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.

90-866938081 MAY 2009 Page 9

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.

90-866938081 MAY 2009 Page 11

Section 1 - Limited Warranty

Notes:

Page 12 90-866938081 MAY 2009

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

90-866938081 MAY 2009 Page 13

Section 2 - Getting to Know Your Power Package

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34014

34022

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

Page 14 90-866938081 MAY 2009

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

90-866938081 MAY 2009 Page 15

Section 2 - Getting to Know Your Power Package

24575

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

Page 16 90-866938081 MAY 2009

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.

90-866938081 MAY 2009 Page 17

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.

90-866938081 MAY 2009 Page 19

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 (–)

Page 20 90-866938081 MAY 2009

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

Table of Contents

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

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

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

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

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

Special Digital Throttle and Shift

......................................................................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

(DTS) Features

90-866938081 MAY 2009 Page 23

Section 3 - On the Water

Procedure for a Stuck Trim Tab Control

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

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

Page 24 90-866938081 MAY 2009

Safe Boating Suggestions

In order to safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions, and also consider the following suggestions.

• Know and obey all nautical rules and laws of the waterways. Cummins MerCruiser Diesel strongly recommends that all powerboat operators complete

a boating safety course. Courses are offered in the U.S.A. by the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency. Inquiries may be made to the Boating Hotline at 1‑800‑368‑5647 or the Boat U.S. Foundation at 1‑800‑336‑BOAT.

• Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs are properly made.

• Check safety equipment on board. Here are some suggestions of the types of safety equipment to carry when boating:

Approved fire extinguishers Paddle or oar Signal devices: flashlight, rockets or flares, flag, and whistle or horn

Section 3 - On the Water

Transistor radio Tools necessary for minor repairs First aid kit and instructions Anchor and extra anchor line Waterproof storage containers Manual bilge pump and extra drain plugs Spare operating equipment, batteries, bulbs, and fuses Drinking water Compass and map or chart of the area

Watch for signs of weather change and avoid foul weather and rough-sea

•

boating.

Tell someone where you are going and when you expect to return.

•

• Passenger boarding. Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive unit into neutral is not sufficient.

• Use personal flotation devices. Federal law requires that there be a U. S. Coast Guard–approved, wearable‑type life jacket (personal flotation device), correctly sized and readily accessible for every person aboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.

• Prepare other boat operators. Instruct at least one person aboard in the basics of starting and operating the engine and handling the boat in case the driver becomes disabled or falls overboard.

• Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat’s operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Cummins MerCruiser Diesel dealer/distributor or the boat manufacturer.

90-866938081 MAY 2009 Page 25

Section 3 - On the Water

• Ensure that everyone in the boat is properly seated. Do not allow anyone to sit or

•

• Be alert. The operator of the boat is responsible by law to maintain a proper lookout

• Never drive your boat directly behind a water skier in case the skier falls. As an

• Watch fallen skiers. When using your boat for water skiing or similar activities, always

• Report accidents. Boat operators are required by law to file a Boating Accident Report

ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat; anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement.

Never be under the influence of alcohol or drugs while boating (it is the law).

Alcohol or drugs impairs your judgment and greatly reduce your ability to react quickly.

Know your boating area and avoid hazardous locations.

by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when operating the boat above idle or planing transition speed. Watch out for others, keep your eyes on the the water, and be aware of your wake.

example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier who was 61 m (200 ft.) in front of you in five seconds.

keep a fallen or down skier on the operator’s side of the boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds US $500.00 or 4) there is complete loss of the boat. Seek further assistance from local law enforcement.

Be Alert to Carbon Monoxide Poisoning

Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.

Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness and nausea.

WARNING

Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide.

GOOD VENTILATION

Ventilate the passenger area, open the side curtains or forward hatches to remove fumes.

Page 26 90-866938081 MAY 2009

1. Example of desired air flow through the boat.

POOR VENTILATION

Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.

Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near an operating engine may be exposed to a hazardous level of carbon monoxide.

1. Examples of poor ventilation while a boat is stationary:

Section 3 - On the Water

mc79553-1

a - Operating the engine when the boat

is moored in a confined space

2. Examples of poor ventilation while a boat is moving:

a - Operating the boat with the trim angle

of the bow too high

Basic Boat Operation

Freezing Temperature and Cold Weather Operation

IMPORTANT: If the boat is operated during periods of freezing temperature, take precautions to prevent freezing damage to the power package. Damage caused by freezing is not covered by Cummins MerCruiser Diesel Limited Warranty.

NOTICE

Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system. If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.

b - Mooring close to another boat with its

engine operating

b - Operating the boat with no forward

hatches open (station wagon effect)

mc79554-1

mc79556-1

NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine.

In order to operate the engine in temperatures of 0° C (32° F) or lower, observe the following instructions:

90-866938081 MAY 2009 Page 27

Section 3 - On the Water

21604

• At the end of each daily operation, completely drain the seawater section of the cooling system to protect against damage by freezing.

• At the end of each daily operation, drain the water from the water separator, if equipped. Fill the fuel tank at end of daily operation to prevent condensation.

• Use the required permanent‑type antifreeze solution to protect components against damage by freezing.

• Use proper cold weather lubrication oil; ensure that the crankcase contains a sufficient amount.

• Make certain that the battery is of sufficient size and is fully charged. Check that all other electrical equipment is in optimum condition.

• At temperatures of –20° C (–4° F) and below, use a coolant heater to improve cold starting.

• If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Cummins MerCruiser Diesel Authorized Repair Facility for information about special cold weather equipment and precautions.

See Section 6 for cold weather or extended storage related information.

Drain Plug and Bilge Pump

The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a drain plug, a bilge pump, or both a drain plug and a bilge pump. Install the drain plug and check the operation of the bilge pump, if equipped, before putting the boat in the water.

Check these items on a regular basis to ensure that the level of water does not come into contact with your power package. Components on your engine will be damaged if submerged.

Damage caused by submersion is not covered by the Cummins MerCruiser Diesel Limited Warranty.

Protecting People in the Water

WHILE THE BOAT IS MOVING

A person in the water may find it very difficult to take quick action to avoid a boat heading in their direction, even at slow speeds.

Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

Whenever a boat is moving (even coasting) and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury.

Page 28 90-866938081 MAY 2009

WHILE THE BOAT IS STATIONARY

27301

A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers. Stop the engine immediately whenever anyone in the water is near your boat.

Shift into neutral and shut off the engines before allowing people to swim or be in the water near your boat.

Do not allow people to swim around the boat with the Skyhook Electronic Anchor engaged. The Skyhook Electronic Anchor causes the drives to move and the propellers to turn without notice. Having the engines in neutral does not protect the swimmers. Swimmers in the area of the propellers are at risk of getting injured.

Wave and Wake Jumping

Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

WARNING

Section 3 - On the Water

Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with enough speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the water.

The primary concern is the boat changing direction while in the midst of the jump. In such cases the landing may cause the boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat.

Impact with Underwater Hazards

Reduce speed and proceed with caution whenever you are driving a boat in shallow water or in areas where the waters are suspected of having floating or underwater obstacles that could be struck by the underwater drive components, skegs, or the boat bottom.

mc79680-1

90-866938081 MAY 2009 Page 29

Section 3 - On the Water

IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed. Under these conditions, reduce boat speed to a minimum.

The following demonstrate some, but not all, examples of what can happen if the boat strikes a floating or underwater object:

• The boat could move in a new direction. Such an unexpected change in direction or

• A rapid reduction in speed. This can cause occupants to be thrown forward, even out

• Impact damage to the underwater drive components, skeg, or boat.

Keep in mind that one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed when driving in waters known to have underwater obstacles.

After striking a submerged object, stop the engine as soon as possible and inspect the drive systems for any broken or loose parts, and the hull for any damage. If damage is present or suspected, the power package should be taken to an Authorized Cummins MerCruiser Diesel Repair Facility for a thorough inspection and any necessary repair.

The boat should be checked for hull fractures, transom fractures, and water leaks.

turn can throw occupants out of their seats or out of the boat.

of the boat.

WARNING

Operating a boat with impact damage can result in product damage, serious injury, or death. If the boat experiences an impact, have an Authorized Cummins MerCruiser Diesel Repair Facility inspect the vessel and power package and perform repairs as necessary.

Operating with damaged underwater drive components or boat bottom could cause additional damage to other parts of the power package, or could affect control of the boat. If continued operation is necessary, do so at greatly reduced speeds.

Zeus Drive Impact Protection

IMPORTANT: Although the design of the Zeus drive provides some impact protection, no design can ensure total protection from impact damage under all conditions.

The Zeus drive has some impact protection by design, since the drive is mounted in a tunnel above the bottom of the hull. If the drive strikes a floating or submerged object while the boat is moving, the skeg is designed to break away, absorbing some of the impact and possibly reducing damage to the propellers and the exposed lower part of the drive. In extreme cases, large fixed or floating objects struck by the skeg and the exposed lower part of the drive may cause the lower part of the drive to shear off. This shearing off of the lower part of the drive is a design feature to protect the hull and drive system.

NOTE: If the lower part of the drive shears off due to a severe impact, make immediate note of the GPS location to assist in recovery efforts. If recovery of the damaged parts of the drive is possible, return the damaged parts to your Authorized Cummins MerCruiser Diesel Repair Facility for possible repair and reuse.

If an impact occurs and damage is present or suspected, if the boat does not respond as it should, or if water is present in the gear lube monitor bottle, have your boat inspected at the nearest Authorized Cummins MerCruiser Diesel Repair Facility.

Operating in reverse gear offers less impact protection. Use extreme caution when operating in shallow water or where underwater objects are known to be present. Use extreme care to prevent striking submerged objects while operating in reverse.

Page 30 90-866938081 MAY 2009

Zeus Drive Alignment

The Zeus Drives are aligned by the boat manufacturer, and must not be adjusted by anyone other than your Cummins MerCruiser Diesel Authorized Service and Repair Facility. The Zeus drives automatically recalibrate to this setting at each startup. The drives do not need to be re‑aligned under normal use.

Conditions Affecting Boat Operation

Weight Distribution (Passengers and Gear) Inside the Boat

Shifting weight to the rear (stern):

• Causes the bow to bounce in choppy water.

• Increases the danger of a following wave splashing into the boat when coming off

plane.

• Can cause the boat to porpoise at extremes. Shifting weight to the front (bow):

• Improves ease of planing.

• Improves rough water ride.

• Can cause the boat to veer back and forth (bow steer) at extremes.

Section 3 - On the Water

Bottom Of Boat

Cavitation

Ventilation

To maintain maximum speed, the boat bottom should be:

• Clean and free of barnacles and marine growth.

• Straight and smooth (fore and aft). Marine vegetation can accumulate when the boat is docked. Remove this growth before

operation; it can clog the water inlets and outlets, causing the engine to overheat.

Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object, such as a gear housing or a propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the gear housing or the propeller. Common causes of cavitation are:

• Weeds or other debris snagged on the propeller

• Bent propeller blade

• Raised burrs or sharp edges on the propeller

Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed‑up and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:

• A missing propeller diffuser ring.

• A damaged propeller or gear housing, which allows exhaust gases to escape between

propeller and gear housing.

Propeller Selection

IMPORTANT: The installed propellers must allow the engine to reach engine Rated Speed (RPM) with the boat fully loaded and with all customer stores on board. With the boat less than fully loaded the engines should reach engine Rated Speed (RPM) with less than a 100% load. Use the VesselView display to verify engine RPM and percent load.

90-866938081 MAY 2009 Page 31

Section 3 - On the Water

It is the responsibility of the boat manufacturer or the selling dealer to equip the power package with the correct propellers. Refer to the engine Information Data Tag located on the engine for the specified engine Rated Speed (RPM). Information for the location of the engine data tag can be found in the engine owners manual.

If full throttle engine RPM is below the engine Rated Speed (RPM), the propellers will have to be changed to prevent loss of performance and possible engine damage.

After initial propeller selection, certain issues may require a propeller with a lower pitch. They include:

• Operating with increased load (additional passengers or gear).

• Shifting the center of gravity of the vessel.

• The addition of towers or canvas.

• Fouling of the hull and running gear.

• High ambient temperatures.

• Operating at high elevation.

It is the responsibility of the boat owner to ensure that the correct propellers are installed at delivery and maintained over the life of the boat. Because of the many variables of boat design, only testing will determine the best propeller for a particular boat. If the engine is not able to reach the engine Rated Speed (RPM), contact your boat builder, boat dealer, or an Authorized Cummins MerCruiser Diesel Repair Facility for assistance in propeller selection. A list of propellers for the Zeus drive can be located in the Zeus drive parts manual. Refer to the Zeus drive Mercury Parts Manual—90-879150112.

Getting Started

Break‑In Period (New or With Replacement Gears)

Always perform these procedures on new drive units. This break‑in procedure allows the proper seating of drive unit gears and related components, which greatly reduces the likelihood of problems.

• Avoid full throttle starts.

• Do not operate at any one constant speed for extended periods of time.

• Do not exceed 75% of full throttle during the first 5 hours. During the next 5 hours, operate at intermittent full throttle.

• Shift the drive into forward gear a minimum of 10 times during break‑in, with run‑in time at moderate RPM after each shift.

• After the first 25 hours and not to exceed 30 hours, change the transmission fluid and filter including the transmission fluid in the drop box, if equipped.

• After the first 25 hours and not to exceed 30 hours, change the gear lube in the drive including the gear lube in the gear lube monitor.

DC Voltage Regulator Switch, 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. To allow the regulator to be turned on and off a switch is provided by the boat manufacturer. The switch is on a separate circuit.

Switching the power on provides regulated power to the VIP and other 12‑volt circuits to allow the vessel to start. Switching the DC voltage regulator off prevents the regulator from drawing power when the vessel is not operated.

Have your manufacturer or dealer show you the location and identify the DC voltage regulator switch for reference.

Page 32 90-866938081 MAY 2009

1. Turn the switch on before attempting to start the engine.

41198

2. Leave the switch on when the vessel is operating.

3. Turn the switch off when the vessel is not operating.

Starting and Stopping the Engines

Your Zeus power package is equipped with a SmartStart system, as well as an engine start and stop system for emergency use , that is remotely mounted on the VIP for each engine. The VIP is usually located in the engine room.

In normal circumstances, start and stop the engine from the helm using the start/stop button of the SmartStart system.

Refer to Section 2—Getting to Know Your Power Package for additional information on the E‑stop switch used for emergency stopping of the engines.

NORMAL STARTING

1. Perform the drive checks listed in Section 5—Routine Maintenance, Each Day Start

and When Refueling.

2. Perform the checks and steps listed in the engine's operation and maintenance manual

available for this package.

3. Open the seacock for the seawater return. Rotate the handle in the direction indicated

by the arrow.

Section 3 - On the Water

Drive cover removed for clarity

a - Handle in open position b - Seawater return (overboard) seacock

90-866938081 MAY 2009 Page 33

Section 3 - On the Water

41197

4. Open the seacock for the seawater inlet. Rotate the handle in the direction indicated

5. Open the seacock (if equipped) for any accessory equipment.

NOTE: When the key switch is turned to the on position the neutral LED lights, on the ERC trackpad, flash on and off if the ERC handles are not in the neutral position. Before starting the engines the ERC handles must be in neutral position, as indicated by the neutral indicator lights on continuously.

6. Move the ERC handles to the neutral position.

NOTE: Ask your dealer for the location of the key switches if the key switches are not located at the helm.

7. Turn the key switch to the on position for each engine to be started.

8. Verify it is safe to start the engines.

9. Corresponding to the engine you want to start, do one of the following:

by the arrow.

Typical inlet seacock—port orientation

a - Seacock for seawater inlet b - Handle in open position c - Former position (closed)

• Press and release the "START/STOP" switch, if equipped with optional SmartStart

switch panel.

• Turn the key switch to the start position. The control system automatically controls the starter to achieve a successful start.

28082

Typical SmartStart switch

Page 34 90-866938081 MAY 2009

NORMAL STOPPING

41199

41196

1. Move the ERC handles to the neutral position.

2. Corresponding to the engine you want to stop, and depending on your equipment, do

3. After stopping the engines you may close the seacocks. Rotate the handles in the

Section 3 - On the Water

one of the following:

• Press and release the "START/STOP" switch, if equipped with optional SmartStart switch panel. Then, turn the respective key switch to the off position.

• Turn the respective key switch to the off position for each engine stopped.

direction indicated by the arrows.

Drive cover removed for clarity

a - Seacock for seawater return b - Handle in closed position

Typical inlet seacock—port orientation

a - Seacock for seawater inlet b - Former position (open) c - Handle in closed position

STARTING AN ENGINE USING THE VIP SMARTSTART SWITCH

You may desire to start an engine from the engine room or under certain circumstances the engine control systems may not be able to automatically start an engine. The engines can be started using the "SMARTSTART" (stop/start) switch on the VIP for each engine.

1. Perform the drive checks listed in Section 5-Routine Maintenance, Each Day Start and When Refueling.

2. Perform the checks and steps listed in the engine's operation and maintenance manual available for this package.

90-866938081 MAY 2009 Page 35

Section 3 - On the Water

41198

41197

3. Open the seacock for the seawater return. Rotate the handle in the direction indicated

4. Open the seacock for the seawater inlet. Rotate the handle in the direction indicated

by the arrow.

Drive cover removed for clarity

a - Handle in open position b - Seawater return (overboard) seacock

by the arrow.

Typical inlet seacock—port orientation

a - Seacock for seawater inlet b - Handle in open position c - Former position (closed)

5. Open the seacock (if equipped) for any accessory equipment.

6. Move the ERC handles to the neutral position.

NOTE: Ask your dealer for the location of the key switches if the key switches are not located at the helm.

7. Turn the key switch to the on position for each engine to be started.

8. Verify it is safe to start the engines.

9. In the engine room, locate the VIP for each engine.

Page 36 90-866938081 MAY 2009

10. Press and release the green "SMARTSTART" (start/stop) switch on the VIP

33930

corresponding to the engine being started. The control system automatically controls the starter to achieve a successful start.

Typical VIP

a - Red "E‑STOP" switch—for emergency use only b - Green "SMARTSTART" (start/stop) switch

STOPPING THE ENGINE USING THE VIP SMARTSTART SWITCH

You may desire to stop an engine from the engine room or under certain circumstances the engine control system may not be able to automatically stop an engine. The engines can be stopped using the "SMARTSTART" (stop/start) switch on the VIP for each engine.

1. Move the ERC handles to the neutral position.

2. Locate the VIP for each engine in the engine room.

3. When the engines are running, press and release the green "SMARTSTART" (stop/ start) switch for each engine you want to stop.

Section 3 - On the Water

Typical VIP

a - Red "E‑STOP" switch—for emergency use only b - Green "SMARTSTART" (start/stop) switch

4. Turn the key switch to the off position for each engine that was stopped.

90-866938081 MAY 2009 Page 37

Section 3 - On the Water

41199

41196

5. After stopping the engines you may close the seacocks. Rotate the handles in the direction indicated by the arrows.

Drive cover removed for clarity

a - Seacock for seawater return b - Handle in closed position

Typical inlet seacock—port orientation

a - Seacock for engine seawater inlet b - Former position (open) c - Handle in closed position

Traditional Maneuvering with Steering and Thrust

You can maneuver your Zeus‑equipped vessel much like a traditional inboard boat. However, the Zeus drive system expands the maneuvering capability of your vessel at both slow and planing speeds. At slow speeds, the drive system is capable of directing the thrust to produce more responsive turning of the vessel. The Zeus drive system features counter‑rotating propellers that do not produce any sideways motion when accelerating or slowing down.

NOTE: During slow‑speed turning with the wheel, the drive on the inside turns as much as 42° to create very tight turns. Different from traditional boats, to tighten the turn, you can increase power to the inside drive.

TO MANEUVER THE BOAT IN FORWARD

Place one or both engines in forward gear and steer with the steering wheel as you would any comparable boat.

TO STEER THE BOAT IN TIGHT TURNS AT LOW SPEEDS

1. To turn the boat in tight turns at low speeds, turn the wheel in the direction of the turn.

2. To increase the turn rate of the boat after the wheel is completely turned, you may increase the power to the inside drive.

Page 38 90-866938081 MAY 2009

TO SPIN THE BOAT ON ITS AXIS AT LOW SPEEDS

25911

1. Center the steering wheel.

2. To spin to the right, place the starboard engine in reverse and the port engine in

forward.

3. To spin to the left, place the port engine in reverse and the starboard engine in

forward.

4. To increase the rate of turn, simultaneously adjust each ERC lever for more throttle.

Maneuvering with the Joystick

The joystick provides single lever interface to maneuver the vessel. Operating the vessel with the joystick is well suited for close quarter operations and when docking. The joystick causes the control system to independently control each pod angle and thrust to move or rotate the boat in a desired direction. For example, if you move the joystick sideways, the control system commands the boat in the sideways direction.

The joystick gives three axis control: fore and aft, port and starboard, and rotational, or any combination thereof. For example, moving the joystick to port causes the boat to move sideways to port. Rotating the joystick causes the boat to rotate around its center. You can move and rotate the joystick at the same time, allowing for very intricate movements for maneuvering in tight quarters.

The control system automatically attempts to dampen bow and stern swinging (referred to as yaw) during joystick operation. An on‑board sensor measures the yaw rate of the boat and actively counteracts the yaw motion of the boat. Factors, such as wind, water conditions or vessel loading, may act upon the vessel beyond the systems capability to correct yaw. Manual yaw correction may be required when commanding the boat in the fore and aft, port and starboard, or diagonal directions. To correct for unintended yaw during any maneuver just rotate the joystick in the direction the bow is desired to rotate.

The following table gives some limited examples of the basic responses to inputs from the joystick. The joystick is proportional, which means that the farther from the center the joystick is moved, the more thrust is applied to the boat in that direction.

To maneuver the boat with the joystick:

1. Move both electronic remote control (ERC) levers to the neutral position.

2. Move the joystick in the direction that you want the boat to move, or twist the joystick

in the direction that you want the boat to rotate. The joystick can be moved and rotated at the same time.

Joystick Input and Boat Response Table

Section 3 - On the Water

Joystick Input

24704

Boat Response

Boat at rest

(shown from light gray to dark gray)

Movement

90-866938081 MAY 2009 Page 39

Section 3 - On the Water

25928

25927

25929

25931

Joystick Input Boat Response

Boat moves forward

24705

Boat moves aft

Movement

(shown from light gray to dark gray)

24706

24707

Boat moves to starboard

without rotating

Boat moves to port

without rotating

24708

Page 40 90-866938081 MAY 2009

Section 3 - On the Water

25926

37774

25924

25923

Joystick Input Boat Response

Boat moves diagonally

forward and to the

starboard without rotating

24709

NOTE: In this maneuver move and twist the joystick for yaw correction, if required.

Boat moves diagonally

forward and rotates

starboard for yaw

correction

Movement

(shown from light gray to dark gray)

24715

24710

Boat moves diagonally aft

and to the starboard

without rotating

Boat moves diagonally aft

and to the port without

rotating

24711

90-866938081 MAY 2009 Page 41

Section 3 - On the Water

25925

25921

25920

25916

Joystick Input Boat Response

Boat moves diagonally forward and to the port

without rotating

24712

Boat rotates clockwise

Movement

(shown from light gray to dark gray)

24713

Boat rotates counter

clockwise

24714

Boat moves diagonally

forward and to the

starboard while rotating

clockwise

24715

Page 42 90-866938081 MAY 2009

Section 3 - On the Water

25918

25917

25930

Joystick Input Boat Response

Boat moves diagonally

forward and to the

starboard while rotating

counterclockwise

24718

Boat moves diagonally forward and to the port

while rotating

counterclockwise

Movement

(shown from light gray to dark gray)

Trim Tabs

AUTOMATIC CONTROL

The Zeus drive comes equipped with an automatic trim tab control feature that operates through the vessel control system to provide basic performance and efficiency improvements under normal conditions.

The automatic trim tab control feature can be engaged (turned on) or disengaged (turned off). To engage the feature, press the "AUTO" trim tab button once. The trim tabs will automatically adjust as the speed of the boat is changed. Pressing it again will disengage the feature.

With the automatic trim tab control feature engaged the port and starboard trim tab switches can be used to adjust the tabs (offset) for natural conditions that affect the attitude of the boat. This setting of the trim tab offset continues until the automatic control feature is disengaged and engaged again or when the key switch is cycled (turned off and on).

24719

Boat moves to the port

while rotating clockwise

24720

90-866938081 MAY 2009 Page 43

Section 3 - On the Water

Manual trim tab control is available to allow trim tab adjustment when not using the automatic trim tab control feature. See Manual Control.

NOTE: The port or starboard manual trim tab rocker switches allow some control of the attitude of the vessel. As an example, to achieve a port bow down attitude, you may press the port bow down rocker switch to deploy the trim tab on the starboard drive and provide the requested vessel attitude adjustment.

MANUAL CONTROL

To manually control or adjust the offset of the trim tabs for your conditions, use the individual port or starboard trim tab switches as needed. Manually adjusted trim tabs will stay in the position set by the operator until the key switch is cycled off and on or the "AUTO" button is pressed. If the "AUTO" button is pressed, the automatic trim tab control feature is engaged and the trim tabs move to a position based on boat speed. See Automatic Control.

NOTE: When controlled manually the trim tabs do not move during acceleration unless the operator presses the trim tab buttons.

USING TRIM TAB OFFSET

Automatic or manual control of trim tab offset could be beneficial in the following conditions.

26318

Typical automatic and manual trim tab switches

During initial acceleration the trim tabs are automatically adjusted (automatic control) or must be manually adjusted (manual control) to bring the boat on plane faster (bow down), to improve forward visibility, and use less power. As the boat comes on plane in automatic control, the trim tabs are brought up so the boat does

Getting on Plane

Smoothing the Ride

Correcting a List

not run with the bow too far down. For the best performance as the boat comes on plane in manual control, the port and starboard trim tabs must be adjusted up so the boat does not run with the bow too far down. In automatic control, the trim tabs can be adjusted (offset) with the port and starboard trim tab switches for best performance when the boat conditions are temporarily outside the normal operating conditions.

To avoid an uncomfortable, jarring ride in certain sea conditions, adjust the trim tabs using either automatic control or manual control. As the wave throws the bow up trim tabs dampen the boat's reaction, leveling and smoothing the ride. In a following sea, put the trim tabs up. This allows the bow to lift, offsetting the waves, which lift the stern. In milder water some boats gently porpoise. Lower the trim tabs, a little at a time, until the lope disappears.

A boat list (leaning to port or starboard) can be caused by unbalanced load or several sea and weather conditions. Using the port or starboard trim tab switches, individual trim tab adjustments can be made in automatic control or manual control to correct a list.

Page 44 90-866938081 MAY 2009

In controlled speed zones, many boats start to fall off plane as speed

def

bah

Low Speed Trim

decreases, thereby reducing visibility. In automatic control or manual control, lowered trim tabs keep the boat on plane longer at lower speeds while maintaining a level boat attitude.

Special Digital Throttle and Shift (DTS) Features

The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Most of the listed features can be operated simultaneously and can help you with:

• Warming the engines.

• Trolling the vessel.

• Docking the vessel.

• Synchronizing the engines.

• Dual helm station transfer.

Section 3 - On the Water

28090

ERC with DTS trackpad

Item Control Function

Illuminate when the transmission is in the neutral gear

a "NEUTRAL" lights

b "TROLL"

c "TRANSFER"

d "DOCK"

e "THROTTLE ONLY"

f "1 LEVER"

g "SYNC"

h "+" (increase) and "–" (decrease)

position. The lights flash when the engine is in throttle only mode.

Troll reduces the propeller speed to lower than that of engine speed for the first 25% of lever travel.

Allows boat control to be transferred to a different helm. Refer to Dual Helm Station Transfer.

Reduces the throttle capacity to approximately 50% of normal throttle.

Allows the boat operator to increase engine RPM for warm‑up, without shifting the transmission into gear.

Enables the throttle and shift functions of both engines to be controlled by the starboard lever.

Turns the auto‑synchronization feature off or on. Refer to Synchronizing Engines.

Increases and decreases idle speed only. The RPM range varies depending on application and engine model.

NOTE: Not all functions may be active.

90-866938081 MAY 2009 Page 45

Section 3 - On the Water

TROLL AND THROTTLE RESPONSE

Troll mode allows the vessel to operate at very low speeds by controlling the transmission. The transmission is capable of reducing the propeller speed lower than the engine speed. Lever control is adjusted so that trolling occurs within the first 25% of lever travel. From 26% to 100% lever travel the engine operates between idle speed and maximum rated engine speed.

31463

"TROLL" button

To engage Troll mode:

1. Place both ERC levers in neutral.

2. Press the "TROLL" button, located on the DTS trackpad attached to the ERC levers.

3. Place either ERC lever into gear.

4. The "TROLL" button lights when the lever or levers are moved out of neutral.

5. The RPM of the engines do not change for the first 25% of ERC lever travel while the transmissions allow some slippage at lower speeds. Engine RPM rises through the remaining 75% of lever travel.

To disengage Troll mode:

1. Bring both ERC levers to neutral.

2. Press the "TROLL" button. The "TROLL" button light turns off.

Page 46 90-866938081 MAY 2009

DOCK

THROTTLE ONLY

Section 3 - On the Water

Dock mode reduces the percent of throttle throughout the range by 50%. This allows better control of engine power in close quarter situations.

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"DOCK" button

To engage Dock mode:

1. Place both ERC levers in neutral.

2. Press the "DOCK" button located on the DTS trackpad attached to the ERC levers.

3. The "DOCK" button light turns on.

4. Place either ERC lever into gear.

5. The engines raise the RPM at a proportionally lower RPM for the ERC lever position,

and with half the power that is usually available.

To disengage Dock mode:

NOTE: Dock only disengages with the levers in a detent.

1. Bring both ERC levers to forward, neutral, or reverse detent.

2. Press the "DOCK" button. Dock mode disengages and the "DOCK" button light turns

off.

To engage Throttle Only mode:

1. Place both ERC levers in neutral.

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2. Press the "THROTTLE ONLY" button, located on the DTS trackpad.

"THROTTLE ONLY" button

3. The "THROTTLE ONLY" button light illuminates and the neutral lights blink.

4. Place either ERC lever into gear.

5. The RPM of the engines can be raised, while the transmissions remain in neutral.

To disengage Throttle Only mode:

NOTE: Pressing the "THROTTLE ONLY" button while the ERC levers are in gear, turns off the button light, but the boat remains in Throttle Only mode until you place the levers in neutral.

1. Bring both ERC levers to neutral. Throttle Only will not disengage unless the ERC levers are in neutral.

2. Press the "THROTTLE ONLY" button. The "THROTTLE ONLY" button light turns off.

3. Notice that the neutral lights remain on.

SINGLE LEVER (1 LEVER) OPERATION

The Zeus single lever (1 Lever) feature simplifies engine management during rough sea conditions by allowing you to grasp a single lever to command both engines simultaneously.

To engage the single lever (1 Lever) mode:

1. Place both ERC levers in neutral.

2. Press the "1 LEVER" button located on the DTS trackpad attached to the ERC levers.

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"1 LEVER" button

Page 48 90-866938081 MAY 2009

3. The "1 LEVER" button light turns on.

4. Place the starboard ERC lever into gear.

5. The engine RPM raises and lowers simultaneously while the transmissions remain in

the same gear.

To disengage the single lever (1 Lever) mode:

1. Place both ERC levers in neutral.

2. Press the "1 LEVER" button. The "1 LEVER" button light turns off.

SYNCHRONIZING THE ENGINES

The system features an automatic engine synchronization feature called Sync. Sync engages automatically at key‑up. The synchronization feature monitors the position of both ERC levers. If both levers are within 10% of one another, the port engine synchronizes to the starboard engine's RPM.

VesselView shows an orange icon if the RPM of the engines are not within 10% of each other, and the icon turns green when they synchronize. The icon turns grey when Sync mode is off.

To disengage Sync mode:

1. Place the ERC levers in any detent.

2. Press the "SYNC" button.

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"SYNC" button

To re‑engage Sync mode, press the "SYNC" button.

Cruise Control

The VesselView system features integrated throttle cruise control called Cruise, which allows the operator to limit the peak RPM of choice below wide open throttle (WOT). Refer to the owners manual provided with your VesselView for operation instructions.

These additional notes are exclusive to your package:

• You can change or disengage Cruise through the VesselView screen at any time.

• Cruise resets when the key is turned off.

• If the cruise limit is changed while the levers are at WOT, Cruise gradually changes to

the new speed.

• Cruise does not disengage if the ERC levers are at a higher engine speed than the

actual RPM. Bring the levers back to the forward detent, then use VesselView to disengage Cruise.

• Skyhook does not function if Cruise is engaged.

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SYNC

1 LEVER

NEUTRAL

TROLL

THROTTLE ONLY

DOCK

TRANSFER

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Helm Transfer

Some boats are designed to allow control of the vessel from more than one location. These locations are commonly referred to as helms or stations. Helm transfer is a term used to describe the method of transferring control from one helm (or station) to another helm.

Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral.

The helm transfer function allows the boat operator to select which helm is in control of the vessel. Before a transfer can be initiated the ERC levers at the active helm and at the helm intended for the transfer must be in the neutral position.

NOTE: If you attempt to transfer helm control when the ERC levers are not in neutral, a beep will sound and the helm transfer will not succeed until the levers at the helms are moved to neutral and transfer is requested again.

Some fault codes may appear on VesselView if other control or navigation functions are attempted after the helm transfer procedure is started. To remove the fault codes it may be necessary to cycle the key switch off and on, and then restart the helm transfer procedure. Ensure that other control and navigation inputs are performed after helm transfer is complete to avoid setting fault codes.

WARNING

The ERC levers must be in neutral to perform a helm transfer. While in neutral your vessel could drift and collide with objects nearby resulting in damage. Keep an adequate look out while performing the helm transfer.

To avoid damage, use extra care when attempting a helm transfer while the vessel is close to docks, piers, or other fixed items or when near other vessels.

Requesting Helm Transfer

NOTE: Any movement of the joystick or ERC levers after pressing the "TRANSFER" button terminates the helm transfer request. A single beep sounds and the transfer button light turns off signaling the end of the transfer request.

To request the transfer of vessel control from one helm to another:

1. At the helm you are requesting be made active and with the ERC levers in neutral, press the "TRANSFER" button one time. After the "TRANSFER" button is pressed, the transfer button light turns on and one beep will sound confirming the impending transfer.

NOTICE

"TRANSFER" button

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NOTE: If the ERC levers at the helms are not in neutral, the neutral lights will flash. Move all the ERC levers to neutral and the neutral light should then be on.

2. With the "TRANSFER" button light and neutral light on, press the "TRANSFER" button

a second time to complete the helm transfer.

3. When the helm transfer is complete, another beep sounds and the transfer button light

turns off.

NOTE: If the helm transfer is not completed in ten seconds the request is automatically cancelled and a double beep sounds. Control will remain at the existing active helm. Press the "TRANSFER" button again to restart helm transfer.

4. The helm where the transfer request was initiated is now active and controls the

vessel.

Helm Transfer and Precision Pilot

Transferring control from an active helm to an inactive helm (from one station to another station) affects the functionality of Precision Pilot modes. Some of the affects are listed.

• Auto Heading mode is disengaged when the ERC levers are moved to neutral for helm

transfer. You must re‑engage Auto Heading at the newly active helm.

• Requesting a helm transfer causes Pilot to go to Standby mode. You will need to input

information at the new helm in control.

• If engaged, Skyhook will disengage when the "TRANSFER" button is pressed the

second time. You must engage Skyhook at the the newly active helm.

• The Resume feature for Auto Heading does not transfer automatically. After engaging

the previous Auto Heading course at the newly active helm, the resume feature works the same as at any active station.

• In Track Waypoint mode the control of the route and display of route data on your chart

plotter does not automatically transfer to the chart plotter at the requested helm. You must turn on the chart plotter at the newly active helm, input the waypoint or waypoint route to be tracked, and re‑engage Track Waypoint.

Section 3 - On the Water

Precision Pilot

Precision Pilot Trackpad Features

GENERAL INFORMATION

Precision Pilot trackpad features includes:

• Precision Pilot (or Pilot) functions are controlled through the Pilot trackpad only.

• Pilot screens are located under the Environment chapter of VesselView.

• The "TURN" buttons provide a 10° course correction for each press to the port or

starboard.

• The "AUTO HEADING", "TRACK WAYPOINT", and "WAYPOINT SEQUENCE"

buttons engage automatic course and heading modes.

• The steering wheel feels locked into a detent when Auto Heading or Track Waypoint

are engaged. Manually overcoming the detent force of the steering wheel automatically puts Pilot into Standby mode.

STANDBY

The elements of the Standby screen are:

• In standby mode, the display shows a digital compass value and the angle of the

drives.

• The compass value is the actual current heading from Pilot.

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• On the right side of the screen, an icon labeled "OFF" indicates that Pilot is not

NOTE: Not all of the functions of Precision Pilot work when DTS functions are engaged. Disengage the DTS functions to use the functions of Precision Pilot.

engaged.

Standby screen on VesselView

a - "OFF" icon b - Heading c - Drive angle reference d - Engine RPM

STANDBY AND ACTIVE LIGHTS

Precision Pilot is disengaged (off) when the "STANDBY" light is illuminated. You must press the button for Auto Heading, Track Waypoint, or Skyhook to engage a mode.

When the "ACTIVE" light is illuminated one mode of Precision Pilot is engaged (on).

a - "STANDBY" light b - "ACTIVE" light

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POWER ICON

Section 3 - On the Water

The power icon located on the buttons for Skyhook, Auto Heading, and Track Waypoint indicate that the buttons can engage or disengage the Precision Pilot function they perform.

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Buttons with Power icons

a - "SKYHOOK" button b - "AUTO HEADING" button c - TRACK WAYPOINT" button

If you press a button that has the power icon when that button light is on, the light turns off for that button and the "STANDBY" light illuminates.

If you press a button that has the power icon when that button light is off, the light turns on for that button, a single beep sounds, and the "ACTIVE" light illuminates, unless another mode is currently active. If another mode is currently active, press the button on the active mode to disengage it, then press the button for the new mode.

If you press a button with the power icon for that button, a single beep sounds, and the "ACTIVE" light illuminates.

Skyhook (If Equipped)

Your vessel may be equipped with a station keeping feature called Skyhook. Skyhook automatically maintains the heading and position of the boat within about 3 meters (10 feet) of a set position. The control system for Skyhook uses GPS and compass heading information to automatically control shift, throttle and steering to keep the boat in approximately one position.

The Skyhook feature can hold your boat nearly stationary, for example, while you wait for a space at the fuel dock, or while waiting for a bridge to open. You can also use Skyhook to maintain your boat's position when the water is too deep for an anchor.

To unlock and be able to use this feature you will have to contact your Authorized Cummins MerCruiser Diesel Repair Facility.

when that button light is off, the light turns on

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Section 3 - On the Water

Skyhook should not be used when the boat is next to a dock, or any other object, including other anchored boats. Because Skyhook holds the boat in an approximate position, not a precise one, it can cause your boat to collide with objects close to the boat causing damage to the boat and the nearby objects. Occasionally the Skyhook system may apply a brief surge in power while holding a position. This may cause a person standing near the edge of the boat to lose their balance and fall.

A rotating propeller, a moving boat, or a device attached to a moving boat can cause serious injury to people in the water. When Skyhook is engaged, the propellers rotate and the boat moves to maintain the position of the boat. Stop the engines immediately whenever anyone is in the water near the boat.

To engage Skyhook the drives must be shifted into neutral. However, after engaging Skyhook the drive response is not the same as with drives normally shifted into neutral. The propellers will turn when Skyhook is activated, and propeller rotation may not be obvious. As in all boats when the engines are running, it is important to ensure no one is in the water near the boat and to make sure passengers are secure. Compliance with this practice is even more important when Skyhook is engaged.

Before engaging (activating) Skyhook the operator must:

• Inform passengers how Skyhook operates, to stay out of the water and off the swim

• Check to see no one is on the swim platform, or in the water anywhere near the boat.

When Skyhook is engaged the operator must:

• Remain at the helm and maintain a vigilant watch.

• Disengage (deactivate) Skyhook if anyone enters the water or approaches the boat

The capability of Skyhook to maintain the position of the boat in a current is dependent on the characteristics of the boat. If you notice your boat drifting sideways while Skyhook is engaged, move the bow or stern more directly into the current to help reduce the effects of the current.

WARNING

platform, and to be alert for any sudden shifts in the boats position.

from the water.

WARNING

When the Skyhook is engaged, the boat stays in a preset position; however, Skyhook can disengage unexpectedly. When Skyhook disengages, the boat does not hold the preset position and may drift, causing the potential of damage or personal injury. The helm operator must be able to take control of the boat when using Skyhook.

Skyhook relies on an operational GPS receiver and operational heading sensor. Occasionally, due to imperfect satellite communications, the GPS signal may be temporarily unavailable. Skyhook continues to operate through a GPS signal outage for up to 10 seconds, but automatically disengages if the GPS signal outage persists. If Skyhook disengages, you are alerted by the sound of a horn and the indicator light on the Precision Pilot keypad for the "SKYHOOK" button turns off. In such a circumstance, the boat will drift with the wind or current because the engines continue to run but the drive units are now in neutral.

Page 54 90-866938081 MAY 2009

Skyhook performance is largely dictated by the performance of the onboard Zeus GPS

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8M0034159

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system. The Zeus GPS system is accurate within 3 meters (10 feet) when receiving a Wide Area Augmentation System (WAAS) correction. WAAS is a system of satellites and ground stations that provide GPS signal corrections, allowing for more accurate positioning of your GPS. When WAAS is not available, the performance of the system maintains the boat within 20 meters (60 feet) of the desired position.

ENGAGING (ACTIVATING) SKYHOOK

IMPORTANT: Activities in the water near the vessel while Skyhook is engaged may result in injury. The Captain (or operator) and passengers should read and observe the warning labels on the boat before Skyhook is engaged.

Section 3 - On the Water

Label adjacent to the Precision Pilot trackpad

Label in the vicinity of the transom boarding area

IMPORTANT: If either of the labels cannot be located or are not legible, they must be replaced before engaging Skyhook. For replacement labels, contact the manufacturer of your boat, your Cummins distributor, or an Authorized Cummins MerCruiser Diesel Repair Facility.

1. Move the ERC levers to neutral and bring the boat to a stop. Skyhook will not engage

until the boat is in neutral and at a speed slow enough for safe engagement.

2. Inform passengers how Skyhook operates, to stay out of the water and off the swim

platform, and to be alert for any sudden shifts in the boats position.

3. Check to see no one is on the swim platform, or in the water anywhere near the boat.

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4. Press the "SKYHOOK" button to request engagement and operation of Skyhook.

WARNING

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"SKYHOOK" button

5. A safety popup (warning screen) appears on VesselView. Read and observe the safety pop‑up.

Skyhook warning screen on VesselView

6. Press the X‑button on VesselView to close the safety pop‑up.

NOTE: Pressing the "SKYHOOK" button will also close the safety pop‑up and then disengage Skyhook.

7. The Skyhook system engages, and a one second solid horn beep sounds one time. The trackpad "SKYHOOK" button light stops blinking and remains on indicating Skyhook is engaged.

NOTE: Some boat manufacturers include additional (secondary) systems of sounds, lights, or other sources to alert you and your passengers that Skyhook is engaged. See your boat manufacturer for information about additional Skyhook notification systems, if equipped.

8. The VesselView "SKYHOOK" screen displays a green circle with the word "ON" when Skyhook engages. Refer to The Skyhook Screen in VesselView.

NOTE: The boat may reverse automatically if it passed the position it was asked to hold— where the "SKYHOOK" button was first pressed.

Page 56 90-866938081 MAY 2009

9. When Skyhook is engaged you must remain at the helm and maintain a vigilant

watch. Disengage Skyhook if anyone enters the water or approaches the boat from the water.

10. Press the "SKYHOOK" button a second time to put Precision Pilot in standby. All lights

other than "STANDBY" turn off.

11. To disengage Skyhook, refer to Disengaging (Deactivating) Skyhook .

THE SKYHOOK SCREEN IN VESSELVIEW

In Skyhook mode VesselView displays a special Skyhook screen. The elements of the Skyhook screen are:

• RPM of the engines.

• The rotation angle of the boat icon shows the yaw of the boat relative to its position

when Skyhook was first engaged.

• The horizontal and vertical displacement of the vessel from the cross hairs is

proportional to the position error reported by the GPS.

• Each gradation of color in the circular target on the VesselView screen is equivalent to

5 meters of error. If the boat exceeds 20 meters of error, then the boat is located at the edge of the circle. The boat continues to try to correct until Skyhook is disengaged.

Section 3 - On the Water

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Skyhook screen on VesselView

a - Location where Skyhook is set b - Location where boat is relative to set location c - 5 meter gradation d - Engine RPM

When Skyhook is engaged (VesselView displays Skyhook "ON" screen), the onboard computer control system controls the engines and shifts the drives automatically. Do not allow people in the water around the boat while Skyhook is engaged. Activities in the water near the vessel while Skyhook is engaged may result in injury.

DISENGAGING (DEACTIVATING) SKYHOOK

IMPORTANT: Both engines and drives must be operational for Skyhook to function. If the necessary reference signals from an engine or drive become unavailable, Skyhook automatically disengages.

1. To disengage the Skyhook, do one of the following:

• Press the "SKYHOOK" button on the Precision Pilot trackpad.

• Move any ERC lever out of neutral.

• Move the joystick.

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NOTE: In each method, the light on the Precision Pilot trackpad for the "SKYHOOK" button will turn off.

2. A single horn beep sounds when the feature disengages.

Auto Heading

In some Precision Pilot modes—"Auto Heading," "Track Waypoint," and "Waypoint Sequence"—the boat navigates a preset course. The boat does not automatically respond to hazards such as other watercraft, obstacles, swimmers, or underwater terrain. Collision with these hazards could cause boat damage, serious injury, or death. The operator must stay at the helm, ready to evade hazards and warn others of course changes.

Auto Heading allows the boat to automatically maintain a compass heading while the boat is underway.

ENGAGING AUTO HEADING

1. Place at least one running engine in forward gear.

NOTE: Auto Heading does not function with the ERC levers in neutral or reverse.

2. Steer the boat to the desired compass heading.

3. Press the "AUTO HEADING" button to engage the Auto Heading mode. The button illuminates and a single horn beep sounds acknowledging engagement. A double horn beep sounds if Auto Heading does not engage.

WARNING

27700

a - "TURN" (course adjust) buttons b - "RESUME" button c - "AUTO HEADING" button

4. Display the Autopilot screen on VesselView. See Mode Display in VesselView.

5. On the VesselView screen for Autopilot, the mode indicator changes from "OFF" to "AUTO".

6. The steering wheel will self‑center and be held in an electronic detent position.

NOTE: If for any reason, you must turn the steering wheel, you will need to apply sufficient force to overcome the electronic detent.

7. Precision Pilot holds the compass heading the boat was following when the "AUTO HEADING" button was pressed and Auto Heading engaged.

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9. To adjust your course while "AUTO HEADING" is engaged, see Course Adjustment

Using the Turn Buttons or Joystick.

10. To disengage Auto Heading refer to Disengaging Auto Heading.

11. Press the "AUTO HEADING" button a second time, Auto Heading goes to Standby

mode and all lights other than "STANDBY" turn off.

COURSE ADJUSTMENT USING THE TURN BUTTONS OR JOYSTICK

While in "AUTO HEADING" mode, the "TURN" buttons (course adjust buttons) change the set course heading each time they are pressed. Tapping the joystick left or right adjusts your course for each tap.

1. Press the "TURN" button in the direction of the desired heading change. Each press

of the button changes the desired heading by 10°.

Section 3 - On the Water

27699

a - Port "TURN" button b - Starboard "TURN" button

2. Move (press) the joystick in the desired direction to make small adjustments in the

chosen heading. Each recognized movement adjusts the chosen heading by 1°.

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NOTE: The joystick must move over 50% of its travel for the movement to be recognized as input.

TO RESUME A HEADING

The "RESUME" button light is on if the previous course heading is available to resume. IMPORTANT: The previous heading can only be resumed within one minute of Auto

Heading being disengaged or if the boat has not turned more than 180°. Press the "RESUME" button to resume the previous heading if you:

• Turned the steering wheel and disengaged Auto Heading.

• Pressed one of the "TURN" (course adjust) buttons with Auto Heading engaged.

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Adjusting heading to starboard

27700

a - "TURN" button b - "RESUME" button c - "AUTO HEADING" button

DISENGAGING AUTO HEADING

1. Disengage the Auto Heading mode with any of the following actions:

• Place the ERC handles for both engines in neutral. The "AUTO HEADING" button

light turns off and the Standby light comes on.

• Turn the steering wheel beyond the electronic detent. The "AUTO HEADING"

button light turns off and the Resume light comes on.

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• Press the "AUTO HEADING" button on the Precision Pilot keypad. The "AUTO HEADING" button light turns off and the Standby light comes on.

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a - "TURN" button b - "RESUME" button c - "AUTO HEADING" button

2. A single horn beep sounds and the mode indicator changes from "AUTO" to "OFF".

3. If Auto Heading disengaged because the steering wheel was turned, the Resume button light turns on. While the Resume button light is on, you can press the "RESUME" button to resume the course in Auto Heading. See To Resume a Heading. If you do not wish to resume the course, press the "AUTO HEADING" button once to engage Standby and press it again to turn the Auto Heading mode off.

a - Mode indicator—"OFF" or "AUTO" b - Current heading

c - Drive positions d - Engine RPM

4. If the ERC Handles were moved to neutral, Auto Heading turns off the "STANDBY" light turns on. You cannot resume your course by pressing the "RESUME" button. See To Resume a Heading.

5. If Auto Heading disengaged because the "AUTO HEADING" button was pressed, the "AUTO HEADING" button light turns off and the Standby light comes on. Press the "AUTO HEADING" button a second time and the Standby light goes off, Auto Heading is disengaged, and the mode is off.

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Section 3 - On the Water

Response Button

1. Press the "RESPONSE" button to increase or decrease how aggressively the vessel

NOTE: Each time you press the "RESPONSE" button, the button light blinks to indicate you changed the response setting for that mode.

reacts to programmed changes when in the Pilot modes. How aggressively the vessel reacts equals a response setting in VesselView.

27704

Track Waypoint

Response button

2. Press the "RESPONSE" button again to increase how aggressively the vessel reacts to programmed changes. The initial button press shows the current response setting. Pressing the button as many as three times will increase how aggressively the vessel reacts by three and then decrease it by returning to the first response setting.

Number of blinks Response setting indicated Aggressiveness of correction

1 1 Mild (for gentle or calm conditions) 2 2 Medium (for moderate conditions) 3 3 Aggressive (for severe conditions)

3. The value setting for the current amount of response appears on the Auto Heading page in VesselView.

WARNING

Track Waypoint allows the boat to automatically navigate to a specific waypoint or sequence of waypoints, called a waypoint route. This feature is intended for use in open waters, free from obstructions above and below the waterline.

When the Track Waypoint feature is activated and the boat is in operation:

• The helm must never be unattended. The feature is not designed to allow unattended operation of the vessel.

• The operator must remain at the helm at all times.

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• It must not be used as the sole source of navigation. IMPORTANT: Track Waypoint can only be used with chart plotters approved by CMD. Waypoint data needs to be provided to VesselView by a third party chart plotter. Refer to

your chart plotter's user manual for details. The accuracy of the feature can be affected by environmental conditions and incorrect

use. Observe the following information when using the Track Waypoint and Waypoint Sequencing feature.

Waypoint data—distance settings Between waypoints Greater than 1.0 nautical mile (1.15 mile) Arrival alarms No less than 0.1 nautical mile (0.12 mile)

ENGAGING TRACK WAYPOINT MODE

To engage the Track Waypoint mode of Precision Pilot:

1. Turn on the chart plotter and select a single waypoint or waypoint route to be tracked.

2. Place at least one ERC handle in forward gear. Track Waypoint does not function if

both handles are in neutral or reverse.

3. Manually steer the boat to the direction of the first waypoint and hold the boat steady

at a safe operating speed.

4. Press the "TRACK WAYPOINT" button on the Precision Pilot keypad. The "TRACK

WAYPOINT" button light turns on and a single horn beep sounds, indicating Track Waypoint engaged. Pilot tracks to the first waypoint on the chart plotter course. Two horn beeps sound if Track Waypoint does not engage.

Section 3 - On the Water

27701

"TRACK WAYPOINT" button

The VesselView "TRACK WAYPOINT" screen displays on VesselView for one second after pressing the "TRACK WAYPOINT" button. The display shows the digital heading that the boat is traveling, the angles of the drives, and engine speed in RPM. See Mode Display in VesselView.

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NOTE: This display screen is activated during VesselView calibration. The GPS system generates the displayed heading based on magnetic North.

Track Waypoint screen

NOTE: Precision Pilot will not initiate turns when Track Waypoint mode is engaged. Turn features are only available in Auto Heading mode.

DISENGAGING TRACK WAYPOINT MODE

1. Disengage the Track Waypoint mode by one of the following methods:

• Press the "TRACK WAYPOINT" button on the Precision Pilot keypad. The

"TRACK WAYPOINT" button light goes off and Pilot goes to Standby. The "STANDBY" light turns on

• Turn the steering wheel hard enough to overcome the force feedback and Pilot

goes to Standby.

• Move both ERC levers back to neutral and Pilot goes to Standby.

• Press either "TURN" button and Pilot goes to Auto Heading mode.

• Press the "AUTO HEADING" button and Pilot goes to Auto Heading mode.

• Turn off the chart plotter and Pilot goes to Standby.

2. You can resume the Track Waypoint heading within one minute, if the vessel has not turned too far and the "RESUME" light is still on or flashing.

TURN BUTTONS OR JOYSTICK IN TRACK WAYPOINT MODE

While in "TRACK WAYPOINT" mode, using the left or right "TURN" buttons on the keypad or using the joystick changes the mode to "AUTO HEADING."

AUTO HEADING BUTTON IN TRACK WAYPOINT MODE

While in "TRACK WAYPOINT" mode, pressing the "AUTO HEADING" button causes Pilot to change to "AUTO HEADING" mode.

ACKNOWLEDGING A TURN DURING A WAYPOINT ARRIVAL

IMPORTANT: Track Waypoint mode does not automatically turn the boat upon arrival at a plotted waypoint.

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1. When the boat enters an waypoint arrival zone as indicated by the chart plotter, a short

horn beep sounds and the "WAYPOINT SEQUENCING" button light starts blinking to inform the operator to make a turn.

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"WAYPOINT SEQUENCE" button

2. If the Waypoint Sequence mode has not been engaged, the "WAYPOINT

SEQUENCE" icon light blinks at the arrival zone.

Waypoint Sequence icon light

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3. VesselView displays a pop‑up screen warning. The operator must determine it is safe to turn the boat. If so, press the "WAYPOINT SEQUENCE" button to acknowledge that it is safe for Pilot to automatically turn the boat and maneuver to the new course.

4. If the waypoint is not acknowledged, the boat continues on its current heading.

5. At the end of the Track Waypoint course, input a new route or take control of the boat. Otherwise, the boat reverts to Auto Heading mode and continues on its last course heading.

WAYPOINT SEQUENCE

1. Place the ERC lever or levers into forward. "WAYPOINT SEQUENCE" does not engage if the levers are in neutral or reverse.

2. If the Track Waypoint button light is not on, press the "TRACK WAYPOINT" button.

3. Press the "WAYPOINT SEQUENCE" button to engage Waypoint Sequence mode.

Pop‑up screen warning

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"WAYPOINT SEQUENCE" mode button

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4. A horn beep sounds on VesselView and the green circle icon on the Pilot screen will

display "TRACK." The "TRACK" icon on the VesselView screen should illuminate.

Waypoint Sequence TRACK icon

5. If you are in a waypoint arrival zone set by the chart plotter, Waypoint Sequence mode

only informs Precision Pilot it is OK to proceed to next waypoint. Waypoint Sequence mode acts as a waypoint acknowledge function and Precision Pilot sounds a horn beep when in the zone.

WARNING

Pressing the enter button to acknowledge that it is OK to turn. The enter button is in the upper right corner of VesselView and has a check mark symbol. Once acknowledged, Pilot tracks to the next waypoint in the route.

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Section 3 - On the Water

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31412

7. Stay alert; the boat turns automatically in this mode. The operator must know if it is

8. If you are not in a previously set waypoint arrival zone, "WAYPOINT SEQUENCE"

safe to turn when the vessel is entering a waypoint arrival zone. Inform passengers that the boat automatically turns so they can be prepared.

Waypoint acknowledge screen

mode starts auto sequencing to the waypoints in the route. Acknowledge that you understand the information presented by the pop‑up screen warning and press the enter button—the button with a check mark symbol.

Pop‑up screen warning

9. Press the "TRACK WAYPOINT" button. The "WAYPOINT SEQUENCE" button light turns on and a single horn beep sounds.

10. Press the "TRACK WAYPOINT" button a second time to put Precision Pilot in Standby mode. All lights other than "STANDBY" turn off.

Contingent Operations

Steering—Emergency Alternative Method

If the electronic steering wheel ceases to operate, the engine throttle handles (ERC handles), trim tabs, and the vessel joystick should still operate. Engine throttles and trim tabs can be used as an emergency alternative for steering in open water where there are no objects or other vessels in close vicinity.

Page 68 90-866938081 MAY 2009

To maintain steering and course heading, closely observe the amount of engine speed used with each throttle handle. Trim tabs can be adjusted to assist in steering the vessel. An operator should regularly practice steering the vessel in this manner to be familiar with using their vessel's throttles and trim tabs for steering.

The joystick can be used as an alternative method of steering when operating the vessel in close vicinity of objects, docks, and other vessels. Engine RPM is limited with joystick operation.

Port Engine Only Operation

The force feedback feature of the steering wheel is only available when the starboard key switch is in the on position. If the starboard key switch is off or there has been damage to the starboard electrical system, the steering wheel will be monitored by the port control system.

However, if only the port side is operational, or only the port key switch is in the on position, the steering wheel will not have end stops provided by the force feedback system. In this case, the drive will always turn in the direction that the steering wheel is being rotated until the mechanical limits of the drive are reached. If there is damage to the port electrical system, the steering wheel will operate normally with complete force feedback and end stops.

The boat can operate as a single‑engine vessel. Note that joystick and station keeping are not available in this condition. However, Zeus features redundant AutoPilot systems, so Auto Heading and Track Waypoint mode are still available during single‑engine operation.

Section 3 - On the Water

Gear Engagement—Emergency Procedure

If a transmission or electrical system is damaged or has experienced a condition resulting in a fault such that a transmission does not respond to the helm controls, it is possible to manually engage a gear. In an emergency you can manually place a transmission into gear by using a suitable wrench to actuate the appropriate gear shifting solenoid.

Note the following:

• It is better to use one drive that works properly than locking and operating the drive that

is not functioning properly. This procedure is for when both drives are not responding to helm control.

• Auto Heading and Track Waypoint will work when emergency gear engagement is in

use.

• Moving the ERC handle into reverse stops the engine.

Locking the transmission in gear using the emergency procedure renders the helm’s shifting control inoperable. Drive carefully with the gear lock engaged. To shift out of gear, turn the key switch to "OFF."

1. Determine the transmission that is not engaging a gear.

2. Stop the engines and remove the key from the key switch.

CAUTION

WARNING

Engine components and fluids are hot and can cause serious injury or death. Allow the engine to cool before removing any components or opening any fluid hoses.

3. Remove the drive cover of the affected transmission. Refer to Section 5—The Drive

Cover.

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Section 3 - On the Water

41213

4. Locate the forward gear solenoid on the port side of the affected transmission (the wire

NOTE: Do not disturb the reverse gear solenoid on the starboard side of the transmission (the wire is tagged "Reverse Gear").

5. Using a 3 mm hex‑head wrench, turn the solenoid screw in the center of the top of the

6. The transmission is now manually engaged in the gear and will not respond to the helm

is tagged "Forward Gear").

forward gear solenoid clockwise until it stops.

controls for shifting in and out of that gear.

a - Forward gear solenoid b - Solenoid screw

7. Ensure that the area around the propellers is clear before starting the engine since the propeller will be turning whenever the engine is operating.

IMPORTANT: The engine does not start with the ERC lever in gear, even though the drive is manually engaged in a gear.

8. When you are ready to start the engine, position the ERC lever in neutral gear before turning the key switch to the start position.

NOTE: Due to the extra load of turning the drive gears and propeller, the starter may turn slower when starting the engine connected to the drive in the emergency setting.

9. Use extra care and caution when operating your boat in this emergency mode. On the drive with the manually engaged gear, you must turn that engine off to stop the propeller from turning or providing thrust.

NOTE: Putting the drive with the gear manually engaged into reverse stops the engine.

10. Immediately take your boat to an Authorized Cummins MerCruiser Diesel Repair Facility and inform them that the drive gear has been manually engaged.

Steering and Trim—Manual Override

The steering and trim system operate using a hydraulic manifold fitted with control valves. If a malfunction occurs in the manifold for the steering and trim system, VesselView should display a fault code. The steering actuator, trim cylinder, or both may not respond to helm control resulting in the loss of normal steering or trim control.

WARNING

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Section 3 - On the Water

41303

CAUTION

A fault in the steering control valve or trim control valve will temporarily cause a malfunction of the steering or trim helm controls on the affected drive. If you lose normal steering or trim control, reduce speed to operate the boat safely.

The table provides a matrix of related drive and trim tab information in the event of a malfunction or failure.

Failure Mode

Steering control valve stuck

Trim tab control valve stuck

Fault Codes

Steering_Spool_Stuck_Fault

Tab_Spool_Stuck_Fault

Drive or Tab Position

Stuck in any position

Engine Management Boat Speed

• Fault code is seen on VesselView

• Drive is in reduced operation mode

• Engine throttle percentage is reduced

No effect on engine management

The maximum boat speed that can be achieved on a single engine, with one engine shut down, or with one drive that is not steerable, will vary on different models. Except in an emergency, normal operation on a single engine should not exceed 50% throttle.

Proceed at a reduced safe operating speed within the duty cycle.

In an emergency, if a steering or trim control valve is stuck, it may be possible to clear the steering fault code by manually overriding the system. A decal with information about the location of specific control valves is affixed to the drive cover (if equipped) and on the bracket attached to the steering manifold on all models. Refer to the Procedure for a Stuck Steering Control Valve or the Procedure for a Stuck Trim Tab Control Valve for additional information.

a - Decal b - Hydraulic manifold for steering and trim

90-866938081 MAY 2009 Page 71

Section 3 - On the Water

41307

41309

Manual‑override buttons on front of manifold

a - Steer‑to‑starboard override button b - Trim‑down override button c - Hydraulic manifold

Manual‑override buttons on rear of manifold

a - Hydraulic manifold b - Trim‑up override button c - Steer‑to‑port override button

WARNING

Accidental engine starting can cause serious injury or death. Remove the key from the ignition switch and engage the lanyard stop or E‑stop switch to prevent the engine from starting when performing service or maintenance on the power package.

PROCEDURE FOR A STUCK STEERING CONTROL VALVE

1. Determine the drive that is not responding to steering control.

2. Shut down the engine and turn the key switch off. Wait at least 30 seconds, if possible.

3. Restart the engine. Confirm the steering fault has cleared.

4. If the steering fault did not clear, repeat the start/stop routine up to three times.

5. If the steering fault does not clear using the above procedure, then shift the transmission into neutral, shut down the engine, turn the key switch off, and alternately push the port and starboard steering manual‑override buttons to release the spool. Refer to the decal on the manifold bracket or on the port‑side of the drive cover, if equipped, for additional information.

6. Restart the engine. At the helm, steer the drive to the port and starboard to confirm the fault has cleared. If the Steering_Spool_Stuck fault remains, then shut down the engine and turn the key switch off on the unresponsive drive. Operate on another engine and drive. Refer to Port Engine Only Operation, if the starboard drive is shut down.

NOTE: Boat speed and maneuverability will be reduced.

Page 72 90-866938081 MAY 2009

PROCEDURE FOR A STUCK TRIM TAB CONTROL VALVE

1. Determine the drive that is not responding to trim control.

2. Shut down the engine and turn the key switch off. Wait at least 30 seconds, if

possible.

3. Restart the engine. Confirm the trim tab fault has cleared.

4. If the trim tab fault did not clear, repeat the start/stop routine up to three times.

5. If the trim tab fault does not clear using the above procedure, then shift the transmission

into neutral, shut down the engine, turn the key switch off, and alternately push the trim‑up and trim‑down manual‑override buttons to release the spool. Refer to the decal on the manifold bracket or on the port‑side of the drive cover, if equipped, for additional information.

6. Restart the engine. At the helm, trim the tab up and down to confirm the fault has

cleared. If the Tab_Spool_Stuck fault remains, then shut down the engine and turn the key switch off on the unresponsive drive. Operate on another engine and drive. Refer to Port Engine Only Operation, if the starboard drive is shut down.

NOTE: Boat speed and maneuverability will be reduced. Oversteer or boat listing may occur with tab in the down position.

End of First Season Checkup

Section 3 - On the Water

At the end of the first season of operation, contact an Authorized Cummins MerCruiser Diesel Repair Facility to discuss or perform scheduled maintenance items. See Section 5 if you are in an area where the product is operated continuously, year‑round, contact your Authorized Cummins MerCruiser Diesel Repair Facility at the end of the first 500 hours of operation or once yearly, whichever occurs first.

90-866938081 MAY 2009 Page 73

Section 3 - On the Water

Notes:

Page 74 90-866938081 MAY 2009

Table of Contents

Section 4 - Specifications

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

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

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

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

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

90-866938081 MAY 2009 Page 75

Section 4 - Specifications

Drive Gear Lubricant

Model

Zeus (during break‑in) 5‑1/4 L (5‑1/2 US qt)

Zeus (after break‑in) 5‑1/4 L (5‑1/2 US qt)

Transmission

IMPORTANT: Always use the dipstick to determine the exact quantity of lubricant (fluid) required.

Transmission Without Drop Box

Description Fluid Capacity Fluid Type Fluid Part Number

Transmission only (without drop box)

Transmission With Drop Box

Fluid Capacity

(includes the drive and

the gear lube monitor)

4 L (4‑1/4 US qt)

Fluid Type Fluid Part Number

Premium Gear Lubricant

High Performance Gear Lube

Synthetic Power Steering Fluid SAE 0W‑30

92‑858058K01

92‑858064K01

92‑858077K01

Description Fluid Capacity Fluid Type Fluid Part Number

Transmission and drop box

5‑1/4 L (5‑1/2 US qt)

Synthetic Power Steering Fluid SAE 0W‑30

92‑858077K01

Transmission With Drop Box and Remote (Engine Mounted) Transmission Oil Cooler

Description Fluid Capacity Fluid Type Fluid Part Number Transmission, drop box

and remote (engine mounted) oil cooler

5‑1/2 L (6 US qt)

Synthetic Power Steering Fluid SAE 0W‑30

92‑858077K01

Steering Actuator and Trim Oil

Description Fluid Capacity Fluid Type Fluid Part Number

Steering actuator and trim system

5‑3/4–6 L (6–6‑1/3 US qt)

Synthetic Power Steering Fluid SAE 0W‑30

92‑858076K01 1/4 L (8 oz)

92‑858077K01 1 L (1 US qt)

Approved Paints

Description Marine Cloud White (CMD part number: 4918660) Obtain locally Mercury Light Gray Primer 92‑80287852 Mercury Phantom Black 92‑802878Q1

Part Number

Approved Lubricants

Tube Ref No.

120

Corrosion Guard Drive exterior surfaces 92-802878 55

Page 76 90-866938081 MAY 2009

Description Where Used Part No.

Section 4 - Specifications

Tube Ref No. Description Where Used Part No.

U-joint and Gimbal Bearing Grease

Driveshaft slip-joint 92-802870A1

Anti-Corrosion Grease Propeller shafts 92-802867Q 1

90-866938081 MAY 2009 Page 77

Section 4 - Specifications

Notes:

Page 78 90-866938081 MAY 2009

Table of Contents

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

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

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

90-866938081 MAY 2009 Page 79

Section 5 - Maintenance

Product Responsibilities

Owner and Operator Responsibilities

It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation, and to return the unit to a Cummins MerCruiser Diesel Authorized Repair Facility for a periodic checkup.

Normal maintenance service and replacement parts are the responsibility of the owner or operator and as such, are not considered defects in workmanship or material within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of your power package will ensure optimum performance and dependability and will keep your overall operating expenses at a minimum. See your Cummins MerCruiser Diesel Authorized Repair Facility for service aids.

Dealer Responsibilities

In general, a dealer's responsibilities to the customer include predelivery inspection and preparation such as:

• Make certain that the power package and other equipment are in proper operating condition before delivery.

• Make all necessary adjustments for maximum efficiency.

• Explain and demonstrate the operation of the power package and boat.

• Provide you with a copy of a Predelivery Inspection Checklist.

• Fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product. All power packages must be registered for warranty purposes.

Do‑It‑Yourself Maintenance Suggestions

Present‑day marine equipment, such as your Cummins MerCruiser Diesel power package, are highly technical pieces of machinery. Special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.

If you are one of those persons who likes to do it yourself, here are some suggestions for you.

• Do not attempt any repairs unless you are aware of the Cautions, Warnings, and procedures required. Your safety is our concern.

• If you attempt to service the product yourself, we suggest you order the service manual for that model. The service manual outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you do not understand. Do not attempt repairs if you do not understand the procedures.

• There are special tools and equipment that are required to perform some repairs. Do not attempt these repairs unless you have these special tools and equipment. You can cause damage to the product in excess of the cost a dealer would charge you.

• Also, if you partially disassemble an engine or drive assembly and are unable to repair it, the dealer's mechanic must reassemble the components and test to determine the problem. This will cost you more than taking it to the dealer immediately upon having a problem. It may be a very simple adjustment to correct the problem.

• Do not telephone the dealer, service office, or the factory to attempt for them to diagnose a problem or to request the repair procedure. It is difficult for them to diagnose a problem over the telephone.

Your local Cummins MerCruiser Diesel Authorized Repair Facility is there to service your power package. They have qualified factory‑trained mechanics.

Page 80 90-866938081 MAY 2009

Inspection

37802

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Section 5 - Maintenance

It is recommended you have the Cummins MerCruiser Diesel Authorized Repair Facility do periodic maintenance checks on your power package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating season when you want trouble‑free boating pleasure.

Inspect your power package at regular intervals to help maintain top operating performance and avoid potential problems before they occur. Check the entire power package carefully, including all accessible engine and drive parts. For engine inspection information, refer to the appropriate Cummins Marine Engine Operation and Maintenance Manual .

1. Check for loose, damaged, or missing parts, hoses, and clamps. Tighten or replace as

necessary.

2. Check electrical connections and leads for damage.

3. Remove and inspect the propellers. If nicked, bent, or cracked, contact your Cummins

MerCruiser Diesel Authorized Repair Facility.

4. Repair nicks and corrosion damage on the power package exterior finish. Contact your

Cummins MerCruiser Diesel Authorized Repair Facility.

While inspecting the power package and drive, certain components can be damaged by the weight of an individual and must not be used as a step. Decals on top of the drive components indicate where no step is allowed. Do not step on components with a decal.

Decal placed where no step is allowed

The Zeus drive cover, if equipped, protects and separates some components after the drive is installed. The drive cover provides added protection against damage to the hoses and other components as a result of mechanical hose abrasion during operation or damage to the hoses, such as being stepped on during service or maintenance. If equipped, keep the drive cover installed except when removed for service.

Typical drive cover, if equipped

For information on removing the drive cover, refer to

Drive Cover, If Equipped.

90-866938081 MAY 2009 Page 81

Section 5 - Maintenance

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41381

Drive Service Point Locations

Starboard

a - Seawater return (discharge) valve b - Transmission fluid drain plug c - Hydraulic oil cooler d - Exhaust outlet connection e - Engine seawater return outlet

f - Muffler seawater bypass g - Seawater inlet seacock h - Hydraulic oil drain plug i - Gearcase drain plug j - Hydraulic oil reservoir

Port

a - Seawater inlet seacock b - Driveshaft (under shield, if equipped) c - Driveshaft shield d - Gear lube monitor fill

e - Hydraulic fluid filter f - Trim tab and anode plates g - Propeller shaft

Page 82 90-866938081 MAY 2009

Top

41460

35639

Section 5 - Maintenance

a - Transmission dipstick b - Gear lube monitor fill cap c - Exhaust elbow d - Driveshaft shield screws

Drop Box

Maintenance Schedules

e - Upper exhaust clamps f - Lower exhaust clamps g - Transmission filter h - Anodes

Drain plug or cap

Application

90-866938081 MAY 2009 Page 83

The following schedules apply to the Zeus drive and driveshaft connection, not to the Cummins engine. For the engine maintenance schedule and procedures, refer to the

Marine Recreational High Output Propulsion Units QSB and QSC Operation and Maintenance Manual available from the manufacturer of the engine.

NOTE: In the maintenance lists, the word check means to visually inspect and then accordingly, correct, replace, or repair the task item.

Section 5 - Maintenance

Routine Maintenance

Task Interval Maintenance to be Performed

Each day start and when

refueling

Every two months of operation

Scheduled Maintenance

IMPORTANT: The drive gear case and gear lube monitor in the vessel have been filled with break‑in gear lube. Break‑in gear lube must be changed after 25 hours and not to exceed 30 hours of operation to prevent premature gear wear. The color of break‑in gear lube is brown. Drain the drive and gear lube monitor of the break‑in gear lube and fill with the specified gear lubricant. Refer to Drive Gear Lube.

• Check the steering actuator and trim tab oil (fluid) level.

• Check the gear lube level in the gear lube monitor.

• Check the transmission oil (fluid) level.

• Check the battery connections and fluid level.

• Treat the power package components inside the boat with Corrosion Guard to protect the product from corrosion.

• Ensure that the gauges and the wiring connections are secure. Clean the gauges (every two months or every 50 hours, whichever occurs first. If operating in saltwater, the interval is reduced to every 25 hours or 30 days, whichever occurs first).

Page 84 90-866938081 MAY 2009

Task Interval Maintenance to be Performed

After the first 25 hours of

operation and not to exceed 30

hours of operation

Every 250 hours of operation

or once a year (whichever

occurs first)

Every 500 hours of operation

or once a year (whichever

occurs first)

Every 1000 hours of operation or two years (whichever occurs

first)

Whenever the VesselView

fault code is displayed

Section 5 - Maintenance

• Change the transmission oil (fluid) and filter, including the transmission

oil in the drop box, if equipped.

• Change the gear lube in the drive gearcase and gear lube monitor.

• Tighten the driveshaft connecting bolts and nuts to specification.

• Inspect and lubricate the driveshaft slip‑joint.

• Inspect the driveshaft U‑joints; lubricate if equipped with grease

fittings.

• Change the gear lube in the drive gearcase and gear lube monitor.

• Change the transmission oil (fluid) and filter, including the transmission

oil in the drop box, if equipped.

• Lubricate the propeller shaft splines and tighten the propeller nuts to

specification.

• Inspect the hydraulic system fittings and hoses found on the drive for

leaks or damage. Check the hose fittings for tightness.

• Check the bonding (continuity) circuit for loose or damaged

connections. Test the MerCathode® unit output.

• Inspect the electrical system for loose, damaged, or corroded

fasteners. Check for lose, damaged or corroded wiring and connectors.

• Inspect the cooling system components found on the drive for damage

or leaks. Check the hose clamps on the hoses for tightness.

• Check that the water inlet openings on the seawater pickup are clean

and not obstructed.

• Inspect the exhaust system connections on the drive for damage or

leaks. Check the hose clamps on the hoses for tightness.

• Treat the power package components inside the boat with Corrosion

Guard to protect the product from corrosion.

• Replace the driveshaft U‑joints.

• Change the hydraulic oil and filter for the steering and trim system.

Maintenance Log

Record all maintenance performed on your power package here. Be sure to save all work orders and receipts.

90-866938081 MAY 2009 Page 85

Section 5 - Maintenance

Date Maintenance Performed Engine Hours

Page 86 90-866938081 MAY 2009

Drive Cover, If Equipped

41462

Removing the Drive Cover

NOTE: The top of the drive cover contains an access panel which provides access to the fill cap on the gear lube monitor and the transmission fluid dipstick without removing the entire cover.

1. Remove the three upper screws (port and starboard) holding the side cover to the top cover.

2. Remove the two lower screws holding the port side cover to the center section.

3. Remove the one lower screw holding the starboard side cover to the center section.

4. Remove the two side covers

5. Remove the two top screws.

6. Lift and remove the top of the drive cover.

Section 5 - Maintenance

Typical drive cover

a - Upper screw (6) b - Lower screw (3) c - Port side cover

d - Top of the drive cover e - Starboard side cover f - Top screw (2)

Cleaning and Inspecting the Drive Cover

1. Clean and wax the cover assembly often using marine cleaners and waxes.

2. Inspect the individual cover parts for cracks or damage; replace if cracked or damaged.

90-866938081 MAY 2009 Page 87

Section 5 - Maintenance

39497

39498

39590

Installing the Drive Cover

1. Carefully install the top cover on the drive. Align the cover with the two threaded holes in the transmission where the lifting rings were removed.

a - Top cover b - Threaded holes

2. Install one large washer on each of the top cover screws.

3. Install the two screws. Tighten the screws to specification.

a - Top cover screw b - Washer c - Torque wrench

Description Nm lb‑in. lb‑ft Top cover screw 61 – 45

4. Install the starboard side cover using four screws.

a - Starboard cover

5. Align and insert the starboard cover into the groove of the H‑trim section on the port

b - Screw (4)

cover.

Page 88 90-866938081 MAY 2009

Section 5 - Maintenance

NOTICE

PushSteer to POR T

PushSteer to STBD

Push-T rim Down

Push-T rim Up

Stee ring and Trim Manua l Override Buttons.

Refer to Operation

manual for procedure.

8M0041040

41329

39506

6. Install the port side cover using five screws.

Typical port side cover

a - Screw (5) b - Port cover

c - H‑trim d - Information decal

7. Tighten the three lower and six upper cover screws to specification.

Description Nm lb‑in. lb‑ft Cover upper screws 10 89 – Cover lower screws 27 – 20

8. Install the hatch cover.

a. Insert the molded clip on the aft end of the hatch cover under the indented‑edge

of the cover top.

a - Hatch cover b - Molded clip c - Indented‑edge

b. Align the hatch cover with the opening in the top cover.

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Section 5 - Maintenance

39514

c. Press down evenly on the front end of the hatch cover. The hatch cover snaps

into its installed position.

Drive Gear Lube

Drive Gear Lubrication

Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

Completing the hatch cover installation

NOTICE

The drive gear lubrication system includes a translucent white monitor the level of the drive gear lubricant (lube). The monitor includes a switch that can detect a low level of gear lubricant and set an audio or visual alarm.

The Checking and Filling procedures as provided are for situations where the gear lubricant level in the monitor is low but lubricant is visible. Filling the monitor to the specified level whenever lubricant is still visible in the monitor is correct.

In some events, such as a seal leaking, the gear lubricant level may have dropped low enough that no lubricant is visible in the monitor. In these situations the operator should have received an audible or visual alarm of a low gear lubricant level. If there has been an audible or visual alarm for low gear lubricant level and the monitor is found empty, filling the system through the gear lube monitor (when no lubricant is visible in the monitor) is not correct and requires additional steps as outlined in the Event Summary table.

IMPORTANT: If the gear lube monitor is empty, air may be trapped in the drive lubrication system by attempting to fill the monitor through the opening in the monitor. Trapped air may cause the lubricant level to appear correct in the monitor but still be low or insufficient in the system.

The steps for correct maintenance of the drive gear lubrication level can be summarized by the following table:

Event Summary Table

Low without an alarm Low with an alarm,

lubricant low but visible in monitor

Event

‑plastic bottle that is used to

Task

Fill the gear lube monitor to the specified level. Refer to Filling.

Remove the drive side cover and fill the gear lube monitor to the specified level. Refer to Filling.

Page 90 90-866938081 MAY 2009

Checking

41152

39506

Section 5 - Maintenance

Event Task

Remove the drive side cover. Pressure fill the drive unit through the steering actuator Monitor empty and with an alarm

until the gear lube appears in the gear lube monitor at the "COLD FILL LEVEL" line.

Refer to the appropriate steps in Changing—With the Boat in the Water and fill the

drive through the steering actuator.

IMPORTANT: The gear lube level in the gear lube monitor rises and falls during drive operation; always check the gear lube level when the drive is cool and the engine is shut down.

NOTE: It is normal to add a small amount of gear lube between change intervals.

IMPORTANT: If the gear lube level is below the "COLD FILL LEVEL" line when checked (especially after the first couple of times the boat is operated for a long period) or if gear lube must be added frequently, there could be a lubricant loss, such as a seal leak. Leaks could result in a lack of lubrication that will damage the drive. Inspect the drive if lubricant loss occurs. Contact your Cummins MerCruiser Diesel Authorized Repair Facility.

1. On models equipped with a drive cover: a. Inspect the gear lube level in the monitor.

a - Port side cover b - Gear lube monitor c - Access cover

b. If necessary, remove the access cover from the drive cover.

a - Access cover b - Molded clip c - Indented‑edge

c. Remove the cap from the gear lube monitor.

2. To check the drive gear lube with the optional drive cover removed, refer to Removing the Drive Cover.

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3. Inspect the gear lube level in the gear lube monitor. The gear lube level should be

NOTE: After the drive has been operated and the gear lube is hot, the fluid expands and may be up to the "MAX OPERATING LEVEL" (hot full line).

between the "COLD FILL LEVEL" (cold full line) and the "MAX OPERATING LEVEL" (hot full line).

"COLD FILL LEVEL" (cold full line)

"MAX OPERATING LEVEL" (hot full line)

IMPORTANT: If any water is visible at the bottom of the gear lube monitor or if the gear lube appears discolored, contact your Cummins MerCruiser Diesel Authorized Repair Facility immediately. These conditions may indicate a water leak in the drive.

4. If the level is lower than the "COLD FILL LEVEL" (cold full line), refer to Filling.

NOTE: The Premium Gear Lubricant used during the break‑in period is brown in color. The color of High Performance Gear Lube, used after break‑in, is blue. Do not mix the gear lubricants.

5. If the cap was removed, ensure that the gasket for the gear lube monitor cap is properly positioned and install the cap. Do not overtighten.

a - Gear lube monitor

b - Cap

6. Install the drive cover if removed. Refer to Installing the Drive Cover.

7. If your model is equipped with a drive cover, install the access cover.

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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

Safe Boating Suggestions

Be Alert to Carbon Monoxide Poisoning

GOOD VENTILATION

POOR VENTILATION

Basic Boat Operation

Freezing Temperature and Cold Weather Operation

Drain Plug and Bilge Pump

Protecting People in the Water

WHILE THE BOAT IS MOVING

WHILE THE BOAT IS STATIONARY

Wave and Wake Jumping

Impact with Underwater Hazards

Zeus Drive Impact Protection

Zeus Drive Alignment

Conditions Affecting Boat Operation

Weight Distribution (Passengers and Gear) Inside the Boat

Bottom Of Boat

Cavitation

Ventilation

Propeller Selection

Getting Started

DC Voltage Regulator Switch, If Equipped

Starting and Stopping the Engines

NORMAL STARTING

NORMAL STOPPING

STARTING AN ENGINE USING THE VIP SMARTSTART SWITCH

STOPPING THE ENGINE USING THE VIP SMARTSTART SWITCH

Traditional Maneuvering with Steering and Thrust

TO MANEUVER THE BOAT IN FORWARD

TO STEER THE BOAT IN TIGHT TURNS AT LOW SPEEDS

TO SPIN THE BOAT ON ITS AXIS AT LOW SPEEDS

Maneuvering with the Joystick

Trim Tabs

AUTOMATIC CONTROL

MANUAL CONTROL

USING TRIM TAB OFFSET

Special Digital Throttle and Shift (DTS) Features

TROLL AND THROTTLE RESPONSE

DOCK

THROTTLE ONLY

SINGLE LEVER (1 LEVER) OPERATION

SYNCHRONIZING THE ENGINES

Cruise Control

Helm Transfer

Requesting Helm Transfer

Helm Transfer and Precision Pilot

Precision Pilot