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Cummins QSB and QSC Zeus Drive Models Identification Record

1. n Al a aN a Maximum mark b Minimum mark c Top of threaded hole d Dipstick 8 If the fluid level is low add the specified transmission fluid to bring the level up to the maximum mark on the dipstick 9 Install the dipstick 10 Install the access cover onto the drive cover if it was removed 11 Install the drive cover if it was removed See Installing the Drive Cover NOTICE 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 The rubber interface ring seal has an outside coating that protects the inner core Tears cuts scrapes or exposure to lubricants or sealing compounds can damage this coating and the inner core causing water to leak into the boat Use caution when installing and working around the interface ring seal to prevent damage Do not use any lubricants or sealing compounds during installation 1 Remove the drive cover See Removing the Drive Cover 2 Lay down oil absorbing wipes or material to catch excess transmission fluid CMD 4082031 90 866938070 AUGUST 2007 Page 83 Section 5 Maintenance 3 Remove the M30 x 1 5 drain plug and sealing washer from the aft starboard end of the transmission and drain the tra
2. 008 38 DOCK oii cates cates cnsct esse essds chess voensedenesesasecsatena s 39 Throttle Only 39 1 One LeV ressisiirnnsriai eneon 40 SYN Cireasa destruc naaa anaE aE EE 40 Cruise Comntrol cccccecccecccceeececeeeeeeeeeeeeees 41 Precision Pilot Track Pad Features 41 General Information cccseeeeeeeeeees 41 NCO sso cetariadttebiiaaas suaedteoraneleametagueecctte 42 Standby and Active Lights e 43 Power ICON 2 ccccceeceeeeeeeeeeeeeeeeeeeeeeeeeeeees 43 RY MOOR scine ai 44 Skyhook Screen Notes 45 Engaging Skyhook 46 Disengaging Skyhook 46 Turn Buttons ccccseeeeeeeeeeeeeeeeeeeeeees 47 Auto Heading 48 Disengage Auto Heading 49 To Resume to a Heading a n 50 Track Waypoint 51 Engaging Track Waypoint Mode 52 Disengaging Track Waypoint Mode 53 Turn Button or Joystick in Track Mode 53 Auto Heading Button in Track Mode 53 Acknowledging a Turn During a Waypoint AIQIVAl si cccssccestcestaacsntacsenacsas cues gat sdansedentieeines 54 Waypoint SEQueNCE cccccceeeeeteeeeseteteee 55 Waypoint Acknowledge n se 56 Response Button c ceceeeeeeeeeeeeeeeees 58 Changing VesselView Mode Display MMES sevens Gueo Gui evi eueiens E 58 End of First Season Checkup 58 Contingent Operations 59 Backup Steering System 59 Port Engine Only Operation ee 59 Gear E
3. 5 Remove the gear lube by pumping the crankcase oil pump from the drive into a suitable container IMPORTANT If any water exits the fill and drain hole or if the gear lube appears milky the drive is leaking Contact your Cummins MerCruiser Diesel Authorized Repair Facility immediately 6 Remove the crankcase oil pump CMD 4082031 90 866938070 AUGUST 2007 Page 75 Section 5 Maintenance Page 76 7 Ensure that the rubber gasket is inside the cap for the gear lube monitor and install the cap Do not overtighten es 27851 a Gear lube monitor b Cap 8 Install a suitable gear lube pump into the fill and drain hole of the steering actuator and begin to fill the drive with the specified gear lube IMPORTANT Use only Mercury or Quicksilver High Performance Gear Lube in the drive 9 Continue to pump gear lube into the drive until the gear lube appears in the gear lube monitor at the COLD FILL LEVEL line Do not overfill p 27853 a COLD FILL LEVEL line b Gear lube level Fluid Capacity includes Drive Model the Sterndrive and the Fluid Type Fluid Part Number Gear lube Monitor 5 2 liters 5 5 quarts ee RenOumaniCe Gear ga 8580esa01 92 ezassoescor 10 Remove the gear lube pump and quickly reinstall the steering actuator fill and drain washer and screw Torque the fill and drain screw Steering actuator fil and drain screw e 11 See Filling and fill the gear lube monitor to t
4. Bt Eis 4 5 27853 a COLD FILL LEVEL line b Gear lube level Fluid Capacity includes Drive Model the Sterndrive and the Fluid Type Fluid Part Number Gear lube Monitor 5 2 liters 5 5 quarts H Performance Gear 92 858065Q01 Page 78 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance 8 Ensure that the rubber gasket is inside the cap for the gear lube monitor and install the cap Do not overtighten piace 3 27851 a Gear lube monitor b Cap 9 Remove the gear lube pump and quickly reinstall the gear case fill and drain screw and washer Daman OOOO O S o e sear case tardaanscew o o 10 See Filling and fill the gear lube monitor to the COLD FILL LEVEL line if the level is low 11 Install the drive propellers See Propellers 12 Check the gear lube level at the gear lube monitor after the first use See Checking NOTE After the drive has been operated and the gear lube is hot the fluid will expand and may be up to the MAX OPERATING LEVEL line hot full line Steering Actuator and Trim Fluid The steering actuator and trim system use a common hydraulic pump and fluid storage reservoir for the combined lubrication and hydraulic fluid Checking 1 Using a clean lint free cloth wipe the dirt and debris away from the cap and exterior of the steering actuator and trim fluid reservoir 2 Remove the cap CMD 4082031 90 866938070 AUGUST 2007 Page 79 Section 5 Maintenance Fi
5. e Use high quality anti fouling paint designed for marine use Page 94 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance e Avoid using anti fouling paint that contains copper material which could conduct electrical current f using copper based or tin based paints is necessary ensure that you comply with all local and federal laws prohibiting their use e Do not paint drain holes or items as specified by the boat manufacturer e Do not paint any anodes or the MerCathode system components e Avoid any electrical interconnection between the paint and drive anodic blocks trim tab anodes or MerCathode system by allowing a minimum of 40 mm 1 1 2 in unpainted area on the hull of the boat around these items and as shown in the following figure 25260 Unpainted area a Minimum unpainted 40 mm 1 1 2 in area around the interface ring seal grommet on models with a molded in tunnel opening or around the bolt on interface ring assembly if equipped Propellers Propeller Removal Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller remove the key from the key switch place the drive in neutral and engage the E stop switch to prevent the engine from starting 1 Place a block of wood between the rear propeller blade and the trim tab CMD 4082031 90 866938070 AUGUST 2007 Page 95 Secti
6. OFF button c Drive positions b Current heading d Engine RPM Pressing the AUTO HEADING button causes VesselView to displays the AUTO HEADING screen for three seconds If the VesselView AUTO HEADING screen does not appear the AUTO HEADING screen needs to be activated in VesselView calibration Precision Pilot still engages whether the screen appears or not NOTE If you press the AUTO HEADING button a second time the pilot goes to Standby mode and all lights other than STANDBY turn off DISENGAGE AUTO HEADING 1 Disengage the AutoPilot mode by any of the following actions e Place the ERC levers for both engines in neutral Turn the steering wheel beyond the electronic detent CMD 4082031 90 866938070 AUGUST 2007 Page 49 Section 3 On The Water Press the AUTO HEADING button on the Precision Pilot keypad The AUTO HEADING button light turns off O PRECISION PILOT O STANDBY ACTIVE ca i SKYHOOK i a i C TURN P OA A SEQUENCE Moaf s NeW Cc AUTO TRACK HEADING RESPONSE WAYPOINT 27700 a TURN button b RESUME button c AUTO HEADING button TO RESUME TO A HEADING The RESUME button light turns on if the previous course heading is available to resume The previous heading can only be resumed within one minute of the AutoPilot being disengaged or if the boat has not turned more than 180 These numbers can be adjusted If you disengage the AutoPilot by turning the steering
7. Refer to the Marine Recreational High Output Propulsion Units QSB and QSC Operation and Maintenance Manual for the specified Engine Rated RPM Select a propeller that will allow the engine power package to operate at the Engine Rated RPM with a full load on board If full throttle operation is below the recommended range change the propellers to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended Engine Rated RPM causes higher than normal wear or damage After initial propeller selection the following common problems may require a lower pitch propeller e Warmer weather and greater humidity can cause a loss of RPM not as significant on these models e Operating in a higher elevation causes a loss of RPM not as significant on these models e Operating with a dirty boat bottom causes a loss of RPM CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water Operating with increased load additional passengers or gear causes a loss of RPM Because of the many variables of boat design only testing will determine the best propeller for a particular application Available propellers are listed in the Diesel Parts And Accessories Guide Contact your Authorized Cummins MerCruiser Diesel Repair Facility for assistance on propeller selection Getting Started Break In Period New or With Replacement Gears Always perform these procedures on new drive units T
8. are submerged in a conductive solution such as saltwater polluted water or water with a high mineral content a chemical reaction takes place causing electrical current to flow between metals The electrical current flow causes the metal that is most chemically active or anodic to erode This is known as galvanic corrosion and if not controlled it will in time cause the need for replacement of power package components exposed to water Refer to the Marine Corrosion Protection Guide 90 88181301 Anodes and MerCathode System Page 90 Anodes help protect against galvanic corrosion by sacrificing their metal to be slowly eroded instead of the metal components on the drive or vessel Corrosion protection for the drive is provided by sacrificial anodes installed on the trim tabs Other sacrificial anodes may be mounted on the vessel to ensure against corrosion of vessel components IMPORTANT Replace the sacrificial anodes if they are eroded 50 percent or more CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance The MerCathode system uses an electrode controller and anode assembly to protect against galvanic corrosion The system should be tested to ensure adequate output The test should be performed where the boat is moored using the Quicksilver Reference Electrode and Test Meter For testing contact a Cummins MerCruiser Diesel Authorized Repair Facility or refer to the appropriate Cummins MerCruiser Drive Service Man
9. or frayed wiring b poii 29037 a MerCathode controller d Anode wire b Reference electrode wire e Battery positive terminal wire c Battery negative terminal wire f Black green continuity wire to bonding stud CMD 4082031 90 866938070 AUGUST 2007 Page 93 Section 5 Maintenance 3 Inspect the bonding stud nut and continuity wire on the center section for corrosion loose connections broken connectors or frayed wiring Oy c i 29036 a Bonding stud b Nut c Black green continuity wire 4 At the specified interval with the boat out of the water lower the trim tabs and inspect the continuity wire located between the trim tab and the hinge block a Hinge block b Trim tab c Screw d Continuity wire Inhibiting Corrosion In addition to the corrosion protection devices follow these steps to inhibit corrosion 1 Paint your power package See Painting the Power Package 2 Spray power package components on the inside of the boat annually with Corrosion Guard to protect the finish from dulling and corrosion 3 Keep all lubrication points well lubricated Painting the Boat IMPORTANT The limited warranty does not cover corrosion damage as a result of improper paint application IMPORTANT Paint renders anodes and the MerCathode system ineffective as inhibitors of galvanic corrosion When painting the boat hull with anti fouling paint observe the following
10. 39 Throttle Only eccer 39 1 One Lever 40 SYNG a EEEE ENN 40 Cruise COMO licsicisccctatieetticntinitecetanatantadaeatinae 41 Precision Pilot Track Pad Features 41 General Information eeeeeeeeeeeeee 41 Standby Serene per ner Dene Pe eer Pee rere aeereer enne 42 Standby and Active Lights 04 43 Power ICOM seteed cates cctesectecesieavertdnusietdens 43 Skyhook eemene ear eee en eee ee ree 44 Skyhook Screen Notes 005 45 Engaging Skyhook seee 46 Disengaging Skyhook s es 46 Turn Buttons sos iesrtcietactinst ctoreucetocimstcnmrestied 47 Auto Heading 2 ccccsscccceeeeeeteees 48 Disengage Auto Heading 49 To Resume to a Heading eee 50 Track Waypoint n 51 Engaging Track Waypoint Mode 52 Disengaging Track Waypoint Mode 53 Turn Button or Joystick in Track Mode E A AA A A E 53 Auto Heading Button in Track Mode 53 Acknowledging a Turn During a Waypoint ANa ee belaptecerattteios 54 Waypoint Sequence ccccccceereees 55 Waypoint Acknowledge 0 56 Response Button ceeeeeeeeees 58 Changing VesselView Mode Display Times re 58 End of First Season Checkup 00 58 Contingent Operations 59 Backup Steering System eee 59 Port Engine Only Operation 59 Gear Engagement Emergency Procedure E AEE 59 Page 19 Section 3 On The Water Safe
11. 4082031 90 866938070 AUGUST 2007 Page 69 Section 5 Maintenance Task Interval Maintenance to be Performed Torque the driveshaft connecting bolts and nuts Inspect and lubricate the driveshaft slip joint Change the gear lube in the drive gearcase Every 250 hours of Operation or Once a Year Change the transmission fluid and filter including the Whichever Occurs First transmission fluid in the drop box if equipped Lubricate and inspect the seacock for engine seawater return seawater overboard Ensure that the seacock opens and closes freely Change the steering actuator fluid and filter Lubricate the propeller shaft splines and torque the propeller nuts 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 Every 500 Hours or Once a Year Whichever Occurs First Inspect the cooling system components found on the drive for damage or leaks Check the hose clamps on the hoses for tightness 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 produc
12. AUGUST 2007 Section 2 Getting to Know Your Power Package a Speedometer inaicates toats b Tachometer Indicates enger a vomer a vtiery voege e Water temporara gauge Indicates engine operating temperata a _ Hourmeter Records engine operating time leon switcn______ Alows operator 1o starr and siop engra 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 steering is two turns lock to lock providing a fast steering response The first few maneuvers at speed can be more abrupt than expected The number of turns lock to lock is adjustable by the distributor if desired Dual Handle Electronic Remote Control ERC with DTS Trackpad 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 neutra
13. 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 O PRECISION PILOT O STANDBY ACTIVE aS SkYHOOK d TURN TURN b l Ca Ca WAYPOINT ims RESUME SEQUENCE aoi men Ce RACK UTO T HEADING RESPONSE WAYPOINT 27703 WAYPOINT SEQUENCE button 1 Place the ERC lever or levers into forward WAYPOINT SEQUENCE does not engage if the levers are in neutral or reverse 2 If not already accomplished press the TRACK WAYPOINT button and note that the button light is on 3 Press the WAYPOINT SEQUENCE button 8 2 MPH pp 1 47 PM AUTOPILOT TRACK oa A IMPORTANT Stay alert The boat turns automatically in this mode The operator must be aware if the boat is in a safe area to turn when the vessel is entering a waypoint arrival zone and inform passengers that the boat automatically turns so they can be prepared CMD 4082031 90 866938070 AUGUST 2007 Page 55 Section 3 On The Water If you are in the waypoint arrival zone set by the chart plotter WAYPOINT SEQUENCE only informs Pilot it is OK to proceed to next waypoint It acts as a waypoint acknowledge function a
14. Top of the drive cover e Starboard side cover f Top screw Maintenance Schedules Application 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 Routine Maintenance Task Interval Maintenance to be Performed Check the steering actuator and trim tab fluid level Each Day Start and When Refueling Check the gear lube level in the gear lube monitor Check the transmission 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 Every Two Months of Operation 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 Scheduled Maintenance Task Interval Maintenance to be Performed After the First 25 Hours and not to Exceed 30 e Change the transmission fluid and filter including the Hours transmission fluid in the drop box if equipped CMD
15. WAYPOINT SEQUENCE button during Track Waypoint mode but not at the arrival waypoint causes the AutoPilot to continue to the next waypoint e The WAYPOINT SEQUENCE light continuously illuminates The VesselView icon is shown when in AutoPilot mode 8 2 PH Zol 1 47 PM AUTOPILOT s TRACK g oe 31411 Waypoint acknowledge screen e In Track Waypoint mode if the Waypoint Sequence mode has not been engaged the WAYPOINT SEQUENCE light blinks at the arrival alarm the AutoPilot controls the vessel to the most recent heading setpoint and VesselView displays a pop up screen 8 2 MPH zol 1 47 PM AUTOPILOT TRACK Please acknowledge that it is safe for the vessel to turn onto the new course 31414 Pop up screen warning CMD 4082031 90 866938070 AUGUST 2007 Page 57 Section 3 On The Water RESPONSE BUTTON O PRECISION PILOT O STANDBY ACTIVE C2 SKYHOOK l ques TURN ae WAYPOINT RESUME SEQUENCE AUTO TRACK HEADING RESPONSE WAYPOINT 27704 Response button 1 Press the RESPONSE button to change the gain for Auto Pilot or Waypoint modes 2 Press the RESPONSE button again to change the gain further Each time you press the RESPONSE button the button light blinks to show you the gain setting for that mode The initial button press shows the current setting value Additional button presses increase the gain in steps up to three and then return to one Pt ft _ Bia orate o cai co
16. When in gear left and right movement of the joystick corresponds to left and right steering of the wheel When in neutral the joystick returns to normal 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 in 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 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 emergen
17. 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 hour out of every eight hours of operation Reduced power must be at or below 200 RPM of the maximum RPM This power rating is for pleasure craft applications that operate less than 500 hours per year 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 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 an
18. a Quicksilver MerCathode system test the system to ensure that it is providing adequate output to protect the underwater metal parts on the boat The test should be made where the boat is moored using a Quicksilver Reference Electrode and Test Meter Page 92 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance Reference Electrode 91 76675T 1 Senses the electrical current in the water when testing the MerCathode system Use to check hull potential Contact a Cummins MerCruiser Diesel Authorized Repair Facility for testing or refer to the appropriate Cummins MerCruiser Diesel Drive Service Manual for testing procedures Trim Tab Anodes CHECKING 1 Inspect the trim tab anodes 2 Replace the anodes if they are eroded 50 percent or more Trim tab anode REPLACING Contact your Cummins MerCruiser Diesel Authorized Repair Facility Continuity Circuits NOTE Refer to the operation and maintenance manual provided by the boat manufacturer for maintenance information about vessel mounted anodes and related continuity circuits The drive system is equipped with ground circuit wires to ensure good electrical continuity between the drive components Good continuity to a ground is essential for the anode and MerCathode system to function most effectively 1 Remove the drive cover Refer to Removing the Drive Cover in this section 2 Inspect the MerCathode controller and wires for loose connections broken connectors
19. and preparation such as e Make certain that the power package and other equipment are in proper operating condition before delivery e Make all necessary adjustments for maximum efficiency Explain and demonstrate the operation of the power package and boat e Provide you with a copy of a Predelivery Inspection Checklist e 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 Page 66 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 e Do not attempt any repairs unless you are aware of the Cautions Warnings and procedures required Your safety is our concern e 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 e There are special tools and equipment that are required to perform some repairs Do not attempt these repai
20. engine RPM for warm up without shifting the transmission into gear M 7 Enables the throttle and shift functions of both engines to be f 1 LEVER controlled by the port lever m a Turns off or on the auto synchronization feature Refer to SYNC n Synchronizing Engines gape ce Increases and decreases settings for various functions like speed of h increase and decrease cruise control NOTE Not all functions may be active CMD 4082031 90 866938070 AUGUST 2007 Page 37 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 is commanded between idle speed and maximum rated engine speed TROLL button To engage Troll mode 1 Place both ERC levers in neutral Press the TROLL button located on the DTS Trackpad attached to the ERC levers Place either ERC lever into gear The TROLL button lights when the lever or levers are moved out of neutral 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 neutra
21. 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 21604 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 WHILE THE BOAT IS STATIONARY 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 s
22. leads Do not splice wires into the harness Do not route harness near sharp edges hot surfaces or moving parts e Fasten cables away from and sharp edges fasteners or objects that could wear into the harness or pinch the harness e Avoid sharp bends in a data harness Minimum bend radius should be 7 6 cm 3 in for installation e Fasten harnesses to the boat at least every 45 7cm 18 in using appropriate fasteners Do not attempt diagnostics without the proper approved service tools Disconnect both the negative and positive battery cables from the battery before electric arc welding on the vessel Attach the welder ground cable no more than 0 61 meters 2 feet from the part being welded Do not connect the ground cable of the welder to any ECM cooling plate or ECM Welding on the engine drive or engine or drive mounted components is not recommended or damage to the engine or drive or related components can result Troubleshooting Charts Troubleshooting Engine Related Problems Troubleshooting engine related problems may require information not found in these troubleshooting charts Additional troubleshooting information can be found in the owners manual for the engine Refer to the appropriate Marine Recreational High Output Propulsion Units QSB or QSC Operation and Maintenance Manual provided with the engine Check VesselView First Page 106 Your VesselView display is the primary information so
23. money order NO COD CMD 4082031 90 866938070 AUGUST 2007 Page 113 Section 8 Customer Assistance Information Other Languages To obtain an Operation Maintenance and Warranty Manual in another language contact the nearest Mercury Marine or Marine Power International Service Center for information A list of part numbers for other languages is provided with your power package Andre sprog Kontakt det n rmeste Mercury Marine eller Marine Power International servicecenter for oplysninger om hvordan du kan anskaffe en Betjenings og vedligeholdelsesmanual pa et andet sprog En liste med reservedelsnumre for andre sprog leveres sammen med din power pakke Andere talen Voor het verkrijgen van een Handleiding voor gebruik en onderhoud in andere talen dient u contact op te nemen met het dichtstbijzijnde internationale servicecentrum van Mercury Marine of Marine Power voor informatie hierover Een lijst met onderdeelnummers voor andere talen wordt bij uw motorinstallatie geleverd Muut kielet Saadaksesi K ytt ja huolto ohjekirjoja muilla kielill ota yhteys l himp n Mercury Marine tai Marine Power International huoltokeskukseen josta saat l hempi tietoja Moottorisi mukana seuraa monikielinen varaosanumeroluettelo Autres langues Pour obtenir un Manuel d utilisation et d entretien dans une autre langue contactez le centre de service apr s vente international Mercury Marine ou Marine Power le plus proche pour toute
24. 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 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 Page 18 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water Section 3 On The Water Table of Contents Safe Boating Suggestions eee 20 Be Alert To Carbon Monoxide Poisoning 21 Good Ventilation 6 c ceccccceeeeeseeeeeeees 21 Poor Ventilation ceeeeeeeeeeeees 22 Basic Boat Operation c ccccccccccseeeeeseeeestteees 22 Freezing Temperature and Cold Weather 1 0 1 0 9 ee 22 Drain Plug and Bilge Pump eee 23 Protecting People in the Water 23 While the Boat is Moving 88 23 While the Boat is Stationary 23 Wave and Wake Jumping 24 Impact with Underwater Hazards 24 Zeus Drive Impact Protection 00 25 Conditions Affecting Boat Operation 25 Weight Distribution Passengers and Gear Inside the BOabt cccccseeeeeeeeeeee
25. steering and accessories Activation of the E stop switch stops the engines immediately but the boat continues to coast for some distance depending upon the velocity and degree of any turn at shutdown However the boat does not complete a full circle 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 Page 12 CMD 4082031 90 866938070 AUGUST 2007 Section 2 Getting to Know Your Power Package 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 e Occupants can be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components e Operator can lose power and directional control in heavy seas strong current or high winds e Operator can lose control when docking Instrumentation VESSELVIEW VesselView is the primary information source for the Zeus drive all engine information fault codes tank levels boat direction and calibrations Refer to the VesselView Operators Manual for more information 27198 VesselView DIGITAL GAUGES IF EQUIPPED The Cu
26. wheel or if you press one of the TURN buttons with AutoPilot still engaged press the RESUME button to resume the previous heading 1 Place at least one engine in forward gear 2 Manually steer the boat to the desired heading and hold the boat steady Page 50 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water 3 Press the AUTO HEADING button on the Precision Pilot keypad The light on AUTO HEADING button illuminates and the system automatically keeps the vessel steering towards the desired course Press either of the TURN buttons or use the joystick to change or adjust the course PRECISION PILOT O STANDBY que ee RESUME CJi O a AUTO HEADING ACTIVE e SKYHOOK H wO WAYPOINT SEQUENCE am o TRACK RESPONSE WAYPOINT a PE a AUTO HEADING button b TURN buttons TRACK WAYPOINT 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 O PRECISION PILOT O STANDBY que cS RESUME CO UTO HEADING ACTIVE TURN p SKYHOOK WAYPOINT SEQUENCE ae RACK T
27. 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 1 800 668 0407 Fax Fax 843 745 1616 Warranty Registration Outside the United States and Canada Page 2 1 Itis 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 res
28. 05 107 Electrical Connections 106 Steering System 108 Troubleshooting Charts c ccceeeeeeeeeeees 106 Trim labs ierra iari 109 Troubleshooting Engine Related Problems Boat Response Chang6s cccccecceee 109 Siete sada dtdaauscavwetdndete E a E 106 Battery Will Not Charge eeeee 109 Check VesselView First 106 Gauges and Instrumentation 6 110 Poor Performan e ccceeeeeeeeeeeeeeeeeeees 107 CMD 4082031 90 866938070 AUGUST 2007 Page 105 Section 7 Troubleshooting Diagnosing Electronically Controlled Fuel System Problems Your Cummins MerCruiser Diesel Authorized Repair Facility has the proper service tools for diagnosing problems on electronically controlled fuel systems The Engine Control Module ECM on these engines has the ability to detect some problems with the system when they occur and store a trouble code in the ECM s memory This code can then be read later by a service technician using a special diagnostic tool Electrical Connections NOTE Refer to Section 6 Electrical System Architecture diagrams and for additional electrical information IMPORTANT To avoid damage to the electrical system refer to the following precautions when working on or around the electrical harness or when adding other electrical accessories Do not tap accessories into the engine harness Do not puncture wires for testing probing Do not reverse the battery
29. 3 Checkin gernenn o ora 93 Replacing icncereesimbecmetnebeeneeentceecemeueateeciter 93 Continuity Circuits 93 Inhibiting COrrosion eeeseeeeeeeeeeeeseeeerereeeee 94 Painting the Boat 94 PrOpellers ccccceccceeeceeeeaeeceeeaeeecaeeeaeeaeeeeeeees 95 Propeller ReMOVaI 0 seeeseeeseeeteeees 95 Propeller Repair ceeeeeeeeeeeeeeeeeeees 97 Propeller Installation eseeeeeeeee 97 Page 65 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
30. 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 Page 20 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 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 E A a a a a E E 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
31. Check the cooling and exhaust system hose clamps for tightness CMD 4082031 90 866938070 AUGUST 2007 Page 87 Section 5 Maintenance Lubrication Driveshaft Slip Joint 1 Remove the top and bottom driveshaft shields on the transmission end as shown i Dee 24126 Top shield and bottom shield at transmission end a Top shield b Bottom shield c Socket head driveshaft shield to transmission retaining hardware d Driveshaft shield upper to lower retaining hardware 2 Lubricate the driveshaft slip joint through the grease fitting by applying approximately 3 6 pumps of specified grease from a typical hand operated grease gun 27749 a Driveshaft slip joint b Grease fitting Where Used V joint and Gimbal Beanng Driveshaft slip joint 92 802870A1 Grease Tube Ref No Where Used H 91 D Engine Coupler Spline Grease Driveshaft slip joint 92 802869A1 3 Apply adhesive to the threads of the screws and bolts of the shield on the transmission end Page 88 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance Tube Ref No Where Used Driveshaft shield retaining F 1 10 Loctite 277 Sead Obtain Locally 4 Install the top and bottom driveshaft shields on the transmission end as shown Tighten the driveshaft shield retaining screws and nuts on the transmission end to specifications De 24126 Top shield and bottom shield at transmission end a Top shield b Bottom shield c Socket
32. Cummins MerCruiser Diesel power package Mercury Marine Attn Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Please copy this form and print or type This is your shipping label Please submit the following order form with payment to Address ZIP or postal code Country CMD 4082031 90 866938070 AUGUST 2007 Page 115 Section 8 Customer Assistance Information Quantity Stock Number _ Total Due a ee ee eee Page 116 CMD 4082031 90 866938070 AUGUST 2007
33. D FILL LEVEL line cold full line Do not overfill as 27853 Shown with drive cover removed a COLD FILL LEVEL line b Gear lube level CMD 4082031 90 866938070 AUGUST 2007 Page 73 Section 5 Maintenance gt High Performance Gear Lube Gear lube monitor 92 858064K01 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 line hot full line 27837 b COLD FILL LEVEL line c MAX OPERATING LEVEL line 3 Ensure that the rubber gasket is inside the cap for the gear lube monitor and install the cap Do not overtighten zs 27851 a Gear lube monitor b Cap Changing WITH THE BOAT IN THE WATER NOTE Change the drive gear lubricant when the drive is at operating temperature Warmer lubricant flows more freely carrying away more impurities and is easier to remove from the drive 1 Place oil absorbent wipes or material around the area to contain any spilled lubricant Page 74 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance 2 Remove the fill and drain screw from the steering actuator a Steering actuator b Fill and drain screw 3 Quickly install an adaptor or suitable threaded fitting into the threaded hole of the drain and fill screw and attach a crankcase oil pump Crankcase Oil Pump 91 90265A 5 Aids in the removal of drive oil without draining the drive a Gear lube monitor b Cap
34. ET 73 ChHangiNg issi riika ers errr re 74 With the Boat in the Water 5 74 With the Boat Out of the Water 77 Steering Actuator and Trim Fluid 005 79 Checking issiima ninnan 79 FNM TG iccoa ixitabagaedeenteccoaiocsancseadurensuccecectannivennses 80 GE VAM iei asirna iaae een de 80 Transmission FlUIC cccccceecceeeceeeeeeeeeeeeeeeeeees 81 Checking siiin oiis ei 81 Filings a eens 82 CHange 83 Seawater Straines cccccccccececeeeeeesseeteeeseeeeees 86 CMD 4082031 90 866938070 AUGUST 2007 Battery eeeeeeseseererrrreriirrrrrrrrererseeressrrrerene 87 ONG Schaal teas cece emctcctcess eae ey e A aE gan 87 Checking Gauges 87 Cleaning Gauges rreren 87 Electrical SYStOM c ccc cicctsccccecssieatteanneentnertee 87 Cooling System and Exhaust System 87 Lubrication aa 88 Driveshaft Slip Joint sssonsennneeseeeneeenereeeeee 88 Seacock Seawater Return Overboard 89 Propeller Shafft ccccsseseseeeeeeeeeeeeeeeeees 90 Corrosion Protection ccccccececcecseeesseeseeeeees 90 Anodes and MerCathode System 90 Reference Electrode Wire of the MerCathode SVS lE a cosa aces a a aR AaS 91 MerCathode Anode 92 COSC ING insoara edessa S a 92 Replacing nadtornonttabenensttetmucmemianelcemebborkact 92 MerCathode System Testing eee 92 Trim Tab Anodes cccccceeeeeeeeeeeeeeeeeeetees 9
35. EVEL line c MAX OPERATING LEVEL line Page 72 CMD 4082031 90 866938070 AUGUST 2007 Filling Section 5 Maintenance 4 Ifthe level is low see Filling 5 If the level is correct install the access cover To check the drive gear lube with the drive cover removed 1 Remove the drive cover See Removing the Drive Cover 2 Inspect the gear lube level in the gear lube monitor The gear lube level should be at the COLD FILL LEVEL cold full line when the drive and fluid are cold 27853 a COLD FILL LEVEL line b Gear lube level IMPORTANT If any water is visible at the bottom of the gear lube monitor or appears at the fill and drain plug hole or if the gear lube appears discolored contact your Cummins MerCruiser Diesel Authorized Repair Facility immediately Both conditions may indicate a water leak in the drive 3 If the level is low see Filling 4 If the level is correct install the drive cover See Installing the Drive Cover IMPORTANT If more than 59 mL 2 fl oz of High Performance Gear Lube is required to fill the gear lube monitor a seal may be leaking Lack of lubrication will damage the drive Contact your Cummins MerCruiser Diesel Authorized Repair Facility If the gear lube level is below the COLD FILL LEVEL line add the specified gear lube 1 Remove the cap from the gear lube monitor 2 Fill the gear lube monitor with the specified gear lube so that the gear lube is level with the COL
36. Identification Record 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 Drive serial number locations a Transmission serial number b Drive serial number decal and plate stamping 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 Please record the following information po Pot Starboard Engine Serial Number j Port Starboard Propeller Information Propeller Part Number a ooo e S 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 Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A Cummins QSB and QSC Zeus Drive Models CMD 4082031 90 866938070 807 2007 Mercury Marine Welcome 2007 Mercury Marine Mercury Mercury Marin
37. Mariana Islands Guam Puerto Rico and the U S Virgin Islands 3 United States includes American Samoa the Commonwealth of Northern Mariana Islands Guam Puerto Rico and the U S Virgin Islands 4 United States includes American Samoa the Commonwealth of Northern Mariana Islands Guam Puerto Rico and the U S Virgin Islands Page 8 CMD 4082031 90 866938070 AUGUST 2007 Section 1 Limited Warranty For products purchased outside the United States and Canada contact the Cummins MerCruiser Diesel Distributor or Cummins MerCruiser Diesel distributor in your country CMD 4082031 90 866938070 AUGUST 2007 Page 9 Section 1 Limited Warranty Notes Page 10 CMD 4082031 90 866938070 AUGUST 2007 Section 2 Getting to Know Your Power Package Section 2 Getting to Know Your Power Package Table of Contents General Information 12 Models Covered cccccccecssesseeessaeeeeaeeeaeeneas 12 Drive Serial Number and Decal Placement EAE E E A AE E E E A 12 Features and Controls cccccccessseeeereneeeeeees 12 Emergency Stop E Stop Switch 12 Instrumentation 13 VESSEIVIEW sw ccctivcctwscttaadetacieltidectaselieels sels 13 Digital Gauges If Equipped 8 13 Analog Gauges If Equipped 14 Electronic Helm Steering 15 CMD 4082031 90 866938070 AUGUST 2007 Dual Handle Electronic Remote Control ERC 2 with DTS Trackpad Features and Operation ssc ahar
38. N PILOT C6 STANDBY ACTIVE eS SKYHOOK l que TURN b es WAYPOINT RESUME SEQUENCE a lt gt SS 0 AUTO TRACK HEADING RESPONSE WAYPOINT 27695 a STANDBY light b ACTIVE light Precision Pilot is disengaged off when the STANDBY light is illuminated You must press a button to engage a mode When the ACTIVE light is illuminated one mode of Precision Pilot is engaged on O PRECISION PILOT O POWER ICON STANDBY ACTIVE cS SKYHOOK fs ques TURN gt WAYPOINT RESUME SEQUENCE ae E2 Co 0 AUTO TRACK HEADING RESPONSE WAYPOINT 27696 Buttons with Power Icons a SKYHOOk button b AUTO HEADING button c TRACK WAYPOINT button The power icon indicates that these buttons have the ability to engage or disengage the Precision Pilot function they perform If you press a button that has the power icon b when that button light is on the light turns off for that button and the STANDBY light illuminates CMD 4082031 90 866938070 AUGUST 2007 Page 43 Section 3 On The Water SKYHOOK Page 44 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 t
39. Q 1 Lubricating the propeller shaft splines CMD 4082031 90 866938070 AUGUST 2007 Page 97 Section 5 Maintenance IMPORTANT Check that both the front and aft propeller part numbers match for port and starboard drives 2 Slide the front thrust hub onto the propeller shaft with the tapered side toward the propeller hub 3 Align the splines and place the front propeller on the propeller shaft The propeller must fit freely on the propeller shaft splines 4 Install the front propeller nut RA a Front propeller b Nut 24031 5 Place a block of wood between the trim tab and the propeller 6 Tighten the front propeller nut to specification using the propeller nut tool Block of wood Trim tab Propeller nut tool Propeller Nut Tool 91 805457T 1 paanan oo 8 Aids in the removal and installation of the front propeller nut Page 98 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance eson SSCS SN Fron propeternt SSCS tts 0 7 Check the propeller for rotation The propeller must not contact the lower drive housing 8 Slide the rear thrust hub onto the propeller shaft with the tapered side toward the propeller hub 9 Align the splines and place the rear propeller on the propeller shaft The propeller must fit freely on the propeller shaft splines 10 Install the rear propeller nut 11 Place a block of wood between the trim tab and the propeller 12 Tighten the re
40. RESPONSE WAYPOINT 27701 TRACK WAYPOINT button 1 Move the ERC levers past the forward detent Track Waypoint does not function if the levers are in neutral or reverse 2 Turn on the chart plotter and select a waypoint Waypoint data needs to be provided by a third party chart plotter CMD 4082031 90 866938070 AUGUST 2007 Page 51 Section 3 On The Water 3 Press the TRACK WAYPOINT button The TRACK WAYPOINT button light turns on a single beep sounds and Precision Pilot engages Pilot begins tracking to a waypoint Two beeps sounds if Track Waypoint does not engage 4 The VesselView TRACK WAYPOINT screen displays on VesselView for one second after pressing the TRACK WAYPOINT button The screen is activated during VesselView calibration See Mode Display in VesselView 3 2 MH rae or 1 46 PM AUTOPILOT TRACK Track Waypoint screen NOTE Pilot does not turn in waypoint mode Turn features are only available in Auto Heading mode The display shows the digital heading that the boat is traveling the angles of the drives and engine speed in RPM The GPS system generates the heading and is represented from magnetic North 5 Turn the steering wheel put the ERC levers in neutral or press the TRACK WAYPOINT button a second time to put Pilot in Standby mode A single beep sounds the TRACK WAYPOINT light turns off and the STANDBY light turns on 6 You can resume the heading within the time limit if t
41. UGUST 2007 Page 107 Section 7 Troubleshooting Symptom Remedy Key off and key on Check Throttle Only button on DTS track pad Put ERC levers in neutral and push the button to disengage if the light is on ERC lever increases engine RPM but does not Check transmission fluid level and fill if necessary See engage gears and boat does not move Section 5 Maintenance Engage gears manually See Section 3 Gear Engagement Emergency Procedure Contact your Authorized Cummins MerCruiser Repair Facility If engine only reaches 50 of WOT check DOCKING button on DTS track pad Put handles in neutral and push button to disengage if light is on Check VesselView to see if cruise control enabled Disable cruise control ERC lever controls engine and drive but does not reach wide open throttle Check propeller for damage Consult your Check VesselView for Guardian fault codes that cause engine power reduction If found have the vessel checked by your Authorized Cummins MerCruiser Diesel Repair Facility to discuss if propellers need to be changed Unlock the Automatic Tab Override switch or raise tabs Check TROLL button on DTS track pad Put handles in Neutral and push TROLL button to disengage if ERC lever controls engine and drive but does not light is on respond in a linear manner Check if dock mode or cruise control are on Turn off or disengage if on Check 1 LEVER button on DTS track pad P
42. an g y i Authorized Cummins MerCruiser Diesel Repair Facility Check VesselView for Guardian fault codes that cause engine power reduction If found have the system checked by your Authorized Cummins MerCruiser Diesel Repair Facility Guardian fault code set Joystick Both remote controls are not in neutral Put remote controls in neutral Joystick does not control boat One or both engines are not running Start engine or engines Response to joystick inputs are erratic or joystick Ensure there are no radios or other sources of operates independent of input electronic or magnetic interference near the joystick Check VesselView for Guardian fault codes that Joystick does not function properly and a fault code is cause engine power reduction If found have the system checked by your Authorized Cummins MerCruiser Diesel Repair Facility Joystick does not work No fault code set cruise Disengage cruise control control engaged Electronic Remote Controls Symptom Adjust detent tension See Section 2 Dual Handle Electronic Remote Control with DTS Trackpad Features and Operation ERC electronic remote control lever is too hard or too easy to get out of neutral detent Adjust handle tension screw See Section 2 Dual Handle Electronic Remote Control with DTS Trackpad Features and Operation ERC lever moves too hard or too easy through its range of motion CMD 4082031 90 866938070 A
43. an 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 permits the propeller to speed up but the boat speed to reduce Cavitation can seriously erode the surface of the gear housing or the propeller Common causes of cavitation are e Weeds or other debris snagged on the propeller Bent propeller blade e 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 e A missing propeller diffuser ring Adamaged propeller or gear housing which allows exhaust gases to escape between propeller and gear housing Propeller Selection Page 26 IMPORTANT The installed propeller must allow the engine to operate at the Engine Rated RPM revolutions per minute Use an accurate service tachometer to verify engine operating RPM It is the responsibility of the boat manufacturer or the selling dealer to equip the power package with the correct propeller Refer to the Diesel Parts And Accessories Guide and read Everything You Need To Know About Propellers
44. ar propeller nut to specification 24037 a Block of wood b Trim tab 25876 Zeus drive propeller assembly a Front thrust hub d Rear thrust hub b Front propeller e Rear propeller c Front propeller nut f Rear propeller nut Description Tm tin Rear propellernut Tt c j o CMD 4082031 90 866938070 AUGUST 2007 Page 99 Section 5 Maintenance Notes Page 100 CMD 4082031 90 866938070 AUGUST 2007 Section 6 Storage Section 6 Storage Table of Contents Cold Weather Freezing Temperature Storage and Battery Storage 103 Seasonal Storage eeen 102 Recommissioning ceeeeeeeeeeeeeeeeeeeee 103 Storage Descriptions 102 T 103 Preparing the Power Package for Storage 102 Die ee aee a a a eases 103 Drive Storage 102 Power Package 103 Engine Storage 2s scessceseseeseeees 103 CMD 4082031 90 866938070 AUGUST 2007 Page 101 Section 6 Storage Cold Weather Freezing Temperature Storage and Seasonal Storage Storage Descriptions IMPORTANT We strongly recommend that this service be performed by a Cummins MerCruiser Diesel Authorized Repair Facility Damage caused by freezing is not covered by the 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
45. ay to dark gray Boat at rest 24704 Boat moves forward Boat moves aft Boat moves to starboard without rotating Page 32 CMD 4082031 90 866938070 AUGUST 2007 CMD 4082031 90 866938070 AUGUST 2007 Boat moves to port without rotating Boat moves diagonally forward and to the starboard without rotating Boat moves diagonally aft and to the starboard without rotating Boat moves diagonally aft and to the port without rotating Section 3 On The Water Movement Joystick Input Boat Response shown from light gray to dark gray 25931 7 25926 N 25924 4 25923 Page 33 Section 3 On The Water __ gt Z o SSO Movement Joystick Input Boat Response shown from light gray to dark gray Boat moves diagonally forward and to the port without rotating 25925 24712 Boat rotates clockwise 25921 Boat rotates counter clockwise 25920 Boat moves diagonally forward and to the starboard while rotating clockwise Page 34 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water fi i Movement Joystick Input Boat Response shown from light gray to dark gray F Boat moves diagonally forward and to the starboard while rotating counterclockwise 25918 Boat moves diagonally forward and to the port while rotating counterclockwise 25917 Boat moves to the port while rotating clockwise 25930 Trim Tab Override The Zeus drive comes equipped with auto
46. boat is not fitted with a seacock leave the water inlet hose disconnected and plugged 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 At the end of each daily operation completely drain the seawater section of the cooling system to protect against damage by freezing e 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 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water e Use the required permanent type antifreeze solution to protect components against damage by freezing e Use proper cold weather lubrication oil ensure that the crankcase contains a sufficient amount e Make certain that the battery is of sufficient size and is fully charged Check that all other electrical equipment is in optimum condition e At temperatures of 20 C 4 F and below use a coolant heater to improve cold starting e f 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
47. ce is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 If you have a question concern or problem that cannot be resolved by your dealership please contact your local distributor of Cummins MerCruiser Diesel products for assistance The distributor will work with you and your dealership to resolve all problems The service office will need the following information e Your name and address e Daytime telephone number e Model and serial numbers for your power package e The name and address of your dealership e The nature of the problem To find the distributor for your area use the service locator on the Cummins MerCruiser Diesel website www cmdmarine com or contact CMD sales or service listed in the yellow pages of the telephone directory Contact 1 800 DIESELS to locate your closest distributor Customer Service Literature English Language English language publications are available from Mercury Marine Attn Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54935 1939 Outside the United States and Canada contact the nearest Mercury Marine or Marine Power International Service Center for further information When ordering be sure to e List your product model year and serial numbers e Check the literature and quantities you want Enclose full remittance in check or
48. cific legal rights and you may also have other rights which vary from state to state Outside the United States and Canada in case of consumer sales in some countries the Owner has 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 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 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 2 United States includes American Samoa the Commonwealth of Northern
49. claimers and limitations of damages and other related information Please review this important information Read This Manual Thoroughly Notice IMPORTANT If you do not understand any portion of this manual contact your dealer for a demonstration of the actual starting and operating procedures Throughout this publication and on your power package dangers warnings cautions and notices accompanied by the International Hazard Symbol may be used to alert the installer and user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly These safety alerts follow ANSI standard Z535 6 2006 for product safety information in product manuals instructions and other collateral materials 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 A DANGER 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 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 informa
50. com If for any reason you cannot obtain service contact the nearest Regional Service Center Outside the United States and Canada contact the nearest Marine Power International Service Center Stolen Power Package If your power package is stolen immediately advise the local authorities and Cummins MerCruiser Diesel of the model and serial numbers and to whom the recovery is to be reported This information about the stolen motor is placed into a file at Cummins MerCruiser Diesel to aid authorities and dealers and distributors in the recovery of stolen motors Attention Required After Submersion 1 Before recovery contact a Cummins MerCruiser Diesel Authorized Repair Facility 2 After recovery immediate service by a Cummins MerCruiser Diesel Authorized Repair Facility is required to prevent serious damage to power package Replacement Service Parts Page 112 Avoid fire or explosion hazard Electrical ignition and fuel system components on Cummins MerCruiser Diesel products comply with U S Coast Guard rules to minimize risk of fire or explosion Do not use replacement electrical or fuel system components that do not comply with these rules When servicing the electrical and fuel systems properly install and tighten all components Marine engines are expected to operate at or near full throttle for most of their life They are also expected to operate in both fresh and saltwater environments These conditions require nume
51. control system applies a thrust to the boat in the sideways direction You can move the joystick in any direction and the boat moves in that direction without turning For example moving the joystick to port causes the boat to move sideways to port Rotating the joystick creates forces that cause 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 computer control system automatically attempts to dampen bow swinging during joystick operation If the joystick is not twisted the computer measures the yaw rate of the boat and actively counteracts the yaw motion of the boat 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 Maneuvering with the Joystick CMD 4082031 90 866938070 AUGUST 2007 Page 31 Section 3 On The Water __ gt Z o S SSO o caucaay Joystick Input Boat Response o caucaay from light gr
52. ct 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 Ifthe 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 dr
53. cted 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 e 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 e Know your boating area and avoid hazardous locations e Be alert The operator of the boat is responsible by law to maintain a proper lookout 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 e Never drive your boat directly behind a water skier in case the skier falls As an 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 e Watch fallen skiers When using your boat for water skiing or similar activities always 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 e Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforce
54. cy you can manually place a transmission into gear by using a suitable wrench to actuate the appropriate gear shifting solenoid Note the following e 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 e Auto Heading and Track Waypoint will work when emergency gear engagement is in use e 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 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 CMD 4082031 90 866938070 AUGUST 2007 Page 59 Section 3 On The Water Page 60 4 Locate the forward gear solenoid on the port side of the affected transmission the wire is tagged Forward Gear 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
55. d 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 CMD 4082031 90 866938070 AUGUST 2007 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 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 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 l
56. d Service Directory CMD 4082031 90 866938070 AUGUST 2007 Page 3 Section 1 Limited Warranty Two Year Limited Warranty Limited Warranty Coverage Extended Major Components Limited Warranty Consumer Products Page 4 Coverage Duration whichever occurs Repair Charge Paid by CMD first Coverage Category Months Hours Parts Labor Removal A Travel Base Engine Warranty 24 1000 Yes Yes Yes Yes Extended Major Components 72 3000 Yes Yes Yes Yes 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 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 Exclude
57. d identify the circuit that they protect After finding and correcting the cause of the overload reset the circuit breaker by pressing the reset button CMD 4082031 90 866938070 AUGUST 2007 Page 17 Section 2 Getting to Know Your Power Package 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 J LA i i aed 4 h 26315 E Port shown starboard similar tem Crou Breaker kanng Protection ocana E E e a gt o ome me The VIP itself is protected by a 30 amp in line fuse between the battery bank and the VIP The in line fuse is often located on the fuse panel Ask your dealer for the location 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 Ask your dealer for the location and operation instructions of all overload protection devices e Circuit breakers are used to protect the backup hydraulic system The 30 amp breakers one for each drive are installed by the boat manufacturer and may vary in appearance and location Ask your dealer for the location and operating instructions e The MerCathode system has a 20 amp in line fuse in the wire that connects from the positive battery terminal to the positive terminal
58. d 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 zinc plugs 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 CMD MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE In the United States and Canada this warranty gives you specific legal rights and you may also have other rights whic
59. e MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Mariner Quicksilver 1 On The Water Alpha Bravo Pro Max OptiMax Sport Jet K Planes MerCathode RideGuide SmartCraft Zero Effort M with Waves logo Mercury with Waves logo and SmartCraft logo are all registered trademarks of Brunswick Corporation Mercury Product Protection logo is a registered service mark of Brunswick Corporation 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 dis
60. e maximum mark on the dipstick Install the dipstick Install the access cover onto the drive cover if it was removed Install the drive cover if it was removed See Installing the Drive Cover You can fill the transmission with fluid through the access cover on the drive cover or with the drive cover removed 1 Remove the drive cover to fill the transmission with the drive cover removed See Removing the Drive Cover then go to step 3 Remove the access cover from the drive cover if filling with the drive cover installed Go to step 3 Remove the dipstick Wipe the dipstick with a clean lint free cloth Check the fluid level as outlined in Checking 4 a Access cover b Transmission c Transmission dipstick Add the specified transmission fluid through the dipstick threaded hole to bring the level up to the maximum mark on the dipstick CMD 4082031 90 866938070 AUGUST 2007 Changing Section 5 Maintenance Fluid Capacity Fluid Type Fluid Part Number Transmission and drop 5 14 liters 5 quarts Synthetic Power box Steering Fluid SAE 92 858077K01 IMPORTANT For a more accurate measurement operate the engine at 1500 RPM for three minutes immediately before checking the fluid level 5 Start the engine and operate at 1500 RPM for three minutes to fill all the hydraulic circuits 6 Stop the engine Quickly unscrew and remove the dipstick 7 Check the fluid level as outlined in Checking
61. e VesselView environment menu The TURN buttons provide a 10 course correction for each press to the port or starboard The joystick provides a 1 course correction for each press to the port or starboard CMD 4082031 90 866938070 AUGUST 2007 Page 41 Section 3 On The Water The steering wheel feels locked into a detent when AUTO or TRACK are engaged Approximately 3 4 4 5 kg 8 10 lb of force are required to overcome this detent Manually overcoming the steering wheel s detent force automatically puts Pilot into standby mode STANDBY 8 2 Fe F 1 45P AUTOPILOT Standby screen on VesselView a OFF icon b Heading c Drive angle reference d Engine RPM e Instandby mode the display shows a digital compass value and the angle of the drives when engaged The compass value is the actual current heading from the AutoPilot e On the right side of the screen an icon labeled OFF indicates that Pilot is not engaged 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 The following information shows the location and explains the function of the Precision Pilot track pad lights and buttons For more information refer to the Precision Pilot Owner s Manual provided with the product Page 42 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water STANDBY AND ACTIVE LIGHTS PO ee es aN S PRECISIO
62. e underwater drive components skegs or the boat bottom 27301 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 e The boat could move in a new direction Such an unexpected change in direction or turn can throw occupants out of their seats or out of the boat e A rapid reduction in speed This can cause occupants to be thrown forward even out of the boat CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water 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 Operating a boat with impa
63. eceuuecsuueeeueseneees 13 Digital Gauges If Equipped 13 Analog Gauges If Equipped 14 Electronic Helm Steering 15 Dual Handle Electronic Remote Control ERC with DTS Trackpad Features and Operation 15 ODE atlOMsissidsesesdarsendescans ine TEE 15 Basic Joystick Operation ccsseeees 17 Electrical System Overload Protection 17 Vessel Interface Panel VIP Overload ProteCtiOn 2 cccccccceeeeeeeeeeseeeeeeeeeeeeeeeeeeeaes 18 Overload Protection for Other Circuits 18 Zeus Drive Alignment 18 Section 3 On The Water Safe Boating Suggestions eres 20 Be Alert To Carbon Monoxide Poisoning 21 Good Ventilation 21 Poor Ventilation ceeseeeeeeeeeeeeeeeeeees 22 Basic Boat Operation ccccccccccccceeceeeesseeeeteees 22 Freezing Temperature and Cold Weather Operation ccccccccececeeeeeeeeeeeeeeeceeeeeeeeeeness 22 Drain Plug and Bilge Pump eee 23 Protecting People in the Water 23 While the Boat is Moving 23 While the Boat is Stationary 00008 23 Wave and Wake JUMPING eeeeeeeeeeeeee 24 Impact with Underwater Hazards 24 Zeus Drive Impact Protection 005 25 Conditions Affecting Boat Operation 0 25 Weight Distribution Passengers and Gear Inside the BOabt cccceeeeeeeeeeeeeeeeeeeeeeeeeeees 25 Bottom Of Boda
64. eeeeeeeeeeeeees 25 Bottom Of Bodat 0 cee ee eeeeeeeeeeeeeeeeeees 26 Cavitation ccccccceeeeeceeeeeeeeeaeeeeeeeeeeeneees 26 Ventilation ccccceceeceeeceeeeeceeeeaeeeeeeseeeeeeeees 26 Propeller Selection ccccccccsecesseeeeeeeeees 26 Getting Sia Gs co sonia ta ten cedar rererere 27 Break In Period New or With Replacement Gears Jinen tae ceed Slated esse e Ees 27 Starting and Stopping the Engines 27 Normal Starting 27 Normal Stopping seeeeeeeeeeeeeees 28 Starting the Engines Manual Override T AT 28 Stopping the Engines Manual Override E E dapov oReageaanSeanenesnyeacueneseenivads 30 Traditional Maneuvering with Steering and TATUS teisa maea eaae 30 To Maneuver the Boat in Forward 31 To Steer the Boat in Tight Turns at Low Speeds aannannneeneennneneeeeneeernrernrrrrrrrreereee 31 To Spin the Boat on its Axis at Low Speeds EEE E PETATE ET EAE EET 31 Maneuvering with the Joystick 31 Trim Tab Override seeeeeeeeeeeeeeeeeees 35 Manual Adjustment ae 35 Trim Tab Override Use ineen 36 Getting on Plane n 36 CMD 4082031 90 866938070 AUGUST 2007 Smoothing the Ride cee 36 Correcting a LISUtscscecxtescsactdeorstessentuesen 36 Low Speed TriM cccccceeeeeeeeneeeeeeeeees 36 Special Digital Throttle and Shift DTS Features ee ee ee 37 Troll and Throttle Response 38 DOGK e E T
65. entro de servicio mas cercano de Mercury Marine o Marine Power International para recibir informacion Con su conjunto motriz se entrega una lista de los numeros de pieza para los otros idiomas Andra sprak For att fa Instruktions och underhallsb cker pa andra spr k kontakta n rmaste Mercury Marine eller Marine Power International servicecenter som kan ge ytterligare information En f rteckning ver artikelnummer pa andra spr k medf ljer ditt kraftpaket Allej glpssej Gia na apoktbsete Yna Egxeir amp dio LeitourgRaj kai Suntbrhshj se Ullh glpssa epikoinwnPste me to plhsiYstero DieqnYj KYntro SYrbij thj Mercury Marine P thj Marine Power gia plhroforRej To pakYto isxyoj saj sunodeyetai api Ynan katUlogo ariqmpn paraggelRaj gia Ullej glpssej Ordering Literature Before ordering literature please have the following information about your power package available Serial United States and Canada For additional literature about for your particular Cummins MerCruiser Diesel power package contact your nearest Cummins MerCruiser Diesel dealer distributor or contact Mercury Marine 920 929 5110 920 929 4894 Attn Publications Department USA Only USA Only P O Box 1939 Fond du Lac WI 54935 1939 Year Outside The United States and Canada Contact your nearest authorized Cummins MerCruiser Diesel dealer distributor or Marine Power Service Center to order additional literature that is available for your particular
66. er inlet and the seacock if equipped for any accessory equipment _ 31243 Typical a Seacock handle in closed position b Direction to move handle to open c Seacock for engine seawater inlet d Seacock if equipped for accessory seawater inlet Move the ERC handles to the neutral position Turn the key switch to the on position for each engine being started Verify that the engines are safe to start Press and release the START STOP button corresponding to the engine being started The onboard computers automatically control the starter to achieve a successful start o Ngo g PORT STBD START START STOP STOP 28082 Typical SmartStart switch NORMAL STOPPING 1 Move the ERC handles to the neutral position 2 When the engines are running press and release the START STOP button corresponding to the engine to be stopped 3 Turn the key switch to the off position STARTING THE ENGINES MANUAL OVERRIDE Under certain circumstances the engine control systems may not be able to automatically start an engine If this is the case start the engine with a manual override switch in the engine room 1 Perform the drive checks listed in Section 5 Routine Maintenance Each Day Start and When Refueling Page 28 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water 2 Perform the checks and steps listed in the engine s operation and maintenance manual available for this package 3 Open the seawat
67. er return seacock if not already in the open position a Seawater return overboard seacock b Seacock handle c Handle in closed position d Handle in open position 4 Open the seacock for the engine seawater inlet and the seacock if equipped for any accessory equipment 1 31243 Typica a Seacock handle in closed position b Direction to move handle to open c Seacock for engine seawater inlet d Seacock if equipped for accessory seawater inlet NOTE The neutral LED lamps flash on and off if the ERC handles are not in the neutral position when the key switch is turned to the on position Also the propellers do not spin and the throttles are not active until the ERC handles are first returned to the neutral position if the engines are started with the ERC handles in a gear position Returning the ERC handles to neutral stops the neutral LED lamps from flashing restoring propeller and throttle control 5 Move the ERC handles to the neutral position 6 Turn the key switch to the on position for each engine to be started 7 Verify that the engines are safe to start 8 Locate the Vessel Interface Panel VIP in the engine room for each engine CMD 4082031 90 866938070 AUGUST 2007 Page 29 Section 3 On The Water 9 Press and hold the green START button on the respective VIP until the engine starts Do not hold the button for more than 30 seconds if the engine fails to start Allow the starter to co
68. esel 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 CMD 4082031 90 866938070 AUGUST 2007 Page 7 Section 1 Limited Warranty 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 1 2 CMD warrants to the first user and each subseque
69. ficient 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 mc79554 1 a Operating the engine when the b Mooring close to another boat with boat is moored in a confined space its engine operating 2 Examples of poor ventilation while a boat is moving mc79556 1 a Operating the boat with the trim b Operating the boat with no forward angle of the bow too high hatches open station wagon effect Basic Boat Operation Freezing Temperature and Cold Weather Operation Page 22 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 cold weather 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
70. freezing temperatures are possible In such cases the seawater section of the cooling system must be completely drained immediately after operation Seasonal storage refers to when the boat is not being operated for one month or more The duration varies according to the geographic location Seasonal storage precautions and procedures include all the steps for freezing weather storage and some additional steps that must be taken when storage will last longer than the short time of freezing weather storage Preparing the Power Package for Storage Drive Storage IMPORTANT Cummins MerCruiser Diesel strongly recommends that this service is preformed by an Authorized Cummins MerCruiser Diesel repair facility Damage caused by freezing is not covered by the Cummins MerCruiser Diesel Limited Warranty 1 Close the seacocks 2 Perform all maintenance specified for completion under the interval of Every 500 Hours or Once a Year Whichever Occurs First in Section 5 Maintenance Schedules Page 102 CMD 4082031 90 866938070 AUGUST 2007 Section 6 Storage Engine Storage Read all precautions and perform all appropriate storage procedures found in the Marine Recreational High Output Propulsion Units QSB and QSC Operation and Maintenance Manual available from the engine manufacturer Battery Storage Whenever the battery will be stored for an extended period of time be sure the cells are full of water and the battery is fully charged and
71. g the Boat 94 Propellersiis d2cisentetavedindsstetienndesiadl adetvevitactsee 95 Propeller REMOVal ccescecceeeeesseeeeeeeeeees 95 Propeller Repaiir ccceeeceeesseeeeeeeeeeees 97 Propeller Installation ccccccsesesseseeeeeeeees 97 Section 6 Storage Cold Weather Freezing Temperature Storage and Seasonal Storage 102 Storage Descriptions 102 Preparing the Power Package for Storage 102 gio 6 i 0 eer eee reece errr er 102 Engine Storage 103 Battery Storage eerrnririiesiieseieesscrescereceretee 103 RECOMMISSIONNG ie tcccrcccrchcretdinonsstsssentneoccuslenselece 103 ENGINE cee cece enk aii aga aan a R 103 DIV ccc icicadystaicheatcetesctetianaigenacerearckoianmnincniceet 103 Power PACKAOG soscsedcistiecnesteitee ante steacsses 103 Section 7 Troubleshooting Diagnosing Electronically Controlled Fuel System PRODIOMS ccro star sbanscaimaearsien cansaearses 106 Electrical Connections 106 Troubleshooting Charts 106 Troubleshooting Engine Related Problems 106 Check VesselView FirSt ccceeceeeeeeee ees 106 Poor Performance 107 JOYS CK Cee 107 Electronic Remote Controls 00668 107 Steering System 108 Trim TAbS cccccccsceceeeeeeeeeeeeeeeeeeeeeaeeeeaeeaaees 109 Boat Response Changes 109 Battery Will Not Charge 109 Gauges and Instrumentation 005 110 Section 8 Customer Assistance Informat
72. geese beaus Sa sieeceurecianeanetceeeiecduecacdina aes 80 Transmission FIUIC cecccecceeeeeeeeeeeeeeeeeeeeeeees 81 ACCUM scncxiatsedascs dace tevestcotets oniafeviceeyacee nts 81 Filli Okene 82 CHangiN geses iinei EE Ei 83 Seawater Strainer ccceecseceeeeneeeeeeeeseeeseeeees 86 Battery asne E EA 87 GAUGES cic crensecantccastcteatceapextentecantcnentadatieeatianastgrentxe 87 Checking Gauges 87 Cleaning Gauges 87 Electrical System eeens 87 Cooling System and Exhaust System 87 L bri atiON eee 88 Driveshaft Slip JOiNt 0 seeeeeeeseeeeeeeees 88 Seacock Seawater Return Overboard 89 Propeller Shaft c eeeeeeeeeeeeeeeeeeeeees 90 Corrosion Protection cc cccceeeeeeceeereeeesneeees 90 Anodes and MerCathode System 90 Reference Electrode Wire of the MerCathode SYS Mica csccicke daeccuctedececptaedgecacetrentenenxeeanentannnes 91 MerCathode Anode ccccceeeeeeeeeeeeeeneees 92 cole dle eee pene ene enesne ery wee terete ererer rere 92 ic C1 011 0 Sone pee eran eee Eeepr err are tr Serene ernerey re 92 CMD 4082031 90 866938070 AUGUST 2007 MerCathode System Testing ee 92 Trim Tab Anodes 93 Checking eeeeeeeeeessesrrrrrrrrrer nnn 93 Replacing irisi innin niinniin seis siri diet 93 Continuity Circuits eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 93 Inhibiting COrrosion a 94 Paintin
73. goes to Standby TURN BUTTON OR JOYSTICK IN TRACK MODE While in TRACK WAYPOINT the left and right TURN buttons on the keypad or joystick inputs changes the mode to AUTO HEADING AUTO HEADING BUTTON IN TRACK MODE While in TRACK WAYPOINT the AUTO HEADING button causes the AutoPilot to change to AUTO HEADING CMD 4082031 90 866938070 AUGUST 2007 Page 53 Section 3 On The Water ACKNOWLEDGING A TURN DURING A WAYPOINT ARRIVAL 1 When the boat enters the waypoint arrival zone of the chart plotter the AutoPilot sounds a short horn alarm and blinks the WAYPOINT SEQUENCING button light informing the operator to make a turn O PRECISION PILOT O STANDBY ACTIVE a SKYHOOK i que TURN D gt l a WAYPOINT ipa RESUME SEQUENCE lt gt co ol Te UTO TRACK HEADING RESPONSE WAYPOINT 27703 WAYPOINT SEQUENCE button 2 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 the Pilot to turn the boat and maneuver to the new course If the waypoint is not acknowledged the boat continues on its current heading 3 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 Page 54 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water WAYPOINT SEQUENCE In some Precision Pilot modes
74. h vary from state to state Outside the United States and Canada in case of consumer sales in some countries the Owner has 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 2 United States includes American Samoa the Commonwealth of Northern Mariana Island Guam Puerto Rico and the U S Virgin Islands 3 United States includes American Samoa the Commonwealth of Northern Mariana Island Guam Puerto Rico and the U S Virgin Islands Page 6 CMD 4082031 90 866938070 AUGUST 2007 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 u
75. he COLD FILL LEVEL line if the level is low 12 Recheck the gear lube level at the gear lube monitor after the first use See Checking 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 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance WITH THE BOAT OUT OF THE WATER 1 Remove the drive propellers See Propellers 2 Remove the gearcase fill and drain screw and sealing washer a Gearcase b Fill drain screw and sealing washer 3 Remove the gear lube monitor cap 8 di an 27851 a Gear lube monitor b Cap 4 Drain the gear lube into a suitable container 5 Allow the gear lube to drain completely IMPORTANT If any water exits the fill and drain hole or if the gear lube appears milky the drive is leaking Contact your Cummins MerCruiser Diesel Authorized Repair Facility immediately IMPORTANT Use only Mercury or Quicksilver High Performance Gear Lube in the drive CMD 4082031 90 866938070 AUGUST 2007 Page 77 Section 5 Maintenance 6 Install a suitable gear lube pump into the gearcase fill and drain hole Fill the drive with the specified gear lube f 28391 a Fill and drain hole b Gear lube and pump 7 Continue to pump gear lube into the drive until the gear lube appears in the gear lube monitor at the COLD FILL LEVEL line Do not overfill
76. he power icon 0 when that button light is off the light turns on for that button a single beep sounds and the ACTIVE light illuminates A rotating propeller a moving boat or a device attached to a moving boat can cause serious injury to people in the water When the Skyhook electronic anchor 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 Your Zeus vessel is equipped with the Skyhook electronic anchor or Skyhook which allows the boat to automatically maintain its position and heading The computer control system maneuvers the drives automatically to keep the boat in one position Skyhook keeps the boat steady without having to use anchors or lines when no people are present in the water near the boat The capability of most vessels limits the ability of Skyhook electronic anchor to counteract currents of up to 2 knots 2 3 MPH when the boat is sideways to the current If you notice your boat drifting sideways while Skyhook electronic anchor is engaged move the bow or stern more directly into the current to help reduce the effects of this situation The Skyhook electronic anchor system relies on an operational GPS receiver and operational heading sensor Occasionally due to satellite geometry or obstructions GPS may be temporarily unavailable Skyhook continues to operate through a GPS outage for up to 10 seconds b
77. he vessel has not turned too far and the RESUME light is still on or flashing ENGAGING TRACK WAYPOINT MODE To engage Track Waypoint mode of Precision Pilot 1 Create and use a route from the chart plotter Refer to your chart plotter user manual for details 2 Place at least one ERC lever in forward gear and establish a safe operating speed Page 52 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water 3 Press the TRACK WAYPOINT button on the Precision Pilot keypad The TRACK WAYPOINT button turns on indicating that Pilot is tracking to the chart plotter s desired course O PRECISION PILOT O STANDBY ACTIVE Gc SKYHOOK r TURN gt ED WAYPOINT RESUME SEQUENCE CS lt gt UTO TRACK HEADING RESPONSE WAYPOINT 27701 TRACK WAYPOINT button 4 A beep sounds and a warning appears on VesselView Press the check to acknowledge the warning DISENGAGING TRACK WAYPOINT MODE Disengage the Track Waypoint mode by any one of the following methods e Press the TRACK WAYPOINT button on the precision pilot keypad The button light goes off and Pilot goes to Standby e Turn the steering wheel hard enough to overcome the force feedback and Pilot goes to Standby e Move both ERC levers back to neutral and Pilot goes to Standby e Press either TURN button and Pilot goes to Auto mode e Press the AUTO HEADING button and Pilot goes to Auto mode e Turn off the chart plotter and Pilot
78. head driveshaft shield to transmission retaining screw M10 x 1 25 25 mm 1 in Jlong and washer d Driveshaft shield upper to lower retaining screw M8 x 1 25 12 mm 1 2 in long nut and washer Description Driveshaft shield retaining screw and nut transmission end Driveshaft shield upper to lower retaining screw and nut Seacock Seawater Return Overboard 1 Lubricate the seacock through the grease fitting by applying approximately 3 6 pumps of specified grease from a typical hand operated grease gun e wooo Typical drive with cover removed for visual clarity a Grease fitting b Seacock seawater return overboard 27979 CMD 4082031 90 866938070 AUGUST 2007 Page 89 Section 5 Maintenance H 94 mn Anti Corrosion Grease 92 802867Q 1 Propeller Shaft 1 Remove the propellers Refer to Propellers 2 Apply a liberal coat of one of the following lubricants to the propeller shafts 94 Cp Anti Corrosion Grease B shafts 92 Eea 1 J 34 Co Special Lubricant 101 Propeller shaft shaft 92 92 802865002 ae L pricant with Propeller shaft 92 802859A1 Install the propellers Refer to Propellers Corrosion Protection NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion Do not use any cleaning equipment such as brushes or high pressure washers to clean the MerCathode assembly Whenever two or more dissimilar metals like those found on the drive
79. his 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 Starting and Stopping the Engines Your Zeus power package is equipped with a SmartStart system as well as a backup manual override engine start and stop system Start and stop the engine from the helm using the SmartStart system in normal circumstances NORMAL STARTING 1 Perform the drive checks listed in Section 5 Routine Maintenance Each Day Start and When Refueling Perform the checks and steps listed in the engine s operation and maintenance manual available for this package Open the seawater return seacock if not already in the open position a Seawater return overboard seacock b Seacock handle c Handle in closed position d Handle in open position CMD 4082031 90 866938070 AUGUST 2007 Page 27 Section 3 On The Water 4 Open the seacock for the engine seawat
80. hut off the engines before allowing people to swim or be in the water near your boat CMD 4082031 90 866938070 AUGUST 2007 Page 23 Section 3 On The Water 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 mc79680 1 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 Page 24 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 th
81. ime expenses cargo damage fines all applicable taxes all business costs and other losses resulting from a Warrantable Failure CMD 4082031 90 866938070 AUGUST 2007 Page 5 Section 1 Limited Warranty 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 publishe
82. in good operating condition It should be clean and free of leaks Follow the battery manufacturer s instructions for storage Recommissioning Engine NOTE Discharge of propylene glycol into the environment may be restricted by law Contain and dispose of propylene glycol in accordance with federal state and local laws and guidelines 1 Drive 2 Power Package On engines that were prepared for cold weather freezing temperature or seasonal storage drain the propylene glycol into a suitable container Dispose of the propylene glycol in accordance with federal state and local laws and guidelines Refer to the Marine Recreational High Output Propulsion Units QSB or QSC Operation and Maintenance Manual available from the engine manufacturer and accomplish recommissioning procedures as specified by the manufacturer Perform all maintenance specified for completion under the interval of Every 500 Hours or Once a Year Whichever Occurs First in Section 5 Maintenance except items that were performed at the time of drive layup Check all fluid levels before first use Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system Always disconnect the negative battery cable first and connect it last Install a fully charged battery Clean the battery cable clamps and terminals Reconnect the cables see the CAUTION listed above Secu
83. information Une liste des num ros de pi ces en d autres langues accompagne votre bloc moteur Andere Sprachen Um eine Betriebs und Wartungsanleitung in einer anderen Sprache zu erhalten wenden Sie sich an das n chste Mercury Marine oder Marine Power International Service Center Eine Liste mit Teilenummern f r Fremdsprachen ist im Lieferumfang Ihres Motors enthalten Altre lingue Per ottenere il manuale di funzionamento e manutenzione in altra lingua contattate il centro assistenza internazionale Mercury Marine o Marine Power pi vicino In dotazione con il gruppo motore viene fornito l elenco dei codici prodotto dei componenti venduti all estero Andre spr k Ytterligere informasjon om bruks og vedlikeholdshandbok p andre spr k kan f s ved henvendelse til n rmeste internasjonale servicecenter for Mercury Marine eller Marine Power En liste over delenumre for andre spr k f lger med aggregatet Outros Idiomas Para obter um Manual de Opera o e Manuten o em outro idioma contate o Centro de Servi o Internacional de Marine Power Pot ncia Marinha ou a Mercury Marine mais pr xima para obter informa es Uma lista de n meros de refer ncia para outros idiomas fornecida com o seu pacote de propuls o Page 114 CMD 4082031 90 866938070 AUGUST 2007 Section 8 Customer Assistance Information Otros idiomas Para obtener un Manual de operaci n y mantenimiento en otro idioma p ngase en contacto con el c
84. ing are conditions where additional minor adjustments to the trim tabs might be beneficial GETTING ON PLANE During initial acceleration the tabs automatically drop bow down to bring the boat on plane faster to improve forward visibility and use less power As the boat comes on plane the tabs are brought up so the bow not plow The tabs can be manually adjusted for the best performance when the boat conditions are temporarily outside the normal operating conditions as when the boat is fully loaded SMOOTHING THE RIDE A head sea can create an uncomfortable jarring ride Put the tabs to a mid position As the wave throws the bow up tabs dampen the boat s reaction leveling and smoothing the ride In a following sea put the tabs up This allows the bow to lift offsetting the waves which lift the stern In milder water some boats gently porpoise Drop the tabs a little at a time until the lope disappears CORRECTING A LIST Listing may be caused by an unbalanced load A little down tab on the side of the heavy load levels the ride List may also occur in a quarter following sea Waves lift the stern unevenly causing the boat to pitch forward and roll opposite the lift If the starboard transom is lifting drop the port tab a little This removes the listing and produce a dryer more level ride LOW SPEED TRIM Page 36 In controlled speed zones many boats start to fall off plane as the speed decreases thereby reducing visibi
85. ion Owner Service ASSIStANCe cccceeeeeeeeeeeeeeeeee 112 Local Repair ServiCe cccccccsseeeeeeeeeeeees 112 Service Away From Home eeees 112 Stolen Power Package 112 Attention Required After Submersion 112 Replacement Service Parts cc 112 Parts and Accessories Inquiries 05 113 Resolving a Problem 113 Customer Service Literature 113 English Language 113 Other Languages eeren 114 Andre Sprogseminarer 114 Andere talen c ccccccceeeeeeeeeeteeeeeeeeeeeeeeaes 114 CMD 4082031 90 866938070 AUGUST 2007 Muut Kielet 0 cccecccceeeeeeeeeeeeeeeeeeeeaeeeees 114 Autres IANMOUSS 2255 cc ccStevedsasack cx ctsJevecetbeetcceeStesees 114 Andere Sprachen c ceeeeeeeeeeeeeeeeeeeeeees 114 Altre INgU Eur ssori roras t oriei 114 Andre Sprak ccseeseeeeeeseeeeeseeseeeeaeeeaeaaaaes 114 Outros IdiOMAS cccccceeeeeeeeeeeeeeeeeeteeeeeees 114 Otros idiOMAS cccceeeeeeeeeeeeeeeeeeeeeaeeneeestees 115 Andra B18 22 eee nee eee ee ee ee 115 aA Cle i ee 115 Ordering Literature 2 0 eee 115 United States and Canada eceeee 115 Outside The United States and Canada 115 Page iii Page iv CMD 4082031 90 866938070 AUGUST 2007 Section 1 Limited Warrant Section 1 Limited Warranty 1 Table of Contents Warranty Information 2 Limi
86. ional to the position error reported by the GPS e 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 e During Skyhook electronic anchor operations the computer control system shifts the engines and 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 e A single beep sounds when the Skyhook is disengaged or the GPS signal is lost CMD 4082031 90 866938070 AUGUST 2007 Page 45 Section 3 On The Water ENGAGING SKYHOOK O Q ee PILOT O STANDBY ACTIVE SkYHOOK H que TURN p C WAYPOINT RESUME SEQUENCE 35 a gt AUTO TRACK HEADING RESPONSE WAYPOINT 27698 SKYHOOK button 1 Move the levers to neutral and bring the boat to a stop Skyhook does not engage until the boat is in neutral and at a speed slow enough for safe engagement The Skyhook light blinks while the mode is waiting for the boat to decelerate enough to engage The boat may reverse automatically if it has passed the position where the SKYHOOK button was pressed in order to get back to the point it was asked to hold When the Skyhook electronic anchor is engaged the boat stays in a preset position however S
87. ive 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 Conditions Affecting Boat Operation Weight Distribution Passengers and Gear Inside the Boat Shifting weight to the rear stern e Causes the bow to bounce in choppy water e Increases the danger of a following wave splashing into the boat when coming off plane e Can cause the boat to porpoise at extremes Shifting weight to the front bow e Improves ease of planing CMD 4082031 90 866938070 AUGUST 2007 Page 25 Section 3 On The Water e Improves rough water ride e Can cause the boat to veer back and forth bow steer at extremes Bottom Of Boat Cavitation Ventilation To maintain maximum speed the boat bottom should be e Clean and free of barnacles and marine growth e Straight and smooth fore and aft Marine vegetation can accumulate when the boat is docked Remove this growth before operation it c
88. kyhook 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 2 Press the SKYHOOK button to turn on Skyhook mode and a single beep sounds A warning screen appears on VesselView while Skyhook maintains the boat s current position and heading Press the check to acknowledge The light stops blinking and remains on constantly once Skyhook is engaged 3 Move the joystick move the ERC levers or press the SKYHOOK button when illuminated to turn off Skyhook A single beep sounds when the function turns off 4 The VesselView SKYHOOK screen displays on VesselView for one second after the SKYHOOK button is pressed and the screen displays a green circle with SH when Skyhook engages The screen must be turned on in VesselView calibration See Mode Display in VesselView 5 Press the SKYHOOK button a second time to put Precision Pilot in standby All lights other than STANDBY turn off DISENGAGING SKYHOOK Page 46 IMPORTANT Under most circumstances both engines and drives must be operational to achieve acceptable Skyhook electronic anchor performance If the necessary reference signals from an engine or drive become unavailable Skyhook automatically disengages To disengage the Skyhook Electronic Anchor you can choose one of the following me
89. l 2 Press the TROLL button The TROLL button light turns off go E o N Page 38 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water DOCK The Dock mode reduces the RPM throughout the range by 50 This allows better control of engine power in close quarter situations 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 any detent 2 Press the DOCK button The DOCK button light turns off THROTTLE ONLY THROTTLE ONLY button To engage Throttle Only mode 1 Place both ERC levers in neutral 2 Press the THROTTLE ONLY button located on the DTS Trackpad CMD 4082031 90 866938070 AUGUST 2007 Page 39 Section 3 On The Water 1 ONE LEVER SYNC Page 40 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 remains in Neutral To disengage Throttle Only mode NOTE Pressing the THROTTLE ONLY button while the ERC levers are in gear turns off the butto
90. l to the first detent for reverse gear Continue pulling the handle back to increase speed in reverse CMD 4082031 90 866938070 AUGUST 2007 Page 15 Section 2 Getting to Know Your Power Package Page 16 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 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 ERC handle tension 1 Remove the side cover 2 Turn the screw clockwise to increase tension on the control handle and counter clockwise to decrease tension 3 Adjust to tension desired To adjust ERC handle detent tension 1 Remove the side cover 2 Turn the screw clockwise to increase tension on the control handle and counter clockwise to decrease tension CMD 4082031 90 866938070 AUGUST 2007 Section 2 Getting to Know Your Power Package 3 Adjust to tension desired 28087 Starboard side with side cover removed a ERC handle tension screw b ERC handle detent tension screw Basic Joystick Operation The joystick offers precise intuitive control of your boat during low s
91. lity Lowering both trim tabs keeps a boat on plane longer at legal lower speeds while maintaining a level boat attitude At idle speed bow steering wandering side to side requires constant correction to maintain a heading Dropping both tabs creates stern drag which improves tracking CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water Tabs can also help reduce roll When a boatis at rest a wave which normally causes rolling must first move water out of the way from above one tab and below the other This dampens rolling Special Digital Throttle and Shift DTS Features The DTS system features several alternate operational modes for the Electronic Remote Control ERC levers Any of the listed features can be operated simultaneously and can help you with e Warming the engines e Synchronizing the engines e Trolling the vessel for docking operations e Allowing access to the slow speed trolling features of the integrated transmission system ERC Levers with DTS Trackpad e e d a aii Illuminate when the transmission is in the neutral gear position The NEUTRAL lone lights flash when the engine is in throttle only mode Fb TROLL TROLL sets the boat speed for slow speed cruising or maneuvering TRANSFER A control to be transferred to a different helm Refer to Helm a DOCK Reduces throttle capacity to approximately 50 of normal throttle THROTTLE ONLY Allows the boat operator to increase
92. lling Changing Page 80 3 Inspect the fluid level which should be 25 mm 1 in below the bottom of the filler neck of the reservoir 27857 a Correct fluid level b Reservoir c Bottom of filler neck d Cap 4 If the level is low see Filling 1 Using a clean lint free cloth wipe the dirt and debris away from the cap and exterior of the steering actuator and trim fluid reservoir 2 Remove the cap 3 Fill the reservoir with the specified fluid until the fluid is 25 mm 1 in below the bottom of the filler neck of the reservoir Do not overfill 4 Install the cap 27857 a Correct fluid level b Reservoir c Bottom of filler neck d Cap Fluid Capacity Fluid Type Fluid Part Number Steering actuator and Synthetic Power Steering Fluid SAE 92 858077K01 OW 30 trim system 5 3 4 to 6 liters approximate total 6 to 6 1 3 quarts capacity Contact your local Cummins MerCruiser Diesel Authorized Repair Facility CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance Transmission Fluid Checking You can check the transmission fluid level through the access cover on the drive cover or with the drive cover removed 1 If the drive cover is removed go to step 3 2 If the drive cover is installed remove the access cover from the drive cover then go to step 3 a Access cover b Transmission c Transmission dipstick 3 Remove the dipstick Wipe the dipstick
93. matic trim tabs that operate via computer control to provide basic performance control and efficiency improvements However a trim override allows manual adjustments for natural conditions that affect the attitude of the boat MANUAL ADJUSTMENT You can manually adjust the automatic tabs for conditions by using the individual tab switches as needed The trim tabs continue to operate normally with the additional adjustments until cleared or adjusted again or until a change in the speed of the boat causes the tabs to automatically readjust CMD 4082031 90 866938070 AUGUST 2007 Page 35 Section 3 On The Water Activating the override switch turns off the automatic tabs With the automatic tabs turned off the port PORT and starboard STBD switches provide total control of the tabs While this is possible we do not recommend overriding the automatic tabs as it is difficult for the operator to adjust the tabs as efficiently as the automatic control 26318 Typical trim tab switches with auto override TRIM TAB OVERRIDE USE The automatic trim tab system provided with your Zeus drive does a good job of trimming the vessel under normal conditions However conditions are not always normal and additional minor adjustments are often desired to fine tune the boat s attitude for the most comfortable and efficient operation Achieving trim is obtaining the desired operating attitude when operating in less than ideal conditions The follow
94. ment 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 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 1 Example of desired air flow through the boat mc79553 1 CMD 4082031 90 866938070 AUGUST 2007 Page 21 Section 3 On The Water POOR VENTILATION Under certain conditions permanently enclosed or canvas enclosed cabins or cockpits with insuf
95. mmins MerCruiser Diesel SmartCraft instrument package augments the information provided by VesselView A few of the functions the instrument package can display are Engine RPM e Boat speed e Coolant temperature e Oil pressure e Battery voltage e Fuel consumption CMD 4082031 90 866938070 AUGUST 2007 Page 13 Section 2 Getting to Know Your Power Package e Engine operating hours Typical SmartCraft gauges a Tachometer b Speedometer c LCD System View display The SmartCraft instrument package also aids in identifying the fault codes associated with the sounding of the engine audio warning system The SmartCraft instrument package displays critical engine alarm data and other potential problem areas on its LCD display Refer to the manual provided with your gauge package for basic operation information on the SmartCraft Instrument package and for details on the warning functions monitored by the system ANALOG GAUGES IF EQUIPPED Other instrumentation packages have gauges that augment the information provided by VesselView 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 gauges may be included with your power package CRUISELOG 17352 Page 14 CMD 4082031 90 866938070
96. n 10 of each other and the icon turns green when they synchronize The icon turns grey when Sync mode is off SYNC button To disengage Sync mode 1 Place the ERC levers in any detent 2 Press the SYNC button To re engage Sync mode press the SYNC button Cruise Control The VesselView system features integrated throttle cruise control Cruise which allows the operator to limit the peak RPM of choice below Wide Open Throttle WOT VesselView is required for this feature Refer to the owners and operators manual provided with your VesselView for operation instructions These additional notes are exclusive to your package You can change or disengage Cruise through the screen at any time Cruise resets when the key is turned off Skyhook does not function if Skyhook is in effect 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 to disengage Precision Pilot Track Pad Features GENERAL INFORMATION Precision Pilot Pilot functions are controlled through the Pilot track pad only Pilot screens when accessed by the trackpad appear on the VesselView for three seconds unless calibrated otherwise Pressing any button on VesselView dismisses the autopilot screen from the VesselView screen unless the screen was chosen from th
97. n 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 The neutral lights remains on The Zeus system features the ability to command both engines with a single lever This feature simplifies engine management during rough sea conditions by allowing you to grasp a single lever to command both engines simultaneously 4 LEVER button To engage 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 3 The 1 LEVER button lights 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 1 Lever mode 1 Place both ERC levers in neutral 2 Press the 1 LEVER button The 1 LEVER button light turns off The Zeus system features an automatic engine synchronization or Sync feature which engages automatically at key up The synchronization feature monitors the position of both levers If both levers are within 10 of one another the port engine synchronizes to the starboard engine s RPM CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water VesselView shows an orange icon if the RPM of the engines are not withi
98. nd Pilot beeps when in the zone The operator must acknowledge that it is OK to turn by pressing the Waypoint Acknowledge button on the VesselView screen Once acknowledged Pilot tracks to the next waypoint in the route 3 2 MH Z0 1 47 PM AUTOPILOT Please acknowledge that it is safe for the vessel to turn onto the new course 31414 If you are not in the waypoint arrival zone set by third party chart plotter interfaced to Pilot WAYPOINT SEQUENCE engages auto sequencing to the waypoints in the route You must acknowledge the warning screen by pressing the check button 8 2 MPH COLLISION HAZARD MAINTAIN PROPER LOOKOUT Waypoint sequencing will turn boat automatically at waypoints 31412 4 Press the TRACK WAYPOINT button and the VesselView Track screen displays for three seconds the WAYPOINT SEQUENCE button light turns on and a single beep sounds 5 The Track Screen does not appear unless the screen is activated turned on during VesselView calibration Pilot engages whether the screen is on or not See Mode Display in VesselView 6 Press the TRACK WAYPOINT button a second time to put the Pilot in Standby mode All lights other than STANDBY turn off WAYPOINT ACKNOWLEDGE e The Track Waypoint mode does not automatically turn the boat upon the arrival at a waypoint Turns are controlled in the Auto Heading mode Page 56 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water e Pressing the
99. nd inform them that the drive gear has been manually engaged CMD 4082031 90 866938070 AUGUST 2007 Section 4 Specifications Section 4 Specifications Table of Contents Drive Gear Lubricant ccceeeeeeeeeeeeeeeeees 62 Approved Paints cccccccccseecsteeeeeeeeeeeeeeees 62 TIPANSMISSION ccee cece ee eeeeeeeeeeeeeeeeeeeeeeeeaeaaeees 62 Approved Lubricants cccccccececseeeeeeeeeeeeeee 62 Steering Actuator and Trim Fluid 05 62 CMD 4082031 90 866938070 AUGUST 2007 Page 61 Section 4 Specifications Drive Gear Lubricant Fluid Capacity includes the drive and Fluid Type Fluid Part Number the gear lube monitor 5 1 4 liters High Performance Gear 6 1 2 quarts ee Transmission IMPORTANT Always use the dipstick to determine the exact quantity of lubricant or fluid required Transmission With Drop Box Fluid Capacity Fluid Type Fluid Part Number Synthetic Power Steering Fluid SAE 92 858077K01 OW 30 Transmission and drop 5 1 4 liters 5 1 2 quarts Transmission Without Drop Box Fluid Capacity Fluid Type Fluid Part Number Synthetic Power Transmission only 4 liters 4 1 4 quarts Steering Fluid SAE 92 858077K01 OW 30 Steering Actuator and Trim Fluid Fluid Capacity Fluid Type Fluid Part Number Synthetic Power Steering Fluid SAE 92 858077K01 OW 30 Steering actuator and 5 3 4 to 6 liters trim system 6 to 6 1 3 qua
100. ngagement Emergency Procedure 59 Section 4 Specifications Drive Gear LUDrICANL ccc eeeeeeceeeeeeeeeeeeeeeeeeeees 62 TIANSMISSION cecceecceeeeeceeeceeeeeeeusecueeeeeeaeeeeees 62 Steering Actuator and Trim Fluid 0 62 Product Responsibilities cceeeeeeeeeees 66 Owner and Operator Responsibilities 66 Dealer Responsibilities 0 eeeeee 66 Do It Yourself Maintenance Suggestions 66 gil ef teiile a iistiid eE rent reer 67 Drive COVED cccecccccceeeeeeeeceeeeeeeeeeeeeeesaeeeaaeenaaaaen 67 Removing the Drive COVE 67 Cleaning and Inspecting the Drive Cover 68 Installing the Drive Covet eee 68 Maintenance Schedules ccceeeeeeeeeeeeeeees 69 7 AN 0 0 er 0 8 een 69 Routine Maintenance 0 eeeeeeeeee 69 Scheduled Maintenance 69 Maintenance LOQ cccccscescssesseeeeeeeeesces 70 Drive Gear LUDG cc ceeeeeeeeeeeeeeeeeeeeeeeeeeeaes 72 CHECK UAG iiccadsccsctccectctencereeiuaiettenetixemninnenntaneds 72 Filin O erien trot Seem huiatuoass 73 AONE Ok ceri crersunsisteeceerertternieeeniccracegnenereniate 74 With the Boat in the Water 05 74 With the Boat Out of the Water 77 Steering Actuator and Trim Fluid eee 79 ol 4 e Barret ne tesa re rene ry ee eerste rene re 79 PUNE EE 80 Page ii Changin
101. ngine and drive parts For engine inspection information refer to the Marine Recreational High Output Propulsion Units QSB and QSC Operation and Maintenance Manual appropriate for your engine 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 The Zeus drive cover 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 Keep the drive cover installed at all times unless removal is necessary during some maintenance inspections and procedures 25850 Rear view of typical drive cover a Top cover b Starboard side cover c Port side cover When it is necessary to remove the drive cover see Drive Cover Drive Cover 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 c
102. nsmission fluid into a suitable container 28237 a Drain plug and sealing washer b Transmission 4 On models with a drop box remove the M16 x 1 5 drain plug and sealing washer from the lower port side of the drop box and drain the transmission fluid into a suitable container a Drain plug and sealing washer b Drop box 5 Dispose of the fluid properly 6 Clean the exterior of the transmission around the fluid filter assembly 7 Use a 6 mm Allen wrench and remove the fluid filter assembly screw pic my VO n s i 28239 a Fluid filter assembly b Assembly screw Page 84 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance 8 Remove the filter cover assembly 9 Remove and discard the filter element and the O rings aa Oh 01 28242 a Assembly screw f O ring b Washer g Filter element c Cover h Seal d Filter cover assembly i Oil pipe e O ring 10 Coat the new O rings with transmission fluid 11 Install the new O rings and filter element NOTICE Improper installation of the transmission fluid filter assembly may cause the fluid to foam or leak out resulting in decreased efficiency and damage to the transmission Properly seat the transmission fluid filter during installation 12 Install the fluid filter assembly in the transmission cavity by turning the assembly clockwise during installation 13 Using a 6 mm Allen wrench tighten the filter assembl
103. nt 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 Five years or 500 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 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 and Canada this warranty gives you spe
104. ntions _ 3 The screen of the mode you are in is displayed as well as the response popup 1 dedicated to that mode on the VesselView for 3 seconds once the button is pressed The screen needs to be turned on in VesselView calibration See Mode Display in VesselView CHANGING VESSELVIEW MODE DISPLAY TIMES All modes Auto Heading Track Waypoint and Skyhook display a screen on VesselView for three seconds by default The length of time that a screen is visible in VesselView can be changed from no display at all display up to 10 seconds or display the screen until changed To change the display time Open VesselView Select Setting Select Screen Options Select the mode you want to change Select the time option Press x to exit O01 ONS End of First Season Checkup Page 58 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 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water Contingent Operations Backup Steering System If the electronic steering wheel ceases to operate the control system automatically monitors the joystick for steering commands
105. o metal contact Alternator drive belt loose or in poor condition Replace or adjust belt Unacceptable battery condition Test battery Battery charge switch off Turn the battery charge switch on CMD 4082031 90 866938070 AUGUST 2007 Page 109 Section 7 Troubleshootin Possible Cause Check the condition of the connections cables and Shore power not on shore power supply Repair or replace as necessary Gauges and Instrumentation Key off and key on Gauges not working Contact your Authorized Cummins MerCruiser Diesel Repair Facility Page 110 CMD 4082031 90 866938070 AUGUST 2007 Section 8 Customer Assistance Information Section 8 Customer Assistance Information Table of Contents Owner Service Assistance 112 Local Repair Service ccecceeeeseeeee 112 Service Away From Home ossee 112 Stolen Power Package 2 ccee 112 Attention Required After Submersion 112 Replacement Service Parts 00 112 Parts and Accessories Inquiries 113 Resolving a Problem sses 113 Customer Service Literature cere 113 English Language ss 2cc2c ccredtertcanondtentosuccaes 113 Other Languages 114 Andre SOO sbssoestdan edicartec ers scieeeiaeatis 114 Andere talen ccccccccceeeeeeeeeeeeeeeaeeeeeeeaeaees 114 CMD 4082031 90 866938070 AUGUST 2007 Muut kielet cecceeeeeeeeeeeeeeeeeeeeeeeeees 114 A
106. odging 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 Limitations During Both the Base Engine and Drive System and the Extended Major Components Limited Warranties 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 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 perfo
107. ol before attempting to start again 8 ek on savour con J i e z D 4 z 27719 h Starboard VIP shown a Red manual STOP switch b Green manual START switch STOPPING THE ENGINES MANUAL OVERRIDE Under certain circumstances the engine control systems may not be able to automatically stop an engine If this is the case stop the engines with the manual override switch in the engine room 1 Move the ERC handles to the neutral position 2 Locate the Vessel Interface Panel VIP for each engine in the engine room 3 When the engines are running press and hold the respective red STOP button until the desired engine comes to a complete stop 3 27719 re Starboard VIP shown port similar a Red manual STOP switch b Green manual START switch 4 Turn the key switch to the OFF position for each engine stopped 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 Page 30 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water NOTE During slo
108. on 5 Maintenance 2 Turn the rear propeller nut counter clockwise to remove the nut 24037 a Block of wood b Trim tab 3 Slide the propeller and thrust hub off of the propeller shaft 4 Using the propeller nut tool turn the front propeller nut counter clockwise and remove the nut a Block of wood b Trim tab c Propeller nut tool Propeller Nut Tool 91 805457T 1 Aids in the removal and installation of the front propeller nut Page 96 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance 5 Slide the front propeller and the front thrust hub off the propeller shaft a Front thrust hub b Front propeller c Front propeller nut Propeller Repair Some damaged propellers can be repaired Contact your Cummins MerCruiser Diesel Authorized Repair Facility Propeller Installation Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting 1 Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants NOTE Anti corrosion grease Is for saltwater applications only oo Special Lubricant 101 Propeller shaft splines 92 92 802865002 95 Co la bubsicant with Propeller shaft splines 92 802859A1 Anti Corrosion Grease Propeller shaft splines 92 802867
109. over 1 Remove the three upper screws port and starboard holding the side cover to the top cover CMD 4082031 90 866938070 AUGUST 2007 Page 67 Section 5 Maintenance Remove the two lower screws holding the port side cover to the center section aa eg Remove the one lower screw holding the starboard side cover to the center section Remove the two side covers Remove the two top screws Lift and remove the top of the drive cover Typical drive cover a Upper screw 6 b Lower screw 4 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 2 Clean and wax the cover assembly often using marine cleaners and waxes Inspect the individual cover parts for cracks or damage replace if cracked or damaged Installing the Drive Cover 1 2 Remove and retain the two lifting rings if installed Carefully install the top of the drive cover Align the top with the two threaded holes in the transmission where lifting rings were removed Install the two upper screws Install the starboard side cover and the three upper screws and one lower screw Install the port side cover and the three upper and two lower screws CMD 4082031 90 866938070 AUGUST 2007 Page 68 Section 5 Maintenance 6 Tighten all screws securely Typical drive cover a Upper screw port shown b Lower screw port shown c Port side cover d
110. peed 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 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 high current draw turn off or disconnect all the accessories connected to the engine and instrumentation wiring Reset the circuit breaker If the breaker remains open the electrical overload has not been eliminated Contact your Cummins MerCruiser Diesel Authorized Repair Facility to check the electrical system Circuit breakers and fuses provide protection for the electrical system as indicated The circuit breakers are located in various locations throughout the boat Have your dealer show you the location an
111. ponsible 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 CMD 4082031 90 866938070 AUGUST 2007 Section 1 Limited Warranty 3 Acopy 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
112. re each cable clamp when connecting Coat terminals with a battery terminal anti corrosion spray to help retard corrosion NOTICE Failure to provide sufficient cooling water will damage the water pump and cause the engine to overheat Provide a sufficient supply of water at the water inlets during operation Open the seacocks If the boat is not in the water supply cooling water to the water inlet openings Start the engine and closely observe the instrumentation and system view panel Ensure that all systems are functioning correctly CMD 4082031 90 866938070 AUGUST 2007 Page 103 Section 6 Storage 5 Refer to the Marine Recreational High Output Propulsion Units QSB or QSC Operation and Maintenance Manual available from the engine manufacturer and carefully inspect the engine for fuel oil fluid water and exhaust leaks 6 Carefully inspect the drive for lubricant fluid water and exhaust leaks 7 Check the steering system the ERC shift control and throttle control and the joystick for proper operation 8 Check all lubricant and fluid levels after first use Page 104 CMD 4082031 90 866938070 AUGUST 2007 Section 7 Troubleshooting Section 7 Troubleshooting Table of Contents Diagnosing Electronically Controlled Fuel System JOYSTICK eee eeecceeeeeeeeeeeeeeeeeeeeeeenneeeeeeeeeeees 107 Problems ccccccccccccceeccecceeceeeeceeeeeeeeeeeeeeeess 106 Electronic Remote Controls
113. rized Cummins MerCruiser Diesel Repair Facility Check steering actuator fluid level and fill if necessary See Section 5 Maintenance Automatic trim tabs working but erratic Contact your Authorized Cummins MerCruiser Diesel Repair Facility Boat Response Changes Check that both engines are on and functioning properly Restart stopped engine Boat response sluggish Check VesselView for fault codes Check fuel quality Check and drain the water separating fuel filter Shut down engines and check for damage in the engine room Check in the engine room or under the boat for damage to the drives Return to dock at reduced speed Contact your Authorized Cummins MerCruiser Diesel Repair Facility if impact damage is found or suspected Boat vibrates or is slow to respond following a noise or impact Shut down engines Turn off and remove keys Check propellers for damage If damaged return to your Cummins MerCruiser Diesel Authorized Repair Facility for repair or replacement Battery Will Not Charge Turn off non essential accessories like the air Excessive current draw from battery conditioning and hot water heater Check all associated electrical connections and wires especially battery cables Clean and tighten faulty Loose or dirty electrical connections or damaged connections Repair or replace damaged wiring wiring j Ensure area around the ground connections is clean and making good metal t
114. rmed 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 downt
115. rous special parts Exercise care when replacing marine engine parts as specifications are quite different from those of the standard automotive engine Since marine engines must be capable of running at or near maximum RPM much of the time special pistons camshafts and other heavy duty moving parts are required for long life and peak performance These are but a few of the many special modifications that are required in Cummins MerCruiser Diesel marine engines to provide long life and dependable performance CMD 4082031 90 866938070 AUGUST 2007 Section 8 Customer Assistance Information Parts and Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accessories should be directed to your local authorized dealer The dealer has the necessary information to order parts and accessories for you if he does not have them in stock Only authorized dealers can purchase genuine Quicksilver parts and accessories from the factory Cummins MerCruiser Diesel does not sell to unauthorized dealers or retail customers When inquiring on parts and accessories the dealer requires the engine model and serial numbers to order the correct parts Resolving a Problem Satisfaction with your Cummins MerCruiser Diesel product is very important to your dealer and to us If you ever have a problem question or concern about your power package contact your Cummins MerCruiser Diesel Authorized Repair Facility If additional assistan
116. rs 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 e 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 e 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 CMD 4082031 90 866938070 AUGUST 2007 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 Inspection Inspect your power package often and at regular intervals to help maintain top operating performance and correct potential problems before they occur Check the entire power package carefully including all accessible e
117. rts Approved Paints Approved Lubricants Tube Ref No Where Used o Gimbal Bearing Driveshaft slip joint 92 802870A1 Tube Ref No Where Used Engine Coupler Spline Grease Driveshaft slip joint 92 802869A1 Page 62 CMD 4082031 90 866938070 AUGUST 2007 Section 4 Specifications H 94 Dp Anti Corrosion Grease Seacock and propeller shafts 92 802867Q 1 CMD 4082031 90 866938070 AUGUST 2007 Page 63 Section 4 Specifications Notes Page 64 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance Section 5 Maintenance Table of Contents Product Responsibilities c ccccccsseeeeeeees 66 Owner and Operator Responsibilities 66 Dealer Responsibilities ccccceceeeceeees 66 Do It Yourself Maintenance Suggestions 66 Tas 0 te1 0 ee 67 Drive COVED cccccccecccececeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess 67 Removing the Drive Covel eeeeeeeeee 67 Cleaning and Inspecting the Drive Cover 68 Installing the Drive Covet eee 68 Maintenance Schedules seeeeeeeeeeeeee 69 ADP PIICALION s csccsdscescccvas goss sdenesnenevawenssweneaseewesves 69 Routine Maintenance eceeeeeeeeeeee 69 Scheduled Maintenance 69 Maintenance LOQ 22 c cceesesscscccseetereeeese 70 Drive Gear LUDEG 0 cceeeeeeeeeeeeeeeeeeeeeeeees 72 ChHeCkiNgiis sn ornon Adee ieee e aR 72 LLTO r E E E
118. s A E E E 15 OpSatlOM carni ai 15 Basic Joystick Operation seeeeeeeeeeeeeeeee 17 Electrical System Overload Protection 17 Vessel Interface Panel VIP Overload Protection ccccceceeeeeceeeeeeeeeeeeeeeeeeeees 18 Overload Protection for Other Circuits ee E 18 Zeus Drive Alignment 18 Page 11 Section 2 Getting to Know Your Power Package General Information Models Covered Models Covered Engine Model and Serial Number Or Year eae 9 355 Intermittent Zeus 3500 QSB5 9 380 sesso so __ Information not available at time of printing QSB5 9 425 SEG QSB5 9 480 QSB5 9 480 HO Zeus 3800 QSC8 3 550 HO Information not available at time of printing 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 operation and maintenance manual available from the engine manufacturer for the location of the engine data tag that contains the engine serial number and model number Features and Controls Emergency Stop E Stop Switch The emergency stop E stop switch turns off the engines in an emergency situation such as a person overboard or tangled propeller When activated the E stop switch interrupts the power supply to the main power relay including power to the gauges
119. sed 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 Di
120. solenoid screw in the center of the top of the forward gear solenoid clockwise until it stops 6 The transmission is now manually engaged in the gear and will not respond to the helm controls for shifting in and out of that gear 28404 a Forward gear solenoid b Solenoid screw 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 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 a
121. storage in cold weather 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 NOTE As a precaution attach a tag to the key switch or steering wheel of the boat to remind the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine The power package must be protected from freeze damage corrosion damage or both types of damage during storage Storage is any length of time the product is not operated Based on the length of storage certain precautions and procedures must be observed to protect the power package Freeze damage can happen when water trapped in the seawater cooling system freezes For example after operating the boat exposure to freezing temperatures for even a brief period of time could result in freeze damage Corrosion damage is the result of saltwater polluted water or water with a high mineral content trapped in the seawater cooling system Saltwater should not stay in an engine s cooling system for even a brief storage time drain and flush the seawater cooling system after each outing Freezing weather freezing temperature operation refers to operating the boat whenever freezing temperatures are possible Likewise freezing weather storage refers to whenever the boat is not being operated and
122. t cccccececcceeeeeteeeeteeeeeeeeees 26 Cavitation c cccceeeeceeeeeeeeseeneeeeeeeeeeeeaaeeees 26 Ventilation ccccccccecceceeeeceeeeeeeeeeeeeeeaeeeaeaaes 26 Propeller Selection cccceeeeeeeeeeeeeeeeeees 26 Getting ease ctivnscedecacs tec eceetaadiaiateereaceessauiaschees 27 Break In Period New or With Replacement ON 22 tee aoada fe das dase Aa eaa S 27 CMD 4082031 90 866938070 AUGUST 2007 Starting and Stopping the Engines 27 Normal Starting eener 27 Normal Stopping cccccccseeeeeeeeeeeeeeeees 28 Starting the Engines Manual Override 28 Stopping the Engines Manual Override 30 Traditional Maneuvering with Steering and MATT ec eect ctrer teers os cninae ateceete empire enntectememeceanes 30 To Maneuver the Boat in Forward 31 To Steer the Boat in Tight Turns at Low Sped eiir depi EE EER 31 To Spin the Boat on its Axis at Low Speeds 31 Maneuvering with the Joystick 08 31 Trim Tab OVE GG sicvceiciacccetccancretcnacexenccatmeatend 35 Manual Adjustment 35 Trim Tab Override Use 36 Getting ON Plane 36 Smoothing the Ride eee eee eee 36 Correcting a lic Hane eer enter ener renee eer emereeenen 36 LOW Speed THi cccceececeeeeeseeeeeeeeeeeeeeeaes 36 Page i Special Digital Throttle and Shift DTS FO tureS c ceeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeaeneaeaees 37 Troll and Throttle Response
123. t from corrosion Maintenance Log Record all maintenance performed on your power package here Be sure to save all work orders and receipts Page 70 CMD 4082031 90 866938070 AUGUST 2007 Section 5 Maintenance Maintenance Performed CMD 4082031 90 866938070 AUGUST 2007 Page 71 Section 5 Maintenance Drive Gear Lube NOTICE 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 Checking IMPORTANT The gear lube level in the gear lube monitor rises and falls during drive operation Check the gear lube level when the drive is cool and the engine is off 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 To check the drive gear lube with the drive cover installed 1 Remove the access cover from the drive cover 2 Remove the cap from the gear lube monitor a Access cover b Cap c Gear lube monitor 3 Inspect the gear lube level in the gear lube monitor The gear lube level should be at the COLD FILL LEVEL cold full line WAX OPERATING LEVEL 27837 Shown with drive cover removed a Cap b COLD FILL L
124. ted Warranty Coverage 3 Warranty Registration United States and Zeus Drive Limited Warranty Against Corrosion CCANIAG Aeiciaisnicntecccntcunarseanarctenteanansaeacntneataerainuatace 2 WV OF AWG ciccaccivaisecancranarnaanicantnnarcentieeeteniadenase 7 Warranty Registration Outside the United Emission Warranty sis icccicccsivesesccssistdettacensenets 8 States and Camada c cccceeeseeeeeees 2 Transfer Of Warranty 8 CMD 4082031 90 866938070 AUGUST 2007 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 dealers 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
125. thods e Press the SKYHOOK button on the Precision Pilot keypad e Move any lever out of neutral CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water e Operate the boat with the joystick NOTE In each of the methods the light on the SKYHOOK button turns off TURN BUTTONS While in AUTO HEADING mode these buttons respectively change the set heading by a default of 10 While in the HEADING mode tapping the joystick left or right also adjusts your course by 1 per 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 O PRECISION PILOT O STANDBY SS ACTIVE SKYHOOK i i que TURN gt CDS RESUME ATONE Sml e Nee UTO RACK HEADING RESPONSE WAYPOINT 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 The joystick must move over 50 of its travel for the movement to be recognized as input Each recognized movement adjusts the chosen heading by 1 24707 Adjusting heading to starboard CMD 4082031 90 866938070 AUGUST 2007 Page 47 Section 3 On The Water AUTO HEADING O PRECISION PILOT O STANDBY ACTIVE SKYHOOK i C TURN gt EDR WAYPOINT RESUME SEQUENCE oo ihoeT Cc AUTO TRACK HEADING RESPONSE WAYPOINT 27700 a TURN buttons b RESUME but
126. tion essential to the successful completion of the task NOTE Indicates information that helps in the understanding of a particular step or action 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 The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm TABLE OF CONTENTS Section 1 Limited Warranty Warranty Information 2 Warranty Registration United States and Gis 12 9 f EEE Phe fener erry T 2 Warranty Registration Outside the United States and Canada 2 Limited Warranty Coverage 3 Zeus Drive Limited Warranty Against Corrosion WV OMG WING x desecccaveiesuzssaseedaisisatscceeenetwenteieaedts 7 Emission Warranty 8 Transfer Of Warranty 8 Section 2 Getting to Know Your Power Package General Information 12 Models Covered cccccecccecssesseeceuecsueseueeeuaes 12 Drive Serial Number and Decal Placement 12 Features and Controls ccccccsececeseeteeeneeeaes 12 Emergency Stop E Stop Switch 0 12 Instrumentation 13 VeSSEIVICW L 0 ccecccceccceeccsueceeu
127. 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 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water e Ensure that everyone in the boat is properly seated Do not allow anyone to sit or 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 unexpe
128. ton c AUTO HEADING button 1 At least one engine must be running for Auto Heading to function 2 Press the AUTO HEADING button to engage Precision Pilot The button illuminates and a single beep sounds A double beep sounds if Auto Heading does not engage Precision Pilot holds the compass heading the boat following when the AUTO HEADING button is engaged 3 2 H raeea 1 45 PM AUTOPILOT 31409 3 To make adjustments in the default heading while the AUTO HEADING is active and the button light is on press the respective TURN button on the trackpad or tap quickly move the joystick 4 To make a turn e Press one of the TURN buttons in the direction you want the turn Tap the joystick in the direction you want the turn Tapping the joystick left or right adjusts your course by 1 for each movement Page 48 CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water 5 Turn the wheel or press the AUTO HEADING button to disengage the Auto Heading and a single beep sounds If the steering wheel is used to disengage Auto Heading the resume button LED turns on and a single beep sounds While the LED is lit you can press the RESUME button to resume the course in Auto Heading 6 Ifthe ERC Handles are moved to neutral Auto Heading turns off a single beep sounds and the STANDBY light turns on You are not able to resume your course by pressing the RESUME button 8 2M Fo AUTOPILOT 31408 a
129. ual Anodes and MerCathode System Locations Trim tab anode Mounted on the trim tab plate The MerCathode reference electrode and anode are mounted to the composite MerCathode_ cover on the underside of the drive The System MerCathode controller is mounted on the transmission The controller harness connects the components Other sacrificial anodes if equipped may be mounted on the vessel to protect against galvanic corrosion Refer to the operation and maintenance manual provided by the boat manufacturer for additional information about vessel mounted anodes Anode kit if Mounted to the boat transom equipped Reference Electrode Wire of the MerCathode System NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion Do not use any cleaning equipment such as brushes or high pressure washers to clean the MerCathode assembly CMD 4082031 90 866938070 AUGUST 2007 Page 91 Section 5 Maintenance Do not pressure wash the reference electrode of the MerCathode assembly Doing so damages the coating on the reference electrode wire and decrease the corrosion protection a Anode b Reference electrode not visible in this view MerCathode Anode CHECKING 1 Inspect the MerCathode anode and replace the anode if damaged a Anode REPLACING Contact your Cummins MerCruiser Diesel Authorized Repair Facility MerCathode System Testing If the boat is equipped with
130. urce for the various functions of your boat Consult the VesselView display if you suspect something is wrong VesselView displays faults and other information that can be helpful in determining the current status of various systems that could be causing your concern and the solution to the problem CMD 4082031 90 866938070 AUGUST 2007 Section 7 Troubleshooting Poor Performance Check that the Cruise Control is disengaged Throttle not operating properly Turn off Troll or Dock functions on DTS control pad Refer to Special DTS Functionality Damaged or imbr per propell r Replace the propeller See an Authorized Cummins 9 PORSE prop MerCruiser Diesel a Facility Excessive Excessive bilge water e water Drain and check for the cause of Drain and check for the cause of entry Boat overloaded or load improperly distributed Reduce the load or redistribute the load more evenly Boat bottom fouled or O Clean or eor as necessary Tabs locked in the down Tabs locked in the down position Unlock the automatic tab override switch the automatic tab override switch Poor quality of fuel Use a cetane booster as recommended by your Authorized q y Cummins MerCruiser Diesel Repair Facility Run out fuel and fill with fresh fuel The fuel filter may need Water in the fuel F to be drained or changed several times during this process Enaine ar el ctronie fuel svsiam fault Have the engine or electronic fuel system checked by
131. ut automatically disengages if the GPS outage persists If disengagement occurs a horn sounds and the light on the Precision Pilot keypad SKYHOOK button turns off The Skyhook electronic anchor performance is largely dictated by the performance of the onboard GPS 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 We do not recommend Skyhook for close quarter or docking operations CMD 4082031 90 866938070 AUGUST 2007 Section 3 On The Water SKYHOOK SCREEN NOTES SKYHOOK 27716 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 e In Skyhook mode the ON light illuminates a single beep sounds and the display shows engine speed a target with cross hairs and a boat icon e The rotation angle of the boat shows the yaw error Zero yaw error shows the boat pointing upward Positive yaw error causes the boat to rotate counter clockwise Negative yaw error causes the boat to rotate clockwise e The horizontal and vertical displacement of the vessel from the cross hairs is proport
132. ut handles One ERC lever is moved but both engines respond in neutral and push 1 LEVER button to disengage if light is on ERC control joystick and steering wheel do not Restore helm control Press HELM on DTS track pad function Multiple helm boats only Steering System Starboard key switch tuned off Turn on key Steering wheel operates without resistance but Check and start starboard engine steers boat Starboard harness circuit breaker tripped Reset circuit breaker Change to joystick for directional control Check steering actuator fluid level and fill if necessary Steering wheel does not steer the boat See Section 5 Maintenance Contact your Authorized Cummins MerCruiser Diesel Repair Facility Key off and key on Check and start port engine Check trim tab function Steering works but boat is not as responsive Check steering actuator fluid level and fill if necessary See Section 5 Maintenance Contact your Authorized Cummins MerCruiser Diesel Repair Facility Page 108 CMD 4082031 90 866938070 AUGUST 2007 Section 7 Troubleshooting Key off and key on to restore steering wheel Steering wheel turned past end stop self centering cruise control and to eliminate fault code Trim Tabs Symptom Turn off the trim tab override switch Check steering actuator fluid level and fill if necessary Automatic trim tabs not working See Section 5 Maintenance Contact your Autho
133. utres langues ceccceeeeeeeeeeeeeeeesceeeeeees 114 Andere Sprachen cceeeeeeeeeeeeeeeeeeee 114 Altre lINgUe irna 114 Andre spr k cccecceeeeeeeeseteeeeeeeeeeeeeeeeeeeea 114 Outros Idiomas ssneneeeeeeneeeeeee enerne nnee 114 Otros idiomas cceeceeeeeseeeeeteeteteeeeeeeees 115 Andra Spr k sessie ne ce ne ee 115 Allej gl ssej ccccrehretiivinciuntiesndieswemtaedeeacteueed 115 Ordering Literature ccccccscscccsteceeeeeeseseceneee 115 United States and Canada eee 115 Outside The United States and Canada 115 Page 111 Section 8 Customer Assistance Information Owner Service Assistance Local Repair Service Always return your Cummins MerCruiser Diesel CMD powered boat to your authorized dealer distributor should the need for service arise Only the dealer distributor has the factory trained mechanics knowledge special tools and equipment and the genuine Cummins Mercury Marine parts and accessories to properly service your engine and drive should the need occur They know your engine and drive best Contact 1 800 DIESELS to locate your closest distributor Service Away From Home If you are away from your local dealer and the need arises for service contact the nearest Cummins MerCruiser Diesel Authorized Repair Facility Refer to the Yellow Pages of the telephone directory or by using the service locator on the Cummins MerCruiser Diesel website www cmdmarine
134. w 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 e To turn the boat in tight turns at low speeds turn the wheel in the direction of the turn e To increase the turn rate of the boat after the wheel is completely turned you may increase the power to the inside drive TO SPIN THE BOAT ON ITS AXIS AT LOW SPEEDS e Tospin to the right place the starboard engine in reverse and the port engine in forward e Tospin to the left place the port engine in reverse and the starboard engine in forward e To increase the rate of turn simultaneously adjust each ERC lever for more throttle Maneuvering with the Joystick The joystick provides an intuitive driver 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 computer control system to automatically calculate the steering angle of each drive the throttle level and the proper shift and clutch slip percentage to push or rotate the boat in a direction corresponding to the joystick movement or twist For example if you move the joystick sideways the computer
135. with a clean lint free cloth 4 Insert the dipstick resting it on the top of the threaded hole 5 Remove the dipstick and check the fluid level indicated The fluid level should be between the maximum and minimum marks on the dipstick NOTE Fluid from the transmission fluid cooler and hoses may drain into the transmission causing a fluid level slightly above the maximum mark a3 Nig J 28080 Checking dipstick rested on top of threaded hole a Maximum mark b Minimum mark c Top of threaded hole d Dipstick 6 If the level is correct install the dipstick CMD 4082031 90 866938070 AUGUST 2007 Page 81 Section 5 Maintenance Filling Page 82 7 If the fluid level is low add the specified transmission fluid through the dipstick threaded hole to bring the level up to the maximum mark on the dipstick Fluid Type Fluid Part Number Transmission and drop box eee 92 858077K01 NOTE If the transmission fluid level is extremely low see your local Cummins MerCruiser Diesel Authorized Repair Facility IMPORTANT For a more accurate measurement operate the engine at 1500 RPM for three minutes immediately before checking the fluid level 8 9 10 11 12 13 Start the engine and operate at 1500 RPM for three minutes to fill all the hydraulic circuits Stop the engine and quickly check the fluid level If the fluid level is low add the specified transmission fluid to bring the level up to th
136. y If this information is not available observe the following An operating or charging battery produces gas that can ignite and explode spraying out sulfuric acid which can cause severe burns Ventilate the area around the battery and wear protective equipment when handling or servicing batteries Recharging a weak battery in the boat or using jumper cables and a booster battery to start the engine can cause serious injury or product damage from fire or explosion Remove the battery from the boat and recharge in a ventilated area away from sparks or flames Checking Gauges 1 Check that all gauges are securely mounted 2 Check that any viewing systems such as VesselView if equipped are securely mounted 3 Check for loose damaged or corroded wiring and connectors 4 Contact your Cummins MerCruiser Diesel Authorized Repair Facility for correction or repair if necessary Cleaning Gauges Clean gauge by washing with fresh water to remove sand and salt deposits Wipe off with a soft cloth moistened with water The gauge may be scored or damaged if wiped with abrasive material sand saline or detergent compounds etc or washed with solvents such as trichlorethylene turpentine etc Electrical System 1 Check for loose damaged or corroded fasteners 2 Check for loose damaged or corroded wiring and connectors Cooling System and Exhaust System 1 Inspect the cooling and exhaust systems for damage or leaks 2
137. y screw to specification i p i b 4 fe 4 a Assembly screw b Fluid filter assembly penn OOOO S dT Emer essemoy sn s IMPORTANT Use new sealing washers to avoid leaks CMD 4082031 90 866938070 AUGUST 2007 Page 85 Section 5 Maintenance 14 On models with a drop box install the drop box drain plug with a new sealing washer Tighten the drop box drain plug to specification Soa k i ree oF i q a df tiy a Drain plug and sealing washer b Drop box Proposar o o f a j oS 15 Install the transmission drain plug with a new sealing washer Tighten the transmission drain plug to specification a Drain plug and sealing washer b Transmission Description Tm i on f t Transmission drain ptg o NOTE The drop box fills with fluid when the transmission is filled 16 Fill the transmission to the proper level with the specified fluid See Filling 17 Install the drive cover See Installing the Drive Cover 28237 Seawater Strainer Refer to the appropriate Cummins Operation and Maintenance Manual Marine Engine for seawater strainer maintenance instructions Page 86 CMD 4082031 90 866938070 AUGUST 2007 Battery Gauges Section 5 Maintenance All lead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below battery manufacturer s specifications Refer to specific instructions and warnings accompanying your batter
138. 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 Limited Warranty Coverage Engines and Drive Systems Included in this Coverage Marine Propulsion Zeus 3500 Zeus 3800 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 available 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

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