in place.

8.2b Grease splined area and the threads of the forward propeller shaft.

8.3b Place the forward propeller on the propeller shaft until it seats against thrust hub.

8.4b Torque the forward propeller nut to 100 lb.ft (136 Nm) using hex wrench TO-121.

Model 560

8.5b Slide rear thrust prop onto rear prop shaft so the tapers meet. Some grease can be used on tapers to hold in place.

8.6b Grease splined area and the threads of the forward propeller shaft.

8.7b Place the forward propeller on the propeller shaft until it seats against thrust hub.

8.8b Torque the rear propeller nut to 60 lb.ft (81 Nm) using 1

/16” socket wrench.

Model 560

Description Qty Part #

A ............ Forward prop shaft ....................... 1 12-502

B ............ Thrust hub ..................................... 1 12-509

C ............ Rear propeller ............................... 1 variable

D ............ Forward prop nut .......................... 1 12-506

E ............ Rear prop shaft ............................. 1 12-503

F ............ Thrust hub ..................................... 1 12-508

G ........... Rear propeller .............................. 1 variable

H ........... Rear prop nut ............................... 1 12-529

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 38

Step 9: Stern Drive Lubrication

Pour Method:

9.1 Remove the top cover (10-209) of the stern drive by removing the six (6) socket head cap screws (10-110). If applicable, remove emergency tiller arm bracket (12-

388) by removing the two (2) socket head cap screws (12-

421) and two (2) nylon washers (11-033) and the four (4) socket head cap screws (10-110).

9.2 Pour in gear oil until drive is full.

FIGURE 9A

9.3 Wait fteen (15) minutes. Rotate the propeller ve or six (5-6) times in both directions during those fteen (15)

minutes.

9.4 Repeat steps 9.2 and 9.3.

9.5 Replace the top cover and the emergency tiller arm bracket if applicable, and torque to 20 lb. ft. (27 Nm).

NOTE: Make sure top cover o-ring (10-303) is greased

and properly seated.

FIGURE 9B

FIGURE 5C

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 39

Step 9: Stern Drive Lubrication (continued)

Pump Method: (Pump Required)

9.1a Remove the upper breather screw (10-010) located on the top port side of the upper housing (see Figure 9D). Remove the lower drain plug (10-155) located on the lower housing under the tip of the nose cone on the 520 model (see Figure 9E), and the starboard side of the lower housing on the 540 and 560 models (see Figure 9F).

FIGURE 9D

FIGURE 9E

FIGURE 9F

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 40

Step 9: Stern Drive Lubrication (continued)

9.2a Pump gear oil into the drive using a pump from the bottom until it comes out of the top breather plug. Let the gear oil

settle for ten to fteen (15) minutes. Pump additional oil

until it comes out of the top breather plug.

FIGURE 9G

9.3a Replace upper breather screw (see Figure 9D on page 40 in this manual) and lower drain plug (see Figure 9E or 9F on page 40 in this manual depending on stern drive model).

NOTE: Both drain plug and breather screw seal/gasket

(10-285) must be in place and properly seated when

reinstalled.

FIGURE 9H

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 41

Step 10: Trim/Lift Control Module Installation

10.1 Select an appropriate location at the helm to mount the trim/lift control module (the dimensions are 3.125 in. (7.938 cm) x 5.032 in. (12.781 cm) and 4 in. (10 cm) deep, see Figure 10A). The module should be mounted in plain view and reach of the boat operator.

NOTE: For a twin application, it may be desirable to

mount both modules next to each other so they can be operated with one hand simultaneously (see Figure

10B).

FIGURE 10A

FIGURE 10B

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 42

Step 10: Trim/Lift Control Module Installation (continued)

2.510

10.2 Layout the cutout area and mark the four (4) holes that need to be drilled per the drawing below.

NOTE: Do not scale the drawing or use it as a template.

(63.8mm)

4x R3/

(R9.5mm)

(65.1mm)

2.563

1.255

(31.9mm)

2.247

(57.1mm)

4x 011/

(04.5mm)

4.494

(114.1mm)

10.3 Use a reciprocating saw to cut out the area laid out in the previous step. Drill the four (4) holes laid out in the previous step.

NOTE: Touch up and remove burs from the cutout area

with a le.

4.375

(111.1mm)

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 43

Step 10: Trim/Lift Control Module Installation (continued)

10.4 Mount the module in the cutout area using the hardware provided.

NOTE: If access under the panel is limited, the module

may need to be wired before mounting.

FIGURE 10C

10.5 Connect the purple wire to a +12 VDC or +24 VDC source (whichever is the operating voltage of the vessel) that is powered when the ignition key is in the “on” position.

NOTE: Refer to the Trim System Electrical Drawings

(Figure C and Figure D on pages 22 and 23 in this manual) for further documentation on this and proceeding instructions.

NOTE: Battery or batteries must be disconnected while

all electrical connections are being made.

10.6 Connect the blue wire to the positive side of the instrument panel illumination circuit.

FIGURE 10D

FIGURE 10E

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 44

Step 10: Trim/Lift Control Module Installation (continued)

10.7 Connect the eight (8) wire harness (run in Step 4.13) to the eight (8) wire pigtail on the trim/lift control module.

NOTE: Bundle, cable tie and secure any excess harness.

FIGURE 10F

10.8 Mount the module in the cutout area using the hardware provided (if not done in Step 10.4 on page 44 in this manual).

FIGURE 10G

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 45

Step 11: Trim/Lift Pump Filling/Bleeding Procedure

11.1 Fill the trim/lift pump reservoir with Automatic Transmission Fluid type Dextron III or a non-foaming light hy-

draulic uid.

NOTE: If ATF Dextron III is not used, it is recommended

that the trim cylinders be purged of any uid since they are shipped new from Konrad with this uid in them.

FIGURE 11A

11.2 Place the return line of the trim cylinders (the line labeled

“down”) in a container to catch any purged uid. The “up”

line should already be attached from Step 4.12 on page 21 in this manual (Trim/Lift Pump Installation). Hold one

nger 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 switches on the trim/lift control plate.

NOTE: Only the toggle switch whose LED is illuminated

can be used to trim or lift the drive.

NOTE: Fluid may need to be added if the reservoir bottle

level goes below the minimum.

FIGURE 11B

FIGURE 11C

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 46

Step 11:

11.3 With the drive in the up position, attach the “down” line to the trim/lift pump.

11.4 Cycle the drive all the way to the down position 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 uid level of the reservoir. Add

uid if necessary.

Trim/Lift Pump Filling/Bleeding Procedure

(continued)

FIGURE 11D

NOTE: Check entire trim system (inboard and outboard

the transom) for leaks before proceeding.

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 47

Step 12: Setting Trim/Lift Limit & Sender Switch

NOTE: If mechanical trim indicators are used, skip

Step 12 and refer to the manufacturers instructions for installation and adjustment.

FIGURE 12A

12.1 Trim the drive all the way to the down position, approximately negative seven degrees (-7º).

NOTE: In the case where trim limiting trim cylinders

are used, trim the drive all the way to the down position,

approximately negative two degrees (-2º).

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 48

FIGURE 12B

Step 12: Setting Trim/Lift Limit & Sender Switch (continued)

12.2 Loosen the starboard side switch on the transom assembly and rotate the switch until gauge reads DN (farthest down position).

NOTE: If this position cannot be achieved by rotating

the switch, it will be necessary to take the switch completely off the transom assembly and rotate the gray star-

hex shaped knob until desired position is achieved. Re-

mount the switch and ne tune.

FIGURE 12C

12.3 Set the drive at approximately eight degrees (+8°). This can be accomplished by trimming the drive up until the trim cylinder measures 22 in. (56 cm) between the center of the front anchor pin and the center of the rear anchor pin.

NOTE: Alternate method of setting the drive at eight

degrees (+8°): Insert a 1 in.(2.54 cm) shim at the front of

the top cover. Place one end of a level on the 1 in. (2.54 cm) shim and the other end on the back of the top cover. Trim the drive up or down until the level indicates levelness.

12.4 Loosen the port side switch on the transom assembly and rotate until the red and green LED’s are on the verge of switching.

NOTE: If this position cannot be achieved by rotating

the switch, it will be necessary to take the switch off the transom and rotate the gray star-hex shaped knob until desired position is achieved. Remount the switch and ne

tune.

FIGURE 12D

FIGURE 12E

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 49

Step 13: Manual Hydraulic Steering System Installation

13.1 Steering cylinder bracket should have been mounted when the transom assembly was installed (Step 2.3 on page 13 in this manual). If not, take the two (2) nuts and washers off the transom assembly studs, and mount the steering cylinder bracket at this time.

NOTE: It is also necessary to connect the continuity

cable ring to the port side stud (if applicable), if this has

not been previously done.

13.2 Install steering cylinder assembly.

FIGURE 13A

13.3 With the steering cylinder ram and tiller arm in the center position, adjust the drag link to the correct length and attach it between the cylinder and the tiller arm with the hardware provided.

NOTE: For a twin engine installation with an internal

tie bar, verify center to center stern drive mounting distance (on the xed transom assembly) and adjust tie bar to length to match. Attach the tie bar to the tiller arms

with the hardware provided.

13.4 Connect the long continuity wire from the steering bracket to the tiller arm (if applicable).

FIGURE 13B

FIGURE 13C

FIGURE 13D

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 50

Step 13: Manual Hydraulic Steering Installation (continued)

13.5 Determine the correct mounting location for the helm assembly.

NOTE: Be sure there is adequate clearance under the

dash for the helm assembly and hoses.

NOTE: Be sure there is adequate clearance above the

dash for the steering wheel.

Lay out and cut/drill the appropriate area described by the

template provided from the manufacturer.

13.6 Install the helm assembly with the hardware provided.

13.7 Install the steering wheel with the hardware provided.

FIGURE 13E

FIGURE 13F

FIGURE 13G

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 51

Step 13: Manual Hydraulic Steering Installation (continued)

13.8 Determine the correct location and mount the reservalve.

FIGURE 13H

13.9 Mark/identify the two (2) steering lines/hoses (port and starboard). Run the two (2) lines from the steering cylinder to the reservalve. Mark/identify the three (3) steering lines/hoses (port, starboard and reservalve). Run the three (3) lines from the reservalve forward through the starboard raceway, and up to the helm assembly. Fasten lines as necessary. Bundle/coil excess and secure if necessary.

13.10 Attach the two (2) hydraulic steering lines to the steering cylinder assembly, observing port and starboard identication.

NOTE: Please refer to the 30-462R routing diagram

(Figure H on page 54 in this manual) for assistance and further explanation.

FIGURE 13I

FIGURE 13J

500 SERIES INSTALLATION MANUAL JULY 2016PAGE 52

Step 13: Manual Hydraulic Steering Installation (continued)

13.11 Attach the other three (3) hydraulic steering lines to the helm assembly, observing port, starboard and reservalve

identication.

NOTE: Please refer to the 30-462R routing diagram

(Figure H on page 54 in this manual) for assistance and further explanation.

FIGURE 13K

13.12 Attach all ve (5) lines to the reservalve.

NOTE: Please refer to the 30-462R routing diagram

(Figure H on page 54 in this manual) for assistance and further explanation.

13.13 Fill helm assembly or reservoir valve with the appropriate

uid.

13.14 Bleed system per manufacturer’s specications.

NOTE: Additional uid may need to be added during the

bleeding process.

13.15 Check system for leaks.

FIGURE 13L

500 SERIES INSTALLATION MANUALJULY 2016 PAGE 53

DRAWING NO.

FIGURE H: ROUTING DIAGRAM 30-462R

REVISION

SYM

DATE

PLEASE CORRESPOND YOUR

LENGTHS TO THE NUMBERS

ON THE DIAGRAM

30-462R

APP.BY:

DRAWN BY: SC

1:1

SCALE:

Konrad

TITLE:

MAT'L:

.020

TOLERANCE

.XX

NEXT ASS'Y

ROUTING DIAGRAM

DRAWING NUMBER

8/3/06

DATE:

.005

.010

.XXX

RESERVALVE

STARBOARD LINE CONNECTION

TOP CYLINDER PORT FOR

R P

BYPASS HOSE

STEERING CYLINDER

DO NOT SCALE DRAWING

WEIGHT:

THIS DOCUMENT AND THE INFORMATION

CONTAINED HEREIN IS CONFIDENTIAL

CONTENT DISCLOSED, IN WHOLE OR IN

PART, WITHOUT PRIOR WRITTEN CONSENT

OF KONRAD MARINE.

AND PROPRIETARY PROPERTY AND MUST

NOT BE USED, REPRODUCED, OR ITS

30-462R

UNIT

HELM