Mercury Zeus 3000 User Manual

Identification Record

41269

Please record the following information:

The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Cummins MerCruiser Diesel product. When contacting Cummins MerCruiser Diesel (CMD) about service, always specify model and serial numbers.

Refer to the engine operation and maintenance manual available from the engine manufacturer for the location of the engine data tag, which contains the engine serial number and model number.

90-866938081 509

*866938081*

Drive serial number locations

a - Transmission serial number plate b - Drive serial number decal and

stamping

Please record the following information:

Drive Serial Numbers Zeus Drive Serial Number Transmission Serial Number

Port

Starboard

Engine Model and Horsepower Engine Serial Number

Propeller Information Propeller Part Number Pitch

Front ‑

Rear ‑

Boat Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Boat Length

Exhaust Gas Emissions Certificate Number (Europe Only)

The description and specifications contained herein were in effect at the time this guide was approved for printing. CMD, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation.

Port Starboard

© 2009 Mercury Marine CMD Zeus 3000 Series Pod Drive Models

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Bravo Two, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, VesselView, Zeus, Axius, Total Command, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all trademarks or registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

Welcome

You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure operating ease and durability.

With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual, which contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for reference whenever you are on the water.

Thank you for purchasing one of our Cummins MerCruiser Diesel products. We sincerely hope your boating will be pleasant.

Cummins MerCruiser Diesel

Warranty Message

The product you have purchased comes with a limited warranty from Cummins MerCruiser Diesel; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.

Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your dealer for a demonstration of the actual starting and operating procedures.

Notice

Throughout this publication, and on your power package, dangers, warnings, cautions, and

notices, accompanied by the International Hazard Symbol installer and user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.

These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions while performing the service, plus common sense operation, are major accident prevention measures.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

DANGER

WARNING

, may be used to alert the

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates a situation which, if not avoided, could result in engine or major component failure.

IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.

WARNING

The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.

WARNING

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Section 1 - Limited Warranty

Warranty Information...............................................2

Warranty Registration—United States and

Canada.............................................................2

Warranty Registration—Outside the United

States and Canada...........................................2

High Output Recreational Use World‑Wide

Limited Warranty..............................................3

Section 2 - Getting to Know Your Power Package

General Information...............................................14

Models Covered.............................................14

Drive Serial Number and Decal Placement....14

Features and Controls...........................................14

E‑Stop (Emergency Stop) Switch, If

Equipped........................................................14

Instrumentation...............................................15

VesselView...................................................15

SmartCraft Speedometer and Tachometer

Digital Gauges (If Equipped)........................15

System Link Digital Gauges (If Equipped)...16

Electronic Helm Steering................................17

Intermittent Commercial Use World‑Wide

Limited Warranty..............................................7

Zeus Drive Limited Warranty Against Corrosion

(Worldwide)....................................................10

Emission Warranty.........................................11

Transfer Of Warranty......................................11

Dual‑Handle Electronic Remote Control (ERC)—

Features and Operation.................................17

Operation.....................................................17

Basic Joystick Operation................................18

Electrical System Overload Protection...........18

Vessel Interface Panel (VIP) Overload

Protection.....................................................19

Overload Protection for the DC Voltage

Regulator System, If Equipped ...................19

Overload Protection for Other Circuits.........20

Galvanic Isolator and Monitor.........................20

Section 3 - On the Water

Safe Boating Suggestions.....................................25

Be Alert to Carbon Monoxide Poisoning........26

Good Ventilation...........................................26

Poor Ventilation ...........................................27

Basic Boat Operation.............................................27

Freezing Temperature and Cold Weather

Operation........................................................27

Drain Plug and Bilge Pump............................28

Protecting People in the Water.......................28

While the Boat is Moving..............................28

While the Boat is Stationary.........................29

Wave and Wake Jumping..............................29

Impact with Underwater Hazards...................29

Zeus Drive Impact Protection.........................30

Zeus Drive Alignment.....................................31

Conditions Affecting Boat Operation.....................31

Weight Distribution (Passengers and Gear)

Inside the Boat...............................................31

Bottom Of Boat...............................................31

Cavitation.......................................................31

Ventilation.......................................................31

Propeller Selection.........................................31

Getting Started......................................................32

Break‑In Period (New or With Replacement

Gears)............................................................32

DC Voltage Regulator Switch, If Equipped.....32

Starting and Stopping the Engines.................33

Normal Starting............................................33

Normal Stopping..........................................35

Starting an Engine Using the VIP SmartStart

Switch...........................................................35

Stopping the Engine Using the VIP SmartStart

Switch...........................................................37

Traditional Maneuvering with Steering and

Thrust.............................................................38

To Maneuver the Boat in Forward................38

To Steer the Boat in Tight Turns at Low

Speeds.........................................................38

To Spin the Boat on its Axis at Low Speeds 39

Maneuvering with the Joystick.......................39

90-866938081 MAY 2009 Page i

Trim Tabs......................................................43

Automatic Control....................................... 43

Manual Control............................................44

Using Trim Tab Offset.................................44

Special Digital Throttle and Shift (DTS)

Features........................................................45

Troll and Throttle Response........................46

Dock............................................................47

Throttle Only............................................... 47

Single Lever (1 Lever) Operation................48

Synchronizing the Engines......................... 49

Cruise Control............................................... 49

Helm Transfer.......................................................50

Requesting Helm Transfer............................ 50

Helm Transfer and Precision Pilot.................51

Precision Pilot.......................................................51

Precision Pilot Trackpad Features................ 51

General Information.................................... 51

Standby.......................................................51

Standby and Active Lights.......................... 52

Power Icon..................................................53

Skyhook (If Equipped)...................................53

Engaging (Activating) Skyhook...................55

The Skyhook Screen in VesselView........... 57

Disengaging (Deactivating) Skyhook..........57

Auto Heading................................................ 58

Engaging Auto Heading..............................58

Course Adjustment Using the Turn Buttons or

Joystick....................................................... 59

To Resume a Heading ...............................60

Disengaging Auto Heading......................... 60

Response Button...........................................62

Track Waypoint............................................. 62

Engaging Track Waypoint Mode.................63

Disengaging Track Waypoint Mode............64

Turn Buttons or Joystick in Track Waypoint

Mode...........................................................64

Auto Heading Button in Track Waypoint

Mode ..........................................................64

Acknowledging a Turn During a Waypoint

Arrival..........................................................64

Waypoint Sequence....................................66

Contingent Operations......................................... 68

Steering—Emergency Alternative Method....68

Port Engine Only Operation.......................... 69

Gear Engagement—Emergency Procedure. 69

Steering and Trim—Manual Override........... 70

Procedure for a Stuck Steering Control

Valve...........................................................72

Procedure for a Stuck Trim Tab Control

Valve...........................................................73

End of First Season Checkup...............................73

Section 4 - Specifications

Drive Gear Lubricant............................................ 76

Transmission........................................................76

Steering Actuator and Trim Oil.............................76

Section 5 - Maintenance

Product Responsibilities.......................................80

Owner and Operator Responsibilities........... 80

Dealer Responsibilities..................................80

Do‑It‑Yourself Maintenance Suggestions......80

Inspection......................................................81

Drive Service Point Locations.............................. 82

Starboard...................................................... 82

Port................................................................82

Top................................................................83

Drop Box....................................................... 83

Maintenance Schedules.......................................83

Application.....................................................83

Routine Maintenance.................................... 84

Scheduled Maintenance................................84

Maintenance Log...........................................85

Drive Cover, If Equipped...................................... 87

Approved Paints...................................................76

Approved Lubricants............................................ 76

Removing the Drive Cover............................87

Cleaning and Inspecting the Drive Cover......87

Installing the Drive Cover..............................88

Drive Gear Lube...................................................90

Drive Gear Lubrication.................................. 90

Checking....................................................... 91

Filling.............................................................93

Changing.......................................................94

With the Boat in the Water..........................94

With the Boat Out of the Water...................97

Steering Actuator and Trim—Hydraulic Oil.......... 99

Checking....................................................... 99

Filling...........................................................100

Changing.....................................................102

Transmission Oil (Fluid) and Filter.....................102

Checking.....................................................102

Page ii 90-866938081 MAY 2009

Filling............................................................104

Changing......................................................106

Seawater System................................................110

Draining the Seawater System.....................110

Boat out of the Water.................................110

Boat in the water........................................112

Checking the Seawater Pickup on the Drive 115

Seawater Strainer.........................................116

Flushing the Seawater System.....................116

Battery.................................................................116

Gauges................................................................116

Checking Gauges.........................................116

Cleaning Gauges..........................................117

Electrical System.................................................117

Cooling System and Exhaust System.................117

Lubrication...........................................................117

Driveshaft Slip‑Joint ....................................117

Driveshaft U‑Joints ......................................119

Propeller Shaft..............................................121

Corrosion and Corrosion Protection....................122

The Causes of Corrosion.............................122

Corrosion Protection.....................................122

Anodes and MerCathode System ...............123

Reference Electrode Wire of the MerCathode

System.........................................................124

MerCathode Anode......................................124

Checking....................................................124

Replacing...................................................124

MerCathode System Testing........................124

Trim Tab Anode............................................125

Checking....................................................125

Replacing...................................................125

Continuity Circuits........................................126

Inhibiting Corrosion......................................127

Painting the Boat..........................................127

Propellers............................................................128

Propeller Removal........................................128

Propeller Repair...........................................129

Propeller Installation.....................................130

Section 6 - Storage

Storage Descriptions...........................................134

Drive Storage.......................................................134

Cold Weather (Freezing Temperature)

Storage.........................................................134

Seasonal and Extended Storage

Instructions...................................................135

Section 7 - Troubleshooting

Diagnosing Electronically Controlled Fuel System

Problems.............................................................138

Electrical Connections.........................................138

Troubleshooting Charts.......................................138

Troubleshooting Engine Related Problems..138

Check VesselView First................................138

Poor Performance........................................139

Joystick.........................................................139

Engine Storage.............................................135

Battery Storage....................................................135

Recommissioning................................................135

Engine..........................................................135

Drive.............................................................136

Power Package............................................136

Electronic Remote Controls..........................139

Steering System...........................................140

Trim Tabs.....................................................141

Boat Response Changes.............................141

Battery Will Not Charge................................141

Gauges and Instrumentation........................142

Galvanic Isolator...........................................142

Section 8 - Customer Assistance Information

Owner Service Assistance...................................144

Marine Repair Logistics................................144

Local Repair Service....................................144

Service Away From Home............................144

Stolen Power Package.................................144

Attention Required After Submersion...........144

90-866938081 MAY 2009 Page iii

Replacement Service Parts..........................144

Parts and Accessories Inquiries...................145

Resolving a Problem....................................145

Customer Service Literature...............................145

English Language..........................................145

Other Languages...........................................146

Andre sprog...................................................146

Andere talen..................................................146

Muut kielet.....................................................146

Autres langues...............................................146

Andere Sprachen...........................................146

Altre lingue.....................................................146

Section 9 - Pre-Delivery Information

Andre språk...................................................146

Outros Idiomas..............................................147

Otros idiomas.................................................147

Andra språk...................................................147

Allej glþssej....................................................147

Ordering Literature.............................................147

United States and Canada............................147

Outside the United States and Canada.........147

Pre‑Delivery Information.....................................150

Dealer Pre‑Delivery Checklist for Zeus Products

(Before Delivery to the Customer)......................150

Skyhook (If Equipped)...................................150

Before Starting—Key Off...............................151

Before Starting—Key On...............................151

Engines Running at the Dock........................151

Sea Trial........................................................152

After On Water Test.......................................152

Skyhook (If Equipped)...................................152

Page iv 90-866938081 MAY 2009

Section 1 - Limited Warranty

Table of Contents

Warranty Information............................................ 2

Warranty Registration—United States and

Canada............................................................2

Warranty Registration—Outside the United

States and Canada.........................................2

High Output Recreational Use World‑Wide

Limited Warranty.............................................3

Intermittent Commercial Use World‑Wide

Limited Warranty.............................................7

Zeus Drive Limited Warranty Against Corrosion

(Worldwide)...................................................10

Emission Warranty........................................11

Transfer Of Warranty....................................11

90-866938081 MAY 2009 Page 1

Section 1 - Limited Warranty

Warranty Information

Warranty Registration—United States and Canada

The CMD warranty registration center will coordinate warranty registration for both CMD/Cummins and Mercury Marine products, only one Warranty Registration Form is required to be filed for each engine/drive system.

1. To ensure that your warranty coverage begins promptly, your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product.

2. The Warranty Registration Card identifies the name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name, and address. The dealer also certifies that you are the original purchaser and user of the product. A temporary Owner Warranty Registration Card will be presented to you when you purchase the product.

3. Upon receipt of the Warranty Registration Card at the factory, you will be sent an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.

4. Because of your selling dealer’s ongoing interest in your satisfaction, the product should be returned to him for warranty service.

5. The product warranty is not effective until the product is registered at the factory.

NOTE: Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event that a safety recall notification under the Federal Boat Safety Act is required.

6. You may change your registration address at any time, including at time of warranty claim, by calling CMD or sending a letter or fax with your name, old address, new address, and engine serial number to CMD's warranty registration department. Your dealer can also process this change of information.

United States customers or dealers may contact: Cummins MerCruiser Diesel LLC, Inc.

Attn: Warranty Registration Department 4500 Leeds Avenue - Suite 301 Charleston, South Carolina 29405-9987 1-800-668-0407 Fax Fax 843-745-1616

Warranty Registration—Outside the United States and Canada

1. It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the Cummins MerCruiser Diesel Distributor or Cummins MerCruiser Diesel Authorized Dealer responsible for administering the warranty registration and claim program for your area.

2. The Warranty Registration Card identifies your name and address, product model and serial numbers, date of sale, type of use and the selling distributor's and dealer's code number, name and address. The distributor or dealer also certifies that you are the original purchaser and user of the product.

Page 2 90-866938081 MAY 2009

Section 1 - Limited Warranty

3. A copy of the Warranty Registration Card, designated as the Purchaser's Copy, MUST

be given to you immediately after the card has been completely filled out by the selling distributor or dealer. This card represents your factory registration identification, and should be retained by you for future use when required. Should you ever require warranty service on this product, your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim forms.

4. In some countries, the Cummins MerCruiser Diesel Distributor or Cummins MerCruiser

Diesel Authorized Dealer will receive the Factory Copy of the Warranty Registration Card from your distributor or dealer. If you receive a plastic Warranty Registration Card, you may discard the Purchaser's Copy that you received from the distributor or dealer when you purchased the product. Ask your distributor or dealer if this plastic card program applies to you. Center will issue you a permanent (plastic) Warranty Registration Card within 30 days after

5. For further information concerning the Warranty Registration Card and its relationship

to Warranty Claim processing, refer to the International Warranty. See Table of Contents. IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. It is our desire to have ALL products registered at the factory should it ever be necessary to contact you. Make sure your Cummins MerCruiser Diesel Distributor or Cummins MerCruiser Diesel Authorized Dealer fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area.

High Output Recreational Use World‑Wide Limited Warranty

Engines and Drive Systems Included in this Coverage

Marine Propulsion

Zeus 3000 Series Pod Drive

Products Warranted

This limited warranty applies to new Engines and Drive Systems sold by Cummins MerCruiser Diesel LLC. Inc., herein after "CMD", that are branded as Cummins MerCruiser Diesel products and used in Marine

applications anywhere in the world where CMD approved service is available1. and delivered to the first user on or after September 1, 2007. This limited warranty excludes all Engines branded and sold as Cummins Marine Diesel products. The ’Product’ consists of a new CMD Engine and Drive System, as well as accessories, which are approved and supplied by CMD and Cummins, and which are either installed by CMD or a CMD authorized distributor. These Products have the following designation:

High Output Rating

Intended for use in variable load applications where full power is limited to one (1) hour out of every eight (8) hours of operation. Reduced power operation must be at or below cruise speed. Cruise speed is dependent on the engine Rated Speed (RPM):

Engine Rated Speed (RPM)

2000–2800 RPM 200 RPM 2801–3500 RPM 300 RPM 3501–4500 RPM 400 RPM This rating is for pleasure (non‑revenue generating) applications that operate 500 hours or less per year.

Cruise Speed (Reduction from Engine Rated Speed (RPM)

1. Locations in the United States and Canada are listed in the Cummins United States and Canada Sales and Service Directory; other locations are listed in the Cummins International Sales and Service Directory.

90-866938081 MAY 2009 Page 3

Section 1 - Limited Warranty

Base Engine and Drive Limited Warranty

This limited warranty covers any failures of the Product, under normal use and service, which result from a defect in CMD material or factory workmanship (Warrantable Failure) Underwater impact damage is not a warrantable failure. Coverage begins with the retail sale of the Engine and Drive by CMD and continues for the Duration stated in the following table. The Duration commences on either the date of delivery of the Product to the first user, or the date the unit is first leased, rented or loaned, or when the Product has been operated for 125 hours, whichever occurs first. Commercial use of this product voids the warranty. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes.

Two Year Limited Warranty—Limited Warranty Coverage

Coverage Duration

(whichever occurs first)

Coverage Category

Base Engine Warranty 24 1000 Yes Yes Yes Yes Extended Major Components 72 3000 Yes Yes Yes Yes

Extended Major Components Limited Warranty

The Extended Major Components Limited Warranty provision is concurrent with the Base Engine and Drive Limited Warranty and continues beyond the expiration of the Base Engine and Drive Limited Warranty for an additional four years or 2000 hours whichever occurs first. The Extended Major Components Limited Warranty covers Warrantable Failures of the following Engine and Drive parts or castings (Covered parts):

Engine:

Engine Cylinder Block and Head Casting Engine Camshaft and Crankshaft Forging Engine Connecting Rod Forging Engine Gear Train Gears:

—Crankshaft Gear —Camshaft and Camshaft Idler Gear —Accessory Drive Gear —Fuel Pump Gear Engine Gear Cover Casting Flywheel Housing Casting

Months Hours Parts Labor

Repair Charge Paid by CMD

Removal and Installation

Labor

Travel

Bushing and bearing failures are NOT covered.

Drive:

Marine Gear Housing Marine Gear Drop Box Housing Steering Actuator Housing Casting Drive Mid‑section Casting Lower Gear Housing Casting – (Underwater Impact Damage Excluded) Trim Tab Casting – (Underwater Impact Damage Excluded) Bearing Carrier Casting – (Underwater Impact Damage Excluded) Drive Shaft – (Less U‑joints) Intermediate Shaft – (Underwater Impact Damage Excluded) Clamp Rings Steering and Trim Oil Tank Skeg – (Underwater Impact Damage Excluded)

Page 4 90-866938081 MAY 2009

Consumer Products

The warranty on Consumer Products in the United States is a limited warranty. CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied warranties applicable to Consumer

Products terminate concurrently with the expiration of the express warranties applicable to the Product. In the United States, some states do not allow the exclusion of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the limitations or exclusions herein may not apply to you.

These warranties are made to all Owners in the chain of distribution and Coverage continues to all subsequent Owners until the end of the periods of Coverage.

CMD Responsibilities

During the Base Engine and Drive Limited Warranty

CMD will pay for all parts and labor needed to repair the damage to the Product resulting from a Warrantable Failure when performed during normal business hours. All labor costs will be paid in accordance with Cummins and Mercury Marine's published Standard Repair Time guidelines. When it is necessary for mechanics to make on‑site warranty repairs, CMD will pay reasonable travel expenses, including meals, mileage and lodging, for mechanics to travel to and from the repair dock. CMD will pay for the lubricating oil, antifreeze, filter elements, and other maintenance items that are not reusable due to the Warrantable Failure. CMD will pay for reasonable labor costs for Engine and Drive System removal and reinstallation when necessary to repair a Warrantable Failure.

During the Extended Major Components Limited Warranty

CMD will pay for parts and labor for the repair or, at its option, the replacement of the defective covered part and any covered part damaged by a warrantable failure of the defective covered part.

Owner Responsibilities

During the Base Engine and Drive Limited Warranty and the Extended Major Components Limited Warranty

During the Extended Major Components Limited Warranties

Owner is responsible for the cost of all parts and labor required for the repair except for the defective Covered Part and any Covered Part damaged by a Warrantable Failure of the defective Covered Part. Owner is responsible for the operation and maintenance of the Product as specified in the applicable Cummins, MerCruiser, or CMD Operation and Maintenance Manual. Owner is also responsible for providing proof that all recommended maintenance has been performed. Exceeding the operational parameters of the HO rating will void this warranty. The owner of the boat is ultimately responsible for ensuring the engine and drive system is properly operated and maintained. The warranty will be void on any Engines and Drives that are misapplied, not maintained properly or misused. Before the expiration of the applicable warranty, Owner must notify a CMD distributor, authorized dealer, or other repair location approved by CMD of any Warrantable Failure and make the Engine and Drive System available for repair by such facility. Locations in the United States and Canada are listed in the Cummins U.S. and Canada Sales and Service Directory; other locations are listed in the Cummins International Sales and Service Directory. In the event of any Product failure, Owner is responsible for the cost of towing the boat to the repair dock and for all associated docking, storage, and harbor charges. Owner is responsible for communication expenses, meals, lodging, and similar costs incurred as a result of a Warrantable Failure. Owner is responsible for maintaining the Engine hour meter in good working order at all times and to ensure that the hour meter accurately reflects the total hours of operation of the Product. Owner is responsible for the costs to investigate complaints, unless the problem is caused by a defect in CMD material or factory workmanship. Owner is responsible for non‑Engine and non‑Drive System repairs, "downtime" expenses, cargo damage, fines, all applicable taxes, all business costs, and other losses resulting from a Warrantable Failure.

Section 1 - Limited Warranty

90-866938081 MAY 2009 Page 5

Section 1 - Limited Warranty

Limitations

CMD is not responsible for failures or damage resulting from what CMD determines to be abuse or neglect, including, but not limited to: operation without adequate coolants or lubricants; over‑fueling; over‑speed; lack of system maintenance to the engine and drive: improper storage, starting, warm‑up, run‑in or shutdown practices, corrosion of Engine or Drive due to lack of maintenance; unauthorized modifications to the Engine or Drive. CMD is also not responsible for failures caused by incorrect oil or fuel or by water, dirt or other contaminants in the fuel or oil. CMD is not responsible for failure resulting from:

1. Use or application of the Product inconsistent with its rating designation set forth above.

2. Incorrect installation.

3. Engines that do not reach rated RPM because of issues unrelated to the engine (for example, overloading the vessel, selecting an engine with insufficient horsepower for the vessel, improper gear and/or propeller selection, inadequate hull maintenance, etc.).

4. Use of improper propellers.

5. The lack of completing published maintenance procedures.

Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation to show that oil consumption exceeds CMD published standards. CMD does not warrant accessories or parts that are not supplied by Cummins/Mercury Marine Factory. CMD is not responsible for failures of maintenance Components supplied by Cummins/Mercury Marine beyond 90 days After the coverage duration start date. Maintenance Components include, but are not limited to: sea water pump impellers; sacrificial anodes; oil filters; fuel filters; air filters; water filters; and fuel/water separator filters. Except for the accessories noted previously, CMD does not warrant accessories which bear the name of another company. Parts used in warranty repairs may be new Cummins/Mercury Marine parts, or Cummins / Mercury Marine‑approved rebuilt or repaired parts. CMD is Not responsible for failures resulting from the use of Parts not supplied by Cummins/Mercury Marine. A new Cummins/Mercury Marine part or Cummins / Mercury Marine‑approved rebuilt part used to replace a Warranted Part assumes the identity of the Warranted Part it replaced and is entitled to the remaining coverage hereunder.

CMD DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS. CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. THESE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CMD IN REGARD TO THESE ENGINES AND DRIVES. CMD MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

In the United States2. and Canada, this warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Outside the United States rights which cannot be affected or limited by the terms of this warranty. Nothing in this warranty excludes or restricts any contractual rights the Owner may have against third parties.

and Canada, in case of consumer sales, in some countries the Owner has statutory

2. United States includes American Samoa, the Commonwealth of Northern Mariana Island, Guam, Puerto Rico and the U.S. Virgin Islands.

Page 6 90-866938081 MAY 2009

Intermittent Commercial Use World‑Wide Limited Warranty

Engines and Drive Systems Included in this Coverage

Marine Propulsion

Zeus 3000 Series Pod Drive

Products Warranted

Intermittent Rating

This power rating is intended for intermittent use in variable load applications where full power is limited to two hour out of every eight hours of operation. Also, reduced power must be at or below 200 RPM of the maximum rated RPM. This power rating is an ISO3046 Fuel Stop Rating and is for applications that operate less than 1500 hours per year.

Base Engine and Drive Limited Warranty

Section 1 - Limited Warranty

Two Year Limited Warranty—Limited Warranty Coverage

Coverage Duration

(whichever occurs first)

Coverage Category

Base Engine Warranty 24 3000 Yes Yes Yes Yes

CMD Responsibilities

During the Engine and Drive Limited Warranty

CMD will pay for all parts and labor needed to repair the damage to the Product resulting from a Warrantable Failure when performed during normal business hours. All labor costs will be paid in accordance with Cummins and Mercury Marine's published Standard Repair Time guidelines. When it is necessary for mechanics to make on‑site warranty repairs, CMD will pay reasonable travel expenses, including meals, mileage and lodging, for mechanics to travel to and from the repair dock. CMD will pay for the lubricating oil, antifreeze, filter elements, and other maintenance items that are not reusable due to the Warrantable Failure. CMD will pay for reasonable labor costs for Engine and Drive removal and reinstallation when necessary to repair a Warrantable Failure.

Months Hours Parts Labor

Repair Charge Paid by CMD

Removal and Installation

Labor

Travel

90-866938081 MAY 2009 Page 7

Section 1 - Limited Warranty

Owner Responsibilities

During the Base Engine and Drive Limited Warranty

Owner is responsible for the cost of lubricating oil, antifreeze, filter elements, and other maintenance items replaced during warranty repairs unless such items are not reusable due to the Warrantable Failure. Owner is responsible for the operation and maintenance of the Product as specified in the applicable Cummins, MerCruiser, or CMD Operation and Maintenance Manual. Owner is also responsible for providing proof that all recommended maintenance has been performed. This warranty does not cover normal wear and tear of covered parts. Before the expiration of the applicable warranty, Owner must notify a CMD service provider, distributor, authorized dealer, or other repair location approved by CMD of any Warrantable Failure and make the Engine available for repair by such facility. Locations in the United States and Canada are listed in the Cummins U.S. and Canada Sales and Service Directory; other locations are listed in the CMD International Sales and Service Directory. Owner is responsible for the cost of lubricating oil, antifreeze, filter elements, and other maintenance items replaced during warranty repairs unless such items are not reusable due to the Warrantable Failure. Owner is responsible for communication expenses, meals, lodging, and similar costs incurred as a result of a Warrantable Failure. Owner is responsible for non‑Engine and non‑Drive repairs, "downtime" expenses, cargo damage, fines, all applicable taxes, all business costs, and other losses resulting from a Warrantable Failure. In the event of any Product failure, Owner is responsible for the cost of towing the boat to the repair dock and for all associated docking and harbor charges. Owner is responsible for maintaining the Engine hourmeter in good working order at all times and to ensure that the hourmeter accurately reflects the total hours of operation of the Product. Owner is responsible for the costs to investigate complaints, unless the problem is caused by a defect in CMD material or factory workmanship.

Limitations

1. Maintenance Component Limitations:

1. Use or application of the Product inconsistent with its rating designation set forth above.

2. Incorrect installation.

4. Use of improper propellers.

5. The lack of completing published maintenance procedures.

2. Other Component Limitations:

CMD does not warrant components that are not supplied by CMD Factory.

3. CMD supplied alternators and starters limitation:

Warranty coverage is limited to 2 years or 2,000 hours, whichever expires first.

Page 8 90-866938081 MAY 2009

Consumer Products

Section 1 - Limited Warranty

The warranty on Consumer Products in the United States is a limited warranty. CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied warranties applicable to Consumer Products terminate concurrently with the expiration of the express warranties applicable to the Product. In the United States, some states do not allow the exclusion of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to you. CMD is not responsible for failures or damage resulting from what CMD determines to be abuse or neglect, including, but not limited to: operation without adequate coolants or lubricants; over‑fueling; over‑speeding; lack of maintenance of cooling, lubricating or intake systems; improper storage, starting, warm‑up, run‑in or shutdown practices; unauthorized modifications to the engine. CMD is also not responsible for failures caused by incorrect oil or fuel or by water, dirt or other contaminants in the fuel or oil.

CMD is not responsible for failures resulting from:

1. Use or application of the Product inconsistent with its rating designation set forth above.

2. Incorrect installation. Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation to show that oil consumption exceeds CMD published standards. CMD is not responsible for failures of maintenance components supplied by CMD beyond 90 days after the coverage duration start date. Maintenance components include, but are not limited to: sea water pump impellers; zinc plugs; oil filters; fuel filters; air filters; water filters; fuel/water separator filters. Parts used in warranty repairs may be new CMD parts, CMD‑approved rebuilt parts, or repaired parts. CMD is not responsible for failures resulting from the use of parts not supplied by CMD. A new CMD or CMD‑approved rebuilt part used to replace a Warranted Part assumes the identity of the Warranted Part it replaced and is entitled to the remaining coverage hereunder.

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Section 1 - Limited Warranty

Zeus Drive Limited Warranty Against Corrosion (Worldwide)

What Is Covered

Cummins MerCruiser Diesel warrants the Zeus Drive (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.

Duration of Coverage

This limited corrosion warranty provides coverage for three (3) years / 1500 Hours from either the date the product is first sold, or the date on which the product is first put into service, whichever occurs first. The repair and replacement of parts, or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to subsequent purchaser upon proper reregistration of the product. Warranty coverage is terminated for used product repossessed from a retail customer, purchased at auction, from a salvage yard, or from an insurance company that obtained the product as a result of an insurance claim.

Conditions That Must Be Met to Obtain Warranty Coverage

Corrosion prevention devices specified in the Operation, Maintenance, and Warranty manual must be in use on the boat, and routine maintenance outlined in the Operation, Maintenance, and Warranty manual must be timely performed (including without limitation the replacement of sacrificial anodes, use of specified lubricants, and touch‑up of nicks and scratches) in order to maintain warranty coverage. Cummins MerCruiser Diesel reserves the right to make warranty coverage contingent upon proof of proper maintenance.

What Cummins MerCruiser Diesel Will Do

Cummins MerCruiser Diesel and Mercury's sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part, replacing such part or parts with new or CMD / Mercury Marine‑certified, remanufactured parts, or refunding the purchase price of the CMD / Mercury product. CMD / Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

How to Obtain Warranty Coverage

The customer must provide Cummins MerCruiser Diesel with reasonable access to the product for warranty service and a reasonable opportunity to repair the product. Cummins MerCruiser Diesel dealer will arrange for the inspection and any covered repair. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service. Purchaser shall not, unless requested by Cummins MerCruiser Diesel, ship the product or parts of the product directly to Cummins MerCruiser Diesel. Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage.

What Is Not Covered

This limited warranty does not cover electrical system corrosion; corrosion resulting from damage; corrosion that causes purely cosmetic damage; abuse or improper service; corrosion to accessories, instruments, or steering systems; damage due to marine growth; replacement parts (parts purchased by the customer); products used in a commercial application. Commercial use is defined as any work‑related or employment‑related use of the product, or any use of the product that generates income, for any part of warranty period, even if the product is only occasionally used for such purposes.

Page 10 90-866938081 MAY 2009

Emission Warranty

Product Warranted

This Emission Warranty applies to new Engines certified to United States EPA 40 CFR 94 sold by CMD that are installed in vessels flagged or registered in the Unites States.

Coverage

CMD warrants to the first user and each subsequent purchaser that the Engine is designed, built, and equipped so as to conform at the time of sale by CMD with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within the longer of the following periods:

1. High Output Recreational use: five years or 500 hours of operation, whichever occurs first. Intermittent

2. The Base Engine Warranty.

Limitations

The owner may elect to have maintenance, replacement, or repair of the emission control parts performed by a facility other than a CMD distributor, an authorized dealer or a repair location approved by CMD, and may elect to use parts other than new genuine Cummins/Mercury Marine or Cummins / Mercury Marine‑approved rebuilt parts and assemblies for such maintenance, replacement or repair; however, the cost of such service or parts and subsequent failures resulting from such service or parts will not be covered under this emission control system warranty. Failures, except those resulting from a defect in materials, or factory workmanship, are not covered by the WARRANTY.

CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

In the United States other rights which vary from state to state.

Outside the United States statutory rights which cannot be affected or limited by the terms of this warranty. Nothing in this warranty excludes or restricts any contractual rights the Owner may have against third parties

Section 1 - Limited Warranty

1.2.

Commercial use: five years or 5000 hours of operation, whichever occurs first. The Emissions Warranty starts from the date of delivery of the Engine to the first user, or the date the unit is first leased, rented, or loaned, or when the Engine has been operated for 50 hours, whichever occurs first, or

and Canada, this warranty gives you specific legal rights, and you may also have

and Canada, in case of consumer sales, in some countries the Owner has

Transfer Of Warranty

The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications.

To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner's name, address and engine serial number to CMD's warranty registration department.

In the United States mail to: Cummins MerCruiser Diesel LLC, Inc.

Attn: Warranty Registration Department 4500 Leeds Avenue - Suite 301 Charleston, South Carolina 29405 1-800-668-0407 Fax Fax 843-745-1616

Upon processing the transfer of warranty, CMD will send registration verification to the new owner of the product by mail. There is no charge for this service.

For products purchased outside the United States and Canada, contact the Cummins MerCruiser Diesel Distributor or Cummins MerCruiser Diesel distributor in your country.

2. United States includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and the U.S. Virgin Islands.

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Section 1 - Limited Warranty

Notes:

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Section 2 - Getting to Know Your Power Package

Table of Contents

Section 2 - Getting to Know Your Power Package

General Information............................................ 14

Models Covered............................................14

Drive Serial Number and Decal Placement

......................................................................14

Features and Controls........................................ 14

E‑Stop (Emergency Stop) Switch, If Equipped

......................................................................14

Instrumentation.............................................15

VesselView ............................................. 15

SmartCraft Speedometer and Tachometer

Digital Gauges (If Equipped) .................. 15

System Link Digital Gauges (If Equipped)

............................................................... 16

Electronic Helm Steering...............................17

Dual‑Handle Electronic Remote Control (ERC)

—Features and Operation.............................17

Operation ............................................... 17

Basic Joystick Operation...............................18

Electrical System Overload Protection..........18

Vessel Interface Panel (VIP) Overload

Protection ............................................... 19

Overload Protection for the DC Voltage

Regulator System, If Equipped ............. 19

Overload Protection for Other Circuits

............................................................... 20

Galvanic Isolator and Monitor.......................20

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Section 2 - Getting to Know Your Power Package

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General Information

Models Covered

Models Covered Serial Number

Zeus 3000 Series Pod Drive 0M963371 and above

Drive Serial Number and Decal Placement

Serial numbers are the manufacturer's key to numerous engineering details that apply to your drive.

Drive serial number locations

a - Transmission serial number plate b - Drive serial number decal and stamping

Refer to the engine owners manual supplied with the engine for the location of the engine data tag that contains the engine serial number and model number.

Features and Controls

E‑Stop (Emergency Stop) Switch, If Equipped

An E‑stop (emergency stop) switch turns off the engines in an emergency situation, such as a person overboard or a tangled propeller. When activated, an E‑stop switch interrupts the power supply to the engine and transmission. If the boat is equipped with an E‑stop switch at the helm, the E‑stop switch turns off all of the engines. The E‑stop switch on a Vessel Interface Panel (VIP) turns off only the engine connected to VIP.

Typical E‑stop switch at the helm

a - E‑stop switch b - VIP

E-stop switch on a typical VIP

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Section 2 - Getting to Know Your Power Package

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Activation of an E‑stop switch stops the engine, or engines, immediately, but the boat can continue to coast for some distance depending upon the velocity and degree of any turn at shutdown. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

We recommend instructing other occupants on proper starting and operating procedures should they need to operate the engine in an emergency.

Accidental or unintended activation of the switch during normal operation is also possible, which can cause any or all of the following potentially hazardous situations:

• Occupants can be thrown forward due to unexpected loss of forward motion, and passengers in the front of the boat could be ejected over the bow and possibly struck by the propulsion or steering components.

• The operator can lose power and directional control in heavy seas, strong current, or high winds.

• The operator can lose control when docking.

Restarting an engine using the key switch or start button after an E‑stop shutdown without first turning the key switch to the off position for at least 30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting some fault codes are still being displayed, contact your Authorized Cummins MerCruiser Diesel Repair Facility.

Instrumentation

VESSELVIEW

VesselView is the primary information source for the Zeus drive, all engine information, fault codes, tank levels, boat direction, and calibrations. For more information, refer to the VesselView Operators Manual.

VesselView

SMARTCRAFT SPEEDOMETER AND TACHOMETER DIGITAL GAUGES (IF EQUIPPED)

The Cummins MerCruiser Diesel SmartCraft instrument package augments the information provided by VesselView. The instrument package may display:

• Engine RPM

• Boat speed

• Coolant temperature

• Oil pressure

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Section 2 - Getting to Know Your Power Package

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abc

37925

• Battery voltage

• Fuel consumption

• Engine operating hours

• And more

Typical SmartCraft tachometer and speedometer

a - Tachometer b - Speedometer c - LCD System View display

The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system. The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.

For basic operation information on the SmartCraft Instrument package and for details on the warning functions monitored by the system, refer to the manual provided with your gauge package.

SYSTEM LINK DIGITAL GAUGES (IF EQUIPPED)

Some instrumentation packages include gauges that augment the information provided by VesselView and the SmartCraft Tachometer and Speedometer. The owner and operator should be familiar with all the instruments and their functions on the boat. Because of the large variety of instrumentation and manufacturers, have your boat dealer explain the gauges and normal readings that appear on your boat.

The following types of digital gauges may be included with your power package.

Typical System Link digital gauges

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Section 2 - Getting to Know Your Power Package

Item Gauge Indicates a Oil pressure gauge Engine oil pressure b Voltmeter Battery voltage c Water temperature gauge Engine operating temperature d Fuel gauge Quantity of fuel in tank

Electronic Helm Steering

The Electronic Helm Steering is a true drive‑by‑wire system that controls the steering through electronic signals. The feel of the steering is created by computer‑designated resistance.

We recommend that you drive carefully until you have a chance to explore the Zeus system's handling characteristics in an open area without obstructions or other boat traffic, and you are familiar with the boat's responses. The first few maneuvers at speed can be more abrupt than expected.

Dual‑Handle Electronic Remote Control (ERC)—Features and Operation

OPERATION

The electronic remote control (ERC) handle controls the operation of shift and throttle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from the forward position to the neutral position to decrease speed and eventually stop. Pull the control handle back from neutral to the first detent for reverse gear. Continue pulling the handle back to increase speed in reverse.

NOTE: In certain modes, gear position is determined by the position of the shift valves on the transmission, not the position of the ERC levers. When using the joystick or while in Skyhook, the computer moves the transmission in and out of gear even though the handles are in neutral.

28086

a - Neutral b - Forward c - Reverse d - Bow of boat

The amount of force needed to move the ERC handles and to move the ERC handles through the detents is adjustable to help prevent unwanted motion of the handle in rough water.

To adjust the ERC handle detent tension:

1. Remove the side cover of the handle needing adjustment.

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Section 2 - Getting to Know Your Power Package

2. Turn the adjustment screw clockwise to increase tension on the control handle and counter‑clockwise to decrease tension.

3. Adjust to tension desired.

To adjust ERC handle tension:

1. Remove the side cover of the handle needing adjustment.

2. Turn the adjustment screw clockwise to increase tension on the control handle and counter‑clockwise to decrease tension.

3. Adjust to tension desired.

Starboard side cover removed, port similar

a - Detent tension adjustment screw, labeled "De" b - Handle tension adjustment screw, labeled "Fr"

Basic Joystick Operation

The joystick offers precise, intuitive control of your boat during low speed and docking maneuvers. The joystick translates the movement of the joystick into similar movement in the boat. Engine speed is limited in this mode to prevent unacceptable boat dynamics during maneuvers.

While operation with the joystick is easy to learn, we recommend that you drive the boat in the traditional way until you can spend time in an open area free of obstructions and traffic to learn how your boat responds to inputs. Further, we recommend that you occasionally practice maneuvering in the traditional way to maintain your traditional drive docking skills in case joystick control is temporarily not available.

Refer to Section 2—Maneuvering with the Joystick, for complete information concerning joystick operation.

Electrical System Overload Protection

If an electrical overload occurs, a fuse or a circuit breaker opens. Find and correct the cause for the electrical overload before replacing the fuse or resetting the circuit breaker.

NOTE: In an emergency, when you must operate the engine and cannot locate or correct the cause for the electrical overload (high current draw), turn off or disconnect all the accessories connected to the engine and instrumentation wiring. Reset the circuit breaker or replace the fuse. If the circuit remains open, the electrical overload has not been eliminated. Contact your Cummins MerCruiser Diesel Authorized Repair Facility to check the electrical system.

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Section 2 - Getting to Know Your Power Package

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Circuit breakers and fuses provide protection for the electrical system as indicated. The circuit breakers and fuses are located in various locations throughout the boat. Have your dealer show you the location and identify the circuit that they protect.

After finding and correcting the cause of the overload, reset the circuit breaker by pressing the reset button.

VESSEL INTERFACE PANEL (VIP) OVERLOAD PROTECTION

The Vessel Interface Panel (VIP) contains six circuit breakers that help protect the transmission harness, engine harness, vessel sensor harness, and helm harness.

NOTE: A VIP for each engine is located in the engine room.

All similar

Item Circuit Breaker Rating Protection Location on VIP

a 15 A Gear Upper left b 10 A SIM/Vessel Middle left c 10 A Helm Lower left d 5 A Engine Diagnostics Upper right e 5 A VIP Diagnostics Middle right

f 25 A Main Lower right

OVERLOAD PROTECTION FOR THE DC VOLTAGE REGULATOR SYSTEM, IF EQUIPPED

If the vessel is equipped with a 24‑volt system, a DC voltage regulator is required to supply 12‑volt power to the VIP and the other 12‑volt circuits. The power package manufacturer provides a protective fuse for the 24‑volt DC to 12‑volt DC voltage regulator system, if equipped. The spade‑style, in‑line fuse is located in the harness between the voltage regulator and the 24‑volt battery system. The fuse protects the wiring and the regulator against overloads.

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Section 2 - Getting to Know Your Power Package

BATTERY +

BATTERY -

37994

NOTE: For additional information on the on‑off switch for the DC voltage regulator, refer to

Section 3—Getting Started

a - DC voltage regulator b - Wiring to DC voltage regulator c - 30 ampere fuse and holder

The boat manufacturer may replace the fuse and holder with a circuit breaker. Have your boat manufacturer or dealer show you the location and identify the fuse or circuit breaker for your reference.

OVERLOAD PROTECTION FOR OTHER CIRCUITS

Other circuits may be protected by circuit breakers or fuses installed by the boat manufacturer and can vary in appearance and location.

For example, the MerCathode system has a 20‑amp in‑line fuse in the wire that connects from the positive (+) battery terminal to the positive (+) terminal on the controller. If the fuse is defective (open), the system will not operate, resulting in a loss of corrosion protection. Have your dealer show you the location of and service procedures for the fuse.

Ask your dealer for the location and operation instructions of all overload protection devices.

Galvanic Isolator and Monitor

These power packages feature anodes as standard equipment to help protect them from galvanic corrosion under moderate conditions. The MerCathode System and sacrificial anodes provide corrosion protection under normal usage.

Boats connected to AC shore power require additional protection to prevent destructive low‑voltage galvanic currents from passing through the shore‑power ground wire. A Quicksilver Galvanic Isolator or equivalent isolation device is recommended to block the passage of these currents while providing a path to ground for dangerous fault (shock) currents.

IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and anodes may be unable to handle the increased galvanic corrosion potential.

d - To 24‑volt battery system positive

( +)

e - To 24‑battery system negative (–)

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Section 2 - Getting to Know Your Power Package

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A Quicksilver Galvanic Isolator kit includes an audio and visual monitor to alert you to faults that occur. The monitor is a microprocessor controlled, solid state device that will test the integrity of the Quicksilver Galvanic Isolator and the safety grounding lead. This device will also supply impressed current to the drive to aid in corrosion protection.

WARNING

Improperly conducted AC shore power is an electric shock hazard that can result in damage and injury. The AC grounding conductor green wire must be connected between the boats electrical system and the shore power connection in order to provide a path for fault current and to assist the MerCathode in preventing galvanic corrosion on drive components. Install a galvanic isolator or similar isolation device in the AC shore power system in the vessel. Consult a qualified marine electrician for more information.

IMPORTANT: If the Galvanic Isolator alarm sounds and the monitor will not respond to the reset button, AC fault current may be present and the shore power safety grounding conductor circuit to shore may be an open circuit. Disconnect shore power immediately.

Refer to Troubleshooting—Galvanic Isolator for an explanation of the conditions or faults that may be displayed by the monitor.

Galvanic Isolator Monitor and conditions

NOTE: If your vessel is equipped with a galvanic isolator from a manufacturer other than Quicksilver, refer to the instructions provided by the manufacturers.

90-866938081 MAY 2009 Page 21

Section 2 - Getting to Know Your Power Package

Notes:

Page 22 90-866938081 MAY 2009

+ 130 hidden pages

Mercury Zeus 3000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Identification Record

© 2009 Mercury Marine CMD Zeus 3000 Series Pod Drive Models

Welcome

Warranty Message

Read This Manual Thoroughly

Notice

TABLE OF CONTENTS

Warranty Information

Warranty Registration—United States and Canada

Warranty Registration—Outside the United States and Canada

Zeus Drive Limited Warranty Against Corrosion (Worldwide)

Emission Warranty

Transfer Of Warranty

General Information

Models Covered

Drive Serial Number and Decal Placement

Features and Controls

Instrumentation

VESSELVIEW

SMARTCRAFT SPEEDOMETER AND TACHOMETER DIGITAL GAUGES (IF EQUIPPED)

SYSTEM LINK DIGITAL GAUGES (IF EQUIPPED)

Electronic Helm Steering

OPERATION

Basic Joystick Operation

Electrical System Overload Protection

VESSEL INTERFACE PANEL (VIP) OVERLOAD PROTECTION

OVERLOAD PROTECTION FOR THE DC VOLTAGE REGULATOR SYSTEM, IF EQUIPPED

OVERLOAD PROTECTION FOR OTHER CIRCUITS

Galvanic Isolator and Monitor