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Zeus 3000 Series Pod Drive Models

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1. Customer Before Starting Key Off eater Check heat nem Marval Code or Record abe Teed on Font pages do n of al required support publications present Visus pectin Dive segs and popelers are installed Visual rspacion Engine mount isolator mounting are BO Visus nspacton Dives and shields mount screws EGE Visual rspacion n A fuel conection are tit Visus nspacton n Raw water seawater system Pose camps are Visual rspacion EX Visual irspecion n connections secure Visus epson n Coolant recovery bolle and expansion 058 OM Selon n Engine siens check 058 OM Secion V Sheng and im udi Chee Seaton Transmission fui evei check ZOM Sesion 5 n Dive gear ube level chock ZOM Seaton n Seacocks open see Staring and Stopping he Engines ZOM Sesion 3 Before Starting Key On Dealer Check Checkist lam Ll a Ra Rar Sip aay oF Wit Seaton n Check tne Vessel or au cades Wi Section amp Neural gis on the ERC lever assembly ZOM Sesion 3 Page 130 178110070803 OCTOBER 2012 Section 9 Predelvery Information Engines Running at the Dock Manual Code or Dealer Check Checklist nem Key switch andlor starlslep buttons operational check ZOM Seaton 3 Check seawater fion visual check al bypass port Visual inspection
2. wy OCTOBER 2012 Page 1 Section 1 Warranty Warranty Information Warranty Registration United States and Canada 1 To be elige for waranty coverage the product mus be registered wih Mercury Marina At the time of sale the dealer should completa tha warranty registration and immediately submit to Mercury Marine via MercNET E mail or Upon receipt of this waranty registration Mercury Marine record tha registration 2 Warranty coverage is not effective unt your product is registered with Mercury Marine 3 You may change your address at any time including al time of warranty claim by caling Mercury Marine or sending a letar or fax with your name oid address new address and engine serial number to Mercury Marine s Warranty Registration Deparment Your dealer can also process this change of information Mercury Marine Ain Warranty Registration Deparment NG2SO W Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 920 5054 Fax 1 220007 6663 NOTE Registration lists must be maintained by Mercury Marine and any dealer on marine products soki in the United States shouid a sate recall notification under the Federal Safely Ac Do required Warranty Registration Outside the United States and Canada 1 Mis important hat your sling dealer fils the warranty registration card completely and mails o the distributor or Marine Power Service Center responsible for administering
3. shown from light gray to dark gray Boat moves diagonal forward and la the port without rotating Boat rotates clockwise MM gt Boat moves diagonally forward and to the e wy OCTOBER 2012 Page 30 Section 3 On the Water Movement Midas PEA shown fom ight ray o dark gray Boat mores agonal forward and to he 2 starboard wh rotating counterclockwise E Boat moves daganahy forward and tothe Port wile ring counterclockwise y Boat moves to the wie rotating pen Trim Tabs Automatic Control The Zeus drive comes equipped with an automatic tim tab control feature that operates through the vessel control system to provide basie performance and efficiency improvements under normal conditions The automatic tim tab control feature can be engaged tumed on or disengaged turned off To engage the feature press the AUTO trm tab bution ance The tim tabs wil mutomatialy adjust as the speed of Ins boat is changed Pressing i again wil disengage the feature With the automatic tim tab control feature engaged the port and starboard tim tab switches can be used to adjust the tabs offset for natural conditons that affect the atttude of the boat This setting of the trm tab offset continues unti the automatic control feature disengaged and engaged again or when the key switch is cycled umed and on
4. Excessive bige water Drain and check for he cause of erty Boat overloaded or load improperly Rocca the load or redistribute the load mo ny Boat botom fouled or damaged Clean ar repair as necessary Tabs locked in the down postion Unlock the automatic tab verde Swich Poor quality of fue Use celane booster as recommended by a Mercury Dias authorized repair facil TETTE Run cut fuel and with fresh fuel The fuel tar may need to drained or changed several imes during this process Engine or ecrane fuel system Have he engine or electronic fuel system checked by a Mercury Diesel authored fut repair faci Page 120 BOEMOO7OGES OCTOBER 2012 Section 7 Troubleshooting Symptom Remedy Guardian faut code set Check Vessel View for Guardan fault cades hat cause engine power redaction i found have the system checked by a Mercury Diesel authorized repas Joystick Symptom Remedy Joystick does not control boat ah coni levers are notin neural Put Ihe renale conti levers in neutral One oF bath engines ara nek ng Star engine ar enge Response to joystick inputs are eati or ys operates independent of input Ensure hers are no radios ar oiher sources of electronic or magnate interference near he joystick Joystick does not function properly and a fault code Check VesselView for Gua
5. tim tab nade 3 Clean the tim tab anode mounting suceso bare melal Apply adhesive to he rends of the fve iim tab anode seras Tuba RefNo Descipion Were Used Tas Ex Loctite 271 Threadtocker Trim tab anode screw 32809819 7 Instal the anodes the im tab Tighten the screws lo spacicalin a Port anode b Starboard anode Screws 5 Description m en br Trim tab anode screw ME x 20 mm lena 27 E EJ UBOSHODTOSSS wy OCTOBER 2012 Page 108 Section 5 Maintenance Continuity Circuits NOTE Refert the operation and maintenance manual provided by the boat manufacturer for maintenance information about Vessel mounted anodes and related contu Tho drive system is equipped with ground cci wires to ensure good electrical continuity between the drive components Good continuity lo a ground is essentia 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 MarCalhode controler and wires for loose connections broken connectors or frayed wiring Anode vire b Battery postive terminal wire MerCathode controler d Roference electrode wire Blackireen continuity wire to bonding stud Battery negative terminal wire 3 Inspect the bonding stud nut and continuity wire on the centar section for corrosion loose connections broken c
6. Pags 40 18010070883 OCTOBER 2012 Section 3 On the Water Manual rim tab control is available to alow tim tab adjustment when not using the Manual Control tomate tim tab control feature See Typical automatic and manual vim tab switches NOTE The port or starboard manual trim tab rocker switches alow some control of the attitude of the vessel As an example lo achieve a port bow down you may press the port bow down rocker switch to deploy the tab on the starboard drive and provide the requested vessel adjustment Manual Control To manually control or adjust the offset of the trim tabs for your conditions use the individual port or starboard tim tab switches as needed Manually adjusted trim tabs will stay in the positon set by the operator un the key switch is cycled off and on ar ihe AUTO button is pressed I ihe AUTO bution is pressed ihe automatic tim tab control feature is engaged and the im tabs move to a position based on boat speed See Automatic Control NOTE When controlled manualy fe tim tabs do not move during acceleration unless the operator presses the tim tab buttons Using Trim Tab Offset Automatic or manual control of tim tab offset could be beneficial in the following conditions During inal accelerator tha Vim labs are automaticaly adjusted automate contro or must be manualy adjusted manual control to bring the boat on plan faster bow down to improve for
7. Press down evenly on the front of he final postion icess cover Aclck sound can be heard when the access cover snaps into Completing the access cover instalation Filling ifthe gear lube level is below the COLD FILL LEVEL ine add the specified gear lube 1 Remove the cap from the gear ube manitor NOTE Premium Gear Lubricant used during the breakin period is brown in color and must be changed after the 25 hour breakin The color af High Performance Gear Lube used aer breakin is blue DO not mx the gear lubricants 2 Fil the gear lube monitor with the specified gear lube so that the gear ube is level wth the COLD FILL LEVEL e cole full ine Do not over COLD FILL LEVEL ine col fut ino Description Where Used Beer housing and gear ube dring Ersan he Wal y to 25 hours but not to exceed 30 hours of operation 285005801 O peana rs 25 30 hours af operation 3 Ensure hal the rubber gasket is nade the cap for the gear ube monitor and instal the cap Do not over Pags 82 18110070803 OCTOBER 2012 Section 5 Maintenance NOTE After the drive has been operated and the gear lube is hot the fuid expands and may ba up tothe MAX OPERATING LEVEL ine hot ful line MAX OPERATING LEVEL line hot ful Ino Changing Gear Drive Lubricant NOTE Change the dive gear lubricant when the rive is at operating temperatur
8. side cover Saw 8 b Port cover d Information decal 7 Tighten the tree ower and six upper cover screws to specication Desoriplon bin 2 Gover upper sereus 10 Gaver lower screws 27 21 instal Insert the molded cip on the aft end of he access cover under the indented edge of the cover top b Align the access cover with the opening in the top cover a Access cover b Molded cip indented edge Page 78 178110070803 OCTOBER 2012 Section 5 Maintenance 6 Press dom event the front end ofthe access cover The access cover snaps inta its installed postion Completing the access cover installation Drive Gear Lube Drive Gear Lubrication Discharge of ol coolant other enginaldive ude ito the environment is restricted by law Use caution not o spil coolant or other Nuide into the environment when using or servicing your beat Bo aware of the local restrictions governing the disposal orrecycing of waste and contain and dispose offs as required The dive gear lubrication system includes a translucent whita plastic bote that is used to monitor the level of the driva gear lubricant lube The monitor includes switch that can detect a low level of gear lubricant and set an audio or visual alarm The Checking and Filing procedures as provided are for situations where the gear lurcant level in the monitor is low b
9. OCTOBER 2012 Section 1 Warranty Section 1 Warranty Table of Contents 1 Information Warranty Registaion United Siaas and Canada Warranty Rgisaton Outside the United States and Canada Warranty Policy Diesel Models HIGH OUTPUT RECREATIONAL USE WORLDWIDE LIMITED WARRANTY What is Covered Duration of Coverage Two Year Limited Warranty Limited Warranty Coverage Extended Major Componsnis Limited Warranty igh Outpat Rating Consitons That Must Be Met to Obtain Warranty Coverage What Mercury Marine Wil Do Haw to Obtain Warranty Coverage Terminaten of Coverage What Is Not Covered INTERMITTENT COMMERCIAL USE WORLDWIDE LIMITED WARRANTY Products Included in pus Coverage Duration of Coverage Intermittent Commercial Rating Conditons That Must Met to Obtain Waranty Coverage What Mercury Marina Wil Do How ta Obtain Warranty Coverage Termination of Coverage What is Not Covered Zeus Drive Limited Warranty Against Corrosion hat ls Covered Duration of Coverage Conditons That Must Met to Obtain Waranty Coverage What Mercury Wal Do ta Obtain Warranty Coverage What Not Covered 3 Year Limited Warranty Against Corrosion Diesel Models Recreational Use Only What Covered Duration of Coverage Conditions That Must Met to Obtain Waranty Coverage What Mercury Wal Do ta Obtain Coverage What Not Covered Transfer of Warranty
10. 92 858077 01 SAE 0 30 Transmission With Drop Box and Remote Engine Mounted Transmission Cooler Descr Fus Capac Fa Tipe Fu Part Number Transmission drop bor a eed Sana mount ol cooler Steering Actuator and Trim Oil EXE Fila Capacy Faia Type FG Par und Seeing acusar and gargs L G asa usm Siete Power Siena SESS0076KOT VAL system os SM Rud SAE OwO 2 95807K01 1 L 1 US q0 Approved Paints Pai Number Marne Coad Wile 007 082 Nercuy Ug Gray Pinar 325087652 Mercury Phantom Back Approved Lubricants Tubo Rete Decio Where Used Par po pen Guard Dive exterior surfaces 325087855 peo o Ginbar Beara restan pom 2 1 Grease Propeller shafts Obtain Locally Page 88 18010070883 OCTOBER 2012 Section 5 Maintenance Section 5 Maintenance Table of Contents Product Responsibiies Owner and Operator Responsiiis Dealer Responsibilities Dot Yourself Maintenance Suggestions General inspection af Power Package Drive Service Paint Locations Starboard Port Top Drop Box Maintenance Seeds Applicaton Routine Maintenance Scheduled Maintenance Zeus Pod Sacris Anode inspection Maintenance Log Drive Cover I Equipped Removing the Drive Govar Clearing and Inspecting the Drive Cover Instaling the Drive Gov
11. Aeration or removal of parts Damage ta the product for insuficient cooling watar caused by blockage of the cooling system by a foreign body commended RPM range see the Operation Use ofthe product for racing or ather competite activity even by a previous owner of the product voids the warranty Expenses related to launch towing storage telephone rental inconvenience sip fees insurance coverage loan payments loss of ime oss of income or any other type incidental or consequential damages are not covered by this warranty Also expenses associated with the removal e replacement of boat parlons or other material in order to gain access tothe product are not covered by this waranty No individual ar including Mercury Marine authorized dealers has been given authority by Mercury Marine to make any affirmation representation or warranty regarding the product other than those Contained in his limited warranty If such affirmation representation or warranty s made not enforceable against Mercury Marine Page BOEMOO7OGES OCTOBER 2012 Section 1 Warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED
12. Open capacitor in galvanic isolator Replace galvanic isolator Red ight Two Binks green ght Shorted diode in galvanic isolator Replace galvanic isolator Red ight Three Binks from green lah Open diode in galvanic isolator Replace galvanic isolator Fed ight on Four biinks from green light Open connection between galvanic isolator and monitor Defective galvanic isolator Detective Check wiring Replace galvanic isolator Replace Fed and green light alternately bink Aleralsly open safely wire o shore Open boat wire bonding Check wiring Green ight on Red ight blinks once or twice per second Check for improper AC polarity Check or defective AC device AC fault current is being passed through safety Wira once par second iess than OSMOUOESS my OCTOBER 2012 Page 123 Section 7 Troubleshooting Notes Page 124 178110070883 OCTOBER 2012 Section 8 Customer Assistance Information Section 8 Customer Assistance Information Table of Contents Gamer Service Assistance Local Repair Service Service Away From Home Stolen Power Package Attention Required After Submersion Replacement Service Paris Paris and Accessories Inquiries Resolving Problem 126 125 125 E 126 125 125 125 Contact Information for Mercury Maine Customer Service Customer Service Literature Engish Language Other Languages Or
13. objects or other vessels in close vicinity To maintain steering and course heading closely observe the amount of engine speed used with each throtle handle Tim abs can be adjusted to assist in steering the vessel An operator shouid regular practice steering the vessel in this manner to be familar wih using ther vessels throttles and iim tabs or steering wy OCTOBER 2012 Page Si Section 3 On the Water The joystick can be used as alternative method of steering when operating the vessel in close vicinity of object docks and other vessels Engine RPM is limited with joystick operation Port Engine Only Operation The force feedback feature ofthe steering wheel is only available when the starboard key switch is in the on postion If the starboard key switch is off or there has been damage t the starboard electrical system ihe steering wheel wil be monitored by the port control system However if only he port side is operational or only the port key switch isi he on position the steering wheel wil not have end staps provided by the forc feedback system In this case the drive wil always tur in the direction that he steering wheel is being rotated unti the mechanical mits ef the drive are reached If there is damage lo the port electrical system the steering wheel wil operate normally wih complete force feedback and end stops The boat can operat as a single engine vessel Note that joystick and station keepi
14. 22 Straight and smooth fore and Marine vegetation can accumulate when the boat is docked Remove this growth before operation it can clog the water inlets and cule causing the engine to overheat Page 35 8010070883 OCTOBER 2012 Section 3 On the Water Cavitation occurs when water Bow cannot follow the contour of a fast moving underwater object such as a gear housing ora propeller Caviaion increases propeller speed while reducing boat speed Cavitation can seriously erode the surface of he ear housing or the propeller Common causes of cavitation Weeds or other debris snagged on the propeller Bant propeler blade Raised burrs or sharp edges on the propeller Ventilation Venliaton 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 sirike the propeller Blada and cause erosion of ihe blade surface If alowed o Continue eventual blade failure breakage wil occur Excessive ventilation is usualy caused A missing propeller diffuser ing A damaged propeller or gear housing which allows exhaust gases to escape between propeller and gear housing Propeller Selection IMPORTANT Tho sale propeter must alow te engine to reach engine rato speed RPM wth th boat ul loaded and witha customer stores onboard Wt o boat bam uly loaded the engines shouid reach engine rated
15. Ifit is desired to have a shorter lanyard wrap the lanyard around the operators wist or leg or tie a knot in the lanyard Activation of the lanyard stop switch wil slop the engine immediately but the boat wil continue to coast for some distance spending upon the velocity and degree of any tum at shut down However te boat wil not complete a ful circle While he boat is coasting it cause injury to anyone in the boat s path as seriously as the boat would when under power We strong recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency he operator is accidentally ejected If the operator falls out of the boat stop the engine immediately reduce the possiblity of serous Injury or death from being stuck by the boat Aways properly connect the operator to the stop switch using a lanyard Accidental or unintended activation of the switch during normal operation is also a possibilty This could caus the folowing potentially hazardous situations Occupants could be thrown forward due to unexpected loss af forward motion a particular concer for passengers inthe front of the boat who could be ejected over the bow and possil struck by he propulsion or steering components Loss of power and directional control in heavy seas strong current or high winds Loss of control when docking Avoid serious injury or death from decelerat
16. times wil increase how aggressively the vessel reacts by tres then decrease t by reluming tothe frst response Setting Number of Binks Response sting indicated Aggressivonoss of correction 1 1 Mi for gate calm conditions 2 2 for moderate conditons 3 3 Aggressive or severe conditions 3 The value seting for the current amount of response appears on the Auto Heading page in VessalVieu Track Waypoint In somo Precision Plot modes Auto Heading Track Waypoint and Waypoint Sequence tho boat navigates a preset course The boat does not automaticaly respond to hazards such as other watercraft obstacles swimmers or underwater terrain Colicon with these hazards could causo boat damage serious injury or death The operator must stay at the helm ready to evade hazards and wam others of course changes Track Waypoint allows the boat to automaticaly navigate to a specific waypoint or sequence of waypoints called a waypoint route This feature intended for use in apen waters free rom obstructions above and below the watering When the Track Waypoint feature is activated and the boat is in operator The helm must never be unattended The feature is not designed to alow unattended operation of the vassal The operator must remain at the helm at all times mast be used as the sole source of navigation IMPORTANT Track Waypoint can only be used with chart plo
17. A switch in the high pressure fiter system wil set a VesselView faut code to alert the operator when the hydraulic and fiter require changing Change the hydraulic and fiter whenever the VesselView fault code is displayed VessolView Fault Code Reason Task Change the oil and filer as soon as reasonably Filer Dirty Fat Hydraulic fiter is diry EStdt Contact your local Mercury Diesel repair faci for information High pressure fiter system Fiter head with suh switch not shown b Fiter housing with fiter element Transmission Oil Fluid and Filter Checking the Transmission Oil Level 1f he drive is equipped with drive cover you can check the transmission fui level trough the access cover or with the drive cover removed if equipped Page 00 178110070803 OCTOBER 2012 Section 5 Maintenance 1 equipped wilh a drive cover Ift the front of the access cover from the drive cover or remove the drive cover o access the transmission dipstick a Access cover b Molded indented edge 2 Remove the dipstick Wipe the dipstick with clean intres cioth Transmission dipstick wilh cover removed for 3 insert the dipstick resting it an the top of the threaded hole Remove the dipstick and check the oil level indicated The level should be between the maximum and minimum marks he dipstick NOTE the transm
18. Dive Storage 106 Engine Weather Freezing Temperatura Stxage 116 Dive B Seasonal and Extended 160 Power Package Battery Storage m Section 7 Troubleshooting Diagnosing Electronically Conrad Fuel System Electronic Remote Contras Problems 10 Steering System 12 Cannacions 120 Tim Tabs 12 Troubleshooting Charts 120 Boat Response Changes 12 Troubleshooting Engine Related Problems 120 Batey Wi Not Charge Ya Chock Vessalvi First 120 Gauges and nstumentalon Poor Performance 120 Gahan lanator E Joystick 121 Section 8 Customer Assistance Information omer Service Assistance 128 Contac Information for Mercury Marine Customer Service Local Repair Service 125 127 Service Away From Home 125 Cusiomer Serio Literature 127 Stolen Power Package 125 Engish Language 127 Attention Required Afar Submersion 128 Other Languages 128 Replacement Service Parts 428 Ordering Literature 128 Pars and Accessories Inquires 125 United States and Canada 128 Resolving a Problem 125 Outside the United States and Canada 128 Section 9 Predelivery Information 130 Engines Running atthe Dock E Dealer Predelivery Checkist for Zeus Products Bele Delivery Sea Trial E to the Customer 180 Afar On Waler Test E Before Staring Key Of 130 Skyhook if Equipped 132 Before Staring Key 10 OCTOBER 2012 Page i Page 178110070883
19. Front propeller be Nut 5 Place a block of wood between the trim tab and the propeller 6 Tighten the front propeller nut to specication using the propeller nut tool Block of wood b e Propeller nut ool UBOSMODTOSSS wy OCTOBER 2012 Page 118 Section 5 Maintenance Proper Nat Toot SESS T Aids in he removal and installation of the tront propeler nut Descipion zs ER L3 Front proper rur 150 7 Chack the propeller rotation The propeller must nat contact the lower drwa housing Side the rear thrust hub onto the propel shaft wih the tapered side toward the propeller hub 8 Aignthe splines and place the rear propeller on the propeller shaft The propeller mus ft rae on the propeller shaft spines 30 instal the rear propeller nut 11 Place a block of wood between the tim tab and the propeller 12 Tighten the rear propeller nut to specification a Block of wood b Trimtab Zeus drive propeller assembly a Front nust hub b Front propeller Front propeller nut Page d Rear thrust hub 8 Rear propeller f Rear propeller nut Description m mm me Rear propeler rui E 178110070803 OCTOBER 2012 Section 6 Storage Section 6 Storage Table of Contents Storage Descriptions 716 Recammissoning Drive Storage Engine Cold Weather Freezing Temperature S
20. Lever control is adjusted so that troling occurs within the fist 25 fever rave From 26 lo 100 lever travel engine operates between idle speed and maximum rated engine speed TROLL button To engage Troll mode 1 Place both ERC levers in Press the TROLL button located on the DTS trackpad attached to the ERC levers Place either ERC lever into gear 2 3 4 The TROLL bution lights when the lever or levers are moved out of neutral 5 The RPM ofthe engines do not change for the frst 25 of ERC lever travel while the transmissions alow some slippage at lower speeds Engine RPM rises through the remaining 75 of lever travel Ta disengage Troll mode 1 Bring both ERC lovers to neutral 2 Press the TROLL button The TROLL button ight turs of Dock Dock mode reduces the percent of throtle throughout the range by 50 This allows batter contral of engine power in close quarter situations DOCK button To engage Dock mode 1 Place both ERC levers in neutral wy OCTOBER 2012 Page 14 Section 3 On the Water Press the DOCK button located on the DTS trackpad attached to the ERC levers The DOCK button light tums Place either ERC lever into gear the RPM at a proportionally lower RPM for the ERC lever postion and with hal the power hat is usualy To disengage Dock mode NOTE Dock only disengages with the levers in a detent 1 Bring bot
21. OFF positon all electrical circus are off The engine wil not operate wih the key switch in the OFF poston TACC In ihe ACC postion any accessories connected to the electrical circuits can be operated The engine wil not operate wih he key switch in the ACC poston TON inthe ON positon al electrical circuits and instrumentation receive power The engine can be started wih an optional star stop switch START Tumn the key to the start position and release to start the engine NOTE The key can only be removed withthe key switch in the OFF positon A start stop switch is optional equipment The start stop such works in conjunction with the key such Thera is one start stop sich for each engine Each button on a multi engine start stop switch functions independent key switch must be in the postion to siart a stopped angine wih the start stop switch Pressing start stop switch button when an engine running wil shut down the corresponding engine Bilge Blower Toggle Switch Operates the bilge blower equipped ON OFF Page 178110070803 OCTOBER 2012 Section 2 Getting to Know Your Power Package Emergency Stop Switch An emergency stop E stop switch i used to tum off the engines in emergency situation such as a person overboard or a angled propeler When acivated an E stop switch interrupts the power supply lo he engine and transmission If the boat is Equipped win E s
22. Refer la your owners manual 4 Locate the foward gear solenoid on the por side of the affected transmission the wie is tagged Forward NOTE Do not disturb the reverse gear solenoid onthe starboard side of the transmission the wire is tagged Reverse p 8 Using a3 mm hexchead wrench turn the solenoid screw in the center of the top of the forward gear solenoid clockwise unt i stops 8 The transmission is now manually engaged in the gear and wil not respond to the helm controls for siting in and out of that gear Forward gear solenoid b Solenoid screw Page 02 BOEMOO7OGES OCTOBER 2012 Section 3 On the Water spinning propeller a moving boat or any sold device attached to the boat can cause serious injury or death to swimmers Stop tha engine immediately whenever anyone in the water is near your boat T Ensure tha the area around De propellers is dear before staring the engins since the propeller wil be turning whenever hs engine operating IMPORTANT The engine does not start with the ERC lover n gear even though he dive ls manually engaged In a gear 8 When you are ready to start the engine positon tha ERC lever in neural gear before turing the kay switch to the start positon NOTE Due to the extra load of turing the drive gears and propeller the starter may tum slower when starting the engine Gonnecled tothe in the emergency setting 8 Use extra care and caution wh
23. The joystick causes the control system to independently control ach pod angle and trust to move or rotate the Boat in a desired deocton Far example you move the joystick sideways the control system commands the boat in fne sideways direction The joystick gives three axis control fore and aft port and starboard and rotational or any combination thereof For example moving the joystick to causes the boat to move sideways to Rotating the joystick causes boat to rotate around its Center You ean move and ratate joystick at ine same Bme allowing for very intricate movements for maneuvering in baht quarters The control system automatically attempts to dampen bow and siem swinging referred to as during joystick operation An onboard sensor measures the yaw rate of the boat and actively counteracts the yaw motion of the boat Factors such as wind water conditions or vesse loading may act upon the vessel beyond ha systems capabilty to correct yaw Manual yaw Correction may be required when commanding the boat in na fore and aft starboard or diagonal directons To correct for unintended yaw during any maneuver just rotate tha joystick in direction the bow is desired to rotate The folowing table gives some limited examples of the basic responses to inputs rom the joystick The joystick is proportional which means that the farther from the centar the joystick is moved the more trust is applied to the b
24. fault codes are stil being displayed contact your authorized Mercury Diesel repair acy Lanyard Stop Switch Tho purpose of a lanyard top switch sto tum off the engine when the operator moves outside the operators position as in accdenilejection fom the operators postion bad Accidental ejections such as fling overboard ara more Haly to occur in dowssded sport boats bass boats high performance boats Accidental ejections can also occur from poor operating practices siting on the seat or gunwale at planing speeds standing at planing speeds operating at planing speeds in shallow or obstacle infested waters a Stop switch b Lanyard Cips to the operator ROBMOUOESS my OCTOBER 2012 Page 15 Section 2 Getting to Know Your Power Package releasing your grip on the steering wheel that is puling in one direction consuming alcohol or drugs 22 Mihepeed boating maneuvers The lanyard is a cord usually between 122 and 152 cm 4 and 58 in length when stretched wih an element on end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard s colled to make t esi condition as short as possible to minimize keihocd of lanyard entanglement with nearby objects sireiched out lenginis made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operators
25. safety checks to ensure that al lubrication and maintenance instructions are complied wilh for safe operation and to retum tha unit to a Mercury Diesel authorized repair for a periodie checkup Normal maintenance service and replacement parts are the responsibilty of he owner or operator and as such are rot considered defects in workmanship or material wins les of the warranty Individual operating habs and usage contribute to the need for maintenance service Proper maintenance and care of your power package wil ensure optimum performance and dependabiity and wil keep your overall operating expenses at minimum Sea your Mercury Diesel authorized repair facit for service aids Dealer Responsibilities n general dealer s responsibilities to the customer include predelivery inspection and preparation such as Make certain that the power package and other equipment are in proper operating condition before delivery Make all necessary adjustments for maximum efficiency Explain and demonstrate the operation of the power package and boat Provide you with a copy of a Pradelivary Inspection Checklist Fil out the Warranty Registraton Card completely and it to the factory immediately upon sale of the new product Al power packages must be registerad for warranty purposes Do It Yourself Maintenance Suggestions Mercury power packages are highly technical complex pieces of machinery Oniy qualified personnel using the
26. Consul your Check Vesselvisw for Guardian fault codes that cause engine power raducton If found have tha vessel checked by a Mercury Diesel authorized repair faci to discuss propellers need to be changed Unlock he Automate Tab Overide switch orae abs ERC lever controls engine and drive but does nat respond in a near manner Check TROLL bation on OTS rackpad Pul handles in neural and push TROLL bun to disengage fight Check T dock mods or nuse conti are Tum of ar disengage 7 ERC lever is moved but both engines respond Check T LEVER bution on DTS trackpad Put handles in neural push 1 LEVER button to disengage fight iz on ERC coni joystick and searing wheal do not funton estore heim control Press HELM on DTS trackpad Vus eim boats OSMOUOEGS my OCTOBER 2012 Page 121 Section 7 Troubleshooting Steering System Symptom Remedy steers boat Steering wheel operates without resistance but Starboard key swich med af Tum starboard key swish an Check and start starboard engine Starboard hamess circuit breaker Vipped Reset cra breaker Steering wheel does no stear the boat For contingent operation change 1 joystick for directional contro Contact a Mercury Diesel authorized repair faci Check steering actuator fuid level and fil necessary Rafar ta Section 5 Maintenance Refer fo Contingent
27. FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY Zeus Drive Limited Warranty Against Corrosion What Is Covered Mercury Marine warrants that each new noncommercial use Zeus drive system Product wil not be rendered inoperative as a direct resut of corrosion for the period af time descrbad in the folowing Duration of Coverage This mid corrosion warranty provides coverage for 38 months or 1500 hours af use from either the date the products frst sold or ns date which the produet is frst putinta service whichever occurs frst The repair and replacement of parts or the performance o service under this warranty does extend in of this warranty beyond is original expiration date Unexpired warranty coverage can be transfered Io a subsequent purchaser upon proper registration ofthe product Warranty coverage may be terminated for used product repossessed from a rta customer purchased at an auction rom a salvage yard fram an insurance company that obtained tha product as a result of an insurance cam Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage s available only to rta customers that purchase a dealer authorized by Mercury M
28. Gearcase b Fil and drain screw and sealing washer Pags 86 18110070803 OCTOBER 2012 Section 5 Maintenance 3 Remove the gear lube monitor cap Shown without drive cover a Gaar lube monitor Cap Drain the gear lube into a suitable co IMPORTANT I any water exits the fil and drain hole or i tne gear lube appears miky the drive is leaking Contact your Mercury Diesel authorized repair faciy immediate 8 Allow the gear lube to dain completely Properly dispose ofthe gear lube IMPORTANT Uso Mercury or Quicksilver High Performance Gear Lube in the driva Instala suitable gear lube pump into the gearcase fil and drain hole Fl the driva with the specifi gaar lube Fil and drain hole Gear lube and pump Description Part Number Qucsiver Gear Lube Pump DECIES Fluid Capacity nciudes Drive Model drive and tha gear Fluid Type Fd Part Number tube monitor Tigh Performance Gear SZRSSOBKDT TL TUS qj Zeus 5 14 L 5172 US at Lube 92858085001 5L 25 US gal 7 o pump gear lube into the drive unl he gear lube appears in the gear lube monitor at te COLD FILL LEVEL ina Da not ove COLD FILL LEVEL ine 8 Remove the gear lube pump and quicky reinstall the gearcase fll and drain screw and washer UBOSWOUTOSSS OCTOBER 2012 Page 87 Section 5 Maintenance Description bin Gear case f and dran sere 87 LJ 8
29. OCTOBER 2012 Page 3i Section 3 On the Water Have your manufacturer or dealer show you the locaton and ident the DC voltage regulator wich for reference V Tum the switch on before attempting start the engine 2 Leave the switch on when the vessel is operating 3 Tum the switch off when the vessel is not operating Starting and Stopping the Engines Your Zeus power package is equipped with a SmartStart system that includes a start stop button for emergency use that is remotely mounted in the vessel interface panel VIP The VIP is usualy located in the engine room In normal circumstances start and stop the engine from the helm using he starstop bution of the SmartStart system The seawater pumps on vessels equipped wih Zeus pod drives can be damaged by excessive exhaust aeration due to inadequate water fow To ensure adequate water fow across the seawater inlets make sure that ho vessel is underway before exceeding 1500 RPM Starting an Engine Using the VIP SmartStart Switch You may dese o start an engine fram the engine room or under certain circumstances the engine control systems may not be able to automaticaly stat an engine The engines started using the SMARTSTART stricta switch on the VIP for each engine 1 Perform the checks and stops listed in the engine s operation and maintenance manual available for this package NOTE Some vessels ara not equipped wit a seawater retum seacock 2 Op
30. Operations Steering and Trim Manual Override or contact a Mercury Diesel authorized repair faciily Steering works but boat is not as responsive Key off and key Check start port engine Check rim tab funcion Check steering actuator fuid Teve and WT necessary Rafar ts Section 5 Maintenance Contacta Mercury Diesel authored repair faci Steering wheel tumed past end stop Key off and kay onto restore steering wheal self ceniering cuis control and to attempt to erase fault code Trim Tabs Symptom Remedy Automatic trim tabs not working Taro the im tab atch Check steering actuar hid evel and necesa Refer to Section 5 Maintenance Contacta Mercury Diesel authored repair trim tabs working but erate to Section 5 Maintenance Check steering actuator fui level and Al if necessary Rafar Contacta Mercury Diesel authored repair Boat Response Changes Symptom Remedy Verty all engines on and functioning propery Start slopped engine Boat response sluggish Check VesselView for fault codes ool qual Check and arain the water separating fuel lr Boat vibrates ris sow to respond folowing a noise or impact T Shul down engines and check for damage inthe engine room Checkin the angine room or under the boat for damage to t
31. Repair Some damaged propelrs can b raed Contact your Mercury Dese authorized repair facili a Front thrust hub b Front propeller Front propeller nut Propeller Installation Rotating propelers can cause serious injury or death Never operate the boat out of the water wih a propeller installed Before instaling removing a propeller place the drive unit in neutral and engage the lanyard sop such o prevent he engine from staring Place block of wood between the propeler blade and the plate 1 Liberal coat the propeller shaft spline with one af the folowing Quicksilver lubricants NOTE Antcorosio grease is for sataterapplcatans on Tube Reto Desrpion Whore Used PartNo PED Special Lubricant 101 Propeller shaft spines 8028501 1078110070803 OCTOBER 2012 Page 112 Section 5 Maintenance Tube Rete Dessiior Wher Used ure ataron arme rola ati Onan Lacey Lubricating the propeller shat spines IMPORTANT Check that both the front and aft propeller part numbers match for port and starboard drives 2 Side the front thrust hub onto the propeller shaft with the tapered side toward the propeller hub 3 Align the spines and place he font propeller on the propeller shaft The propeller must ft freely on the propeller shaft spines Install the font propeller nut a
32. Thats on gear lookout operational check NEGO Forward Neural Reverse gear operational check ZOM Seaton 3 Idle icresseldocrease operational check ZOM Seaton 3 swich Fequipped eperstonal check ZM Seaton 2 EXE Visual inspection Fluid ake visual check Visual inspection Drive interface ring seal sealing visual check for leak Visual inspection Sea Trial pem Wana Soa or Taal ak opal e Wisin EM LED E IE LESSE Tir eb opio maus an aurai LESSE Seeing opera al sped ranger Trim ia Visi uper rational che ZOH Sel LE LL Vial mper E Sof rcina chc LESE After On Water Test Dealer Check pe Manaos LETT AS LEE Drive interface ring seal sealing grommet visual check for leaks Supply the customer withthe engine owners manual Supply he customer wih the Zeus Operation Maintenance and Warranty Manual Supply the customer wih the VessalViaw operations manual Supply the customer wih the Captain s Briefing Information brochure Supply the customer withthe Warranty Registration Card OSMOUOESS wy OCTOBER 2012 Page 134 Section 9 Predelvery Information Skyhook if Equipped Manual Code or Task Veriy the Si hook haim label is propery displayed at the helm Very the Skyhook pass
33. Tight Turns al Low Speeds 38 Disengaging Auto Heading Spin the Boat on is Axis at Low Speeds 3 Response Buton 5 Maneuvering vith the Joystick 8 Track Waypoint E 40 Engaging Track Waypoint 57 tamal Cani 40 Disengaging Track Waypoint Moda El Manual Cont Button or Joystick in Track Waypoint Mode 58 Using Tab Heading Burton im Tack Waypoint Mode S Special Digtal and Shit DTS Faalues 41 Acknowledging a Tum Durng a Waypoint 58 ral and Throttle Response a Waypoint Sequence E Deck 23 Contingent Operations On 4a Steering Emergency Allemaive Method Single Lever i Lever Operation 44 Port Engine Only Operation Synchronizing the Engines 45 Gear Engagement Emergency Procedure F1 Crise Cont 48 Steering amd Trim Manual Override Procedure for a Stuck Steering Contr Valve 65 Requesting Heim Transfer Procecur far a Stuck Tm Tab Control 65 Pia Transfer and Precision Pici 47 End of First Season Checkup Section 4 Specifications Drive Gear Lubricant Approved Paints E Transmission 68 Approved Lubricants E Sisering Actuator and Trin Section 5 Maintenance Product Responses Dive Gear Lubrication Onnar and Operator Responses 0 Checking Dealer Filing m Dot Yours Maintenance Suggestions 7 Changing Ges Drive Lubricant 5 General Inspection of Power Packa
34. be stopped using the SMARTSTART start stop switch on the VIP for each engine Page 18 18110070803 oy OCTOBER 2012 Section 2 Getting to Know Your Power Package Move the ERC handles to the neutral positon Locate the VIP for each engine in the engine room Inside the VIP or triple or quad installations turn the engine selector switch to the desired engine or engines When the engines running press and release the stastop switch or the green SMARTSTART statist switch for each engine you want to stop a ESTOP sui for emergency use only DESEE D Typical SmariCraf 3 0 VIP for tiles a Engine selector switch b Starstop switch e Ma Typical SmariCraf 3 0 VIP for quads Engine selector switch port and por center b Starstop switch e d Engine selector switch starboard center and starboard 8 Starstop switch 5 Turn the key switch to tha of position for each engine that was stopped TS OCTOBER 2012 Page 15 Section 2 Getting to Know Your Power Package 8 Close the seawater retum seacock if equipped Rotate the handie in the daci n indicated by tha arrow Drive cover removed for clarity a Seawater retum seacock f equipped Hande in closed postion Sescockfor seawater inlet 8 Former positon open Hande in closed postion Electronic Helm Steering The electr
35. limited waranty does not cover the following Routine maintenance tems Adjustments Normal wear and tear Damage caused by abuse Abnormal use Use ofa propeller or gear ratio that does not alow the engine to run in its Maintenance amp Warranty manual Operation of the productin a manner inconsistent wih the recommended operation and duty cycle section of he Operation Maintenance amp Warranty manual Neglect o Accident submersion Improper installation proper instalation specfatons and techniques are set forth in the installation instructions for the product Improper service Use ofan accessory or part hal was not manufactured or sold by Mercury Marine and that damages the Mercury product Operation with or lubricants that are not suitable for use with the product see the Operation Maintenance amp Warranty manual Aeration or removal of parts Damage ta the product for insuficient cooling watar caused by blockage of the cooling system by a foreign body commended RPM range see the Operation Use ofthe product for racing or ather competite activity even by a previous owner of the product voids the warranty Expenses related to launch towing storage telephone rental inconvenience sip fees insurance coverage loan payments loss of ime oss of income or any other type incidental or consequential damages are not covered by this warranty Also expenses associated
36. noncommercial use purchaser upon proper reregisiraton af he product Warranty coverage may be terminated for used product repossessed from a retail customer purchased at an auction a salvage yard or from an insurance company that obtained the product as a result insurance cam Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then after tha Mercury Marine specified predelvery inspection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation Maintenance amp Warranty manual must be in use on the oat and routine maintenance culined inthe Operation Maintenance Warranty manual must be timely performed elucing without lation the replacement of sacris anodes use of spaced lubricants and of ncs and Scratches in order to maintain warranty coverage Mercury Marine reserves the right make warranty coverage contingent upon proof of proper maintenance What Mercury Will Do Mercury s and excusive obligation under this warranty is mit to at our option repairing a corroded part replacing such or parts with new or Mercury Marine certified remanufactured parts or refunding he purchase p
37. should be testad to ensure adequate output The test should be performed where the boat is moored using the Quicksilver Reference Electrode and Test Matar For testing contact a Mercury Diesel authorized repair faclity or refer tothe service manual to help protect against galvanic corrosion The Anodes and MerCathode System Locations Location Figure The MerCathode reference electrode and Un MerCatnode anode are mounted to the compost cover on the underside of the drive The MerCathode system controler is mounted on tha transmission The e hamess connects he componant 1 Other anodes f equipped may be mounted on the vessel to protect against galvanic corrosion Refer to the operation and maintenance manual provided by he boat manufacturer for addtional information about vessel mountad anodes Other Anodes and Locations Doscipton Location Figure Anode kit Mounted to the boat transom equipped Reference Electrode Wire of the MerCathode System OTIC Washing the MerCathode assembly can damage components and lead lo rapid corrosion Do not use any cleaning equipment such as brushes or high pressure washers to cian the MerCathode assembly BO BMDOTOSSS wy OCTOBER 2012 Page 107 Section 5 Maintenance Do not pressure ash the reference electrode af the MerCathade assembly Doing so damages the coating on the reference elect
38. the spin unti grease is expelled from he pressure relief hole in the cap plug a Grease ming lt b Cap plug Expeled grease 4 Apply adhesive to the threads of the fange head screws for the driveshaft shield on the engine ond Tastee Exo EII 7777 a a a E ETE aed poem Sa DS RE Top shila Driveshaft shield to engine screw lt Engine end Description m Bm Driveshaft sied sew engins end 27 OBMOUOESS OCTOBER 2012 Page 103 Section 5 Maintenance Driveshaft U Joints NOTE In adition to the task and interval fer inspecting and lubricating the driveshaft U int every 250 hours or one year whichever occurs frst you must replace the Unas every 1000 hours or two years whichever occus frst Contact Mercury Diesel authorized repair fact or information on the nearest dveshal sence location 1 Remove the driveshaft shield on the engine end Driveshaft shield Scrow wo on each side Engine end gE 2 Remove the cp and bottom driveshaft shields on the transmission end as shown Bottom shld b Driveshaft shield uppertosower retaining hardware 2 e Top shield 82 Drveshaft shield retaining screw 4 3 Visual inspect each U joint bearing for a Seal deterioration or damage 8 The appearance of rust or trating around the yokes any of these conditions exist contact a Mercury D
39. the water inlet openings for the seawater pickup are clean and not obstructed Carefully remove any structions Do not damage the compost seawater pickup cover qmm gt Inlet openings for seawater pickup cavity not visible in this view 2 Lacking trough the niet openings visually inspect the cavity between the inlet cover and the center section plate for marina growth shells crustaceans e If marine growth is found in the cavity contact your Mercury Diesel repair facilty Shown wit cover removed for ary a Seawater inlet to seacock b Cavity shaded area 62 Center section plate d Cover EO OBMOUOESS x OCTOBER 2012 Page 101 Section 5 Maintenance Flushing the Seawater System Before seasonal or extended storage we recommend fushing the seawater cooing system to salt or sit Contact your Mercury Diesel authorized repas facit for additional information Battery Allen c discharge when natin use Recharge every 30 1o 45 deys or when sec graviy ice below ary spots Referto speci instuctine and warsings accompanying your bar this information no availabe obser he along An operating or charging battery produces gas that can ignite and explode spraying out sulfuric acid which can cause severe burns Ventiat the area around the battery and wear protective equipment when handing or servicing batteries Recharging a weak battery in the boat or using jumper cab
40. transmission to bring the level up to the maximum mark on the dipstick 10 instali the dipstick 11 If your model is equipped with a driva cover install the access cover Insert the molded cip on the aft end of he access cover under the indented edge of the cover a Access cover b Molded cip indented edge 8 Align the access cover with the opening in the cover Press down evenly an the front of the access cover click sound can be heard when access cover snaps into final postion Completing the access cover installation Filling You can fl the transmission wih through the access cover on the drive cover or wth the drive cover removed Page 92 178110070803 OCTOBER 2012 Section 5 Maintenance 1 To access the transmission dipstick you must remove te access cover or remove the drive cover if equipped Refer to Removing the Drive Cover 2 Remove the dipstick Wipe the dipstick with a clean cioth Che 3 Access cover b Transmission Transmission dipstick ck the oil level as outined in Checking Transmission pts 3 Add the specie transmission oil rough the dipstick threaded hole to bring the level up to tha maximum mark on the Capaciy Tid Pari Number Traramasion oniy without rop bo EA Transmision and drop box Sythe Poner Steering anes Transmision dup Box and remo
41. weather freezing temperature storage and seasonal storage plus ome addtional stap Refer to the specifie procedures in this section related to the conditons and the length of storage for your application Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect For this reason boats are normaly equipped with a plug pump or both drain plug and a bilge pump Instal the drain plug and check the operation of the bage pump if equipped before puting the boat in the water Check these tems on a regular basis to ensure that the level of water does not come into contact with your power package Components on your engine wil be damaged if submerged Damage caused by submersion is not covered by the Mercury Diesel Limited Warranty Protecting People in the Water While the Boatis Moving A parson in the watar may find iffcul to take quick action to avoid a boat heading in their direction even at slow speeds 2 Always slow down and exercise extreme caution any ime you are boating in an area where there might be people in the watar Whenever a boat is moving even coasting and the gear shift is in neutral here is sufficient force by the water on the propeller to cause the propeller to ratate This neutral propeller rotation can cause serious injury Page 28 BOEMOO7OGES OCTOBER 2012 Section 3 On the Water While the Boat is Stationar
42. BER 2012 Page 105 Section 5 Maintenance 2 Apply a liberal coat of one ofthe folowing lubricants to the propeller shafts Tube Reto Where Used Paro Es Grease Propel sate Obtain Local EDs Special Lubricant 101 Propeller shaft 802859A1 EC Marne peo a Propel shaft 2 Instal he propelers Rafer to Propellers Corrosion and Corrosion Protection The Causes of Corrosion Washing the MerCathode assembly can damage components and lead to rapi corrosion Do not use any cleaning equipment such as brushes or high pressure washers to clean tha MerCathode assembly Whenever two or more dissimilar metals thase found on the drive are submerged in a conductive solution such as saltwater polluted watar or watar with a high mineral content a chemical reaction takes place causing electrical current lo fow Between metals The electrical current fow causes ta metal that is most chemically active or fo erode This is known galvan corrosion an If not controled it wil in time cause the need for replacement of power package components Exposed o water Refer to the Marine Corrosion Protection Guide 00 88181301 Corrosion Protection Thess power packages have anodes as standard equipment to help protect tnem from galvanic corrosion under moderate conditions The MerCathode System and sacrificial anodes wil provide corrosion protection under nor
43. Bo 7 Rating 3 How to Obtain Warranty Coverage 7 Condtors That Must Be Met lo Obtain Warranty What ls Not Covered a Coverage 3 avear Limited Warranty Against Diesel Models What Mercury Marine Wil Do Recreational Use Ony a How to Obtan Warranty Coverage 4 What ls Covered Termination of Coverage 4 Duration of Coverage e Wat is Not Covers H Condon Tha Must Be lic Obi Wananiy INTERMITTENT COMMERCIAL USE WORLDWIDE Coverage a LIMITED WARRANTY 5 What Mercury Wil Bo Products Included in his Coverage 5 How Obtain Warranty Coverage H Duration of Coverage 5 What ls No Covered Intermittent Commercial Rating 500 Transfer ot Warranty Section 2 Getting to Know Your Power Package General information 2 Starting an Engine Using the VIP SmartStart Switch 17 Modes Covered 2 the Engine Using the VIP SmartStart Drive Seral Number and Decal Placemark 12 E Features and 12 Electronic Heim Steering E stumentaton 12 Dust Handle Electron Remote ERC Feslures Vessel 12 and Operation 20 SmanCraf Speedometer and Tachometer Digial Operation 20 Gauges 80 Bascloystck Operon a System Uns Digtal Gauges 1 Electrica System Overload Protection 21 E Vessel Interface Panel VIP Overload Prlecion 22 Emergency Sep Swich 15 Overload Protection far the DC Voltage Regulator Lanyard Stop Swich 15 System I Equipped 2 Vesta tare Panal Vi Ovencad 16 Ovarond Protectio
44. Changing Discharge of coolant or other engine d ive fuids into the environment is restricted by law Use caution not to coolant or other fds into the environment when using or servicing your boat Bo aware of the local restrictions governing the disposal or recycling of waste and contain and dispose of 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 te inner core causing water to leak Into the boat Use caution when intaling and working around the interface ring seal to prevent damage Do not use any lubricants or sealing compounds during instalation 1 Remove the drive cover if equipped Refer to Removing the Drive Cover 2 Lay down ciabsorbing wipes or material to catch excess transmission ol 3 Remove the M30 drain plug and sealing washer rom the af starboard end of the transmission and drain the transmission Mud into a suitable container a Transmission b gt Drain plug and sealing washer Page 9i 178110070803 OCTOBER 2012 Section 5 Maintenance 4 On models with a drop box remove the drain cap from the lower port side of the drop box Drain the transmission into suse container NOTE Except in the cases of extreme contamination ar mechanical fare itis not necessary to drain the fom the engine mounted tran
45. Filha gear lube montor to the COLD FILL LEVEL ina H the level is aw Refer to Filing 10 Ensure that the rubber gasket is inside the for the gear lube monitor and install the cap Do not overtighten 11 Install the drive propelers Refer to Propellers 12 Check the gear lube level at the gear lube moritor afier the frst use Refer to Checking NOTE A er the drive has been operated and the gear lube is hot the fuid expand and may reach the MAX OPERATING LEVEL ine hot ul ine MAX OPERATING LEVEL Ine hot full Iino Steering Actuator and Trim Hydraulic Oil The steering actuator and tim system use a common hydraulic pump itaring system hydraulic storage reservoir for and pressure The pump fiter and storage system are Ine same on al models For specifie procedures oferto Checking Filling and Changing Checking 1 Using a clean intfree cioth wipe the dirt and debris away from the cap and exterior of the steering actuator and tim fuid NOTE The direction to rotate the to apen or close is imprinted on the top of the cap 2 Push down and tum the reservoir and dipstick about 1 3 tum in the open direction RA Reservoir cap and dipstick b Open direction 6 Cose direction 3 Litho cap and dipstick from the neck of the reservoir Page 8 178110070803 OCTOBER 2012 Section 5 Maintenance 4 Inspect the fuid level which should at the f
46. GPS signal may be temporariy unavailable Skyhook continues to operate through a GPS signal outage for up o 10 seconds but automatically disengages f he GPS signal outage persists If Skyhook disongages you are alerted by the sound ofa hom and ths indicator ight on the Precision Pilot keypad fore SKYHOOK button of in such a circumstance the boat wil drift wih the wind or current because the engines continue to run but the dive units are now in Pera Skyhook performances largely dictated by the performance of the onboard Zeus GPS system The Zeus GPS system is accurate within 3 10 R when receiving wide area augmentation system WAAS correction WAAS s a system cf satelites and ground stations that provide GPS signal corrections allowing for more accurate positioning of your GPS When WAAS is ot available he performance of he system maintains the boat within 20 m 60 f of the desired position Engaging Activating Skyhook IMPORTANT Activites in the water near the vessel while Skyhook is engaged may result in injury The Captain or operator and passengers should read and observe the warning labels on the boat before Skyhook is engaged Before activating Skyhook 1 Check that no one is in the water 2 Tell passengers not to enter water Skyhook makes the propellers spin This can injure swimmers awooss15o Label adjacent lo the Precision Pict trackpad Rok the Captain before entering the water sn
47. Isolator E 122 12 12 1 12 OSMOUOESS my OCTOBER 2012 Page 115 Section 7 Troubleshooting Diagnosing Electronically Controlled Fuel System Problems Your Mercury Diesel authorized repair tacit has the proper service tools for diagnosing problems on electronically controled fuel systems The engine control module ECM on these engines has the aby to detect some problems with the system wen they occur and stora a trouble code in the ECMs memory This code can then read later by a service technician using 8 special diagnostic tol Electrical Connections IMPORTANT To avoid damage to the electrical system refer to the folowing precautions when working on or around the electrical harness or when adding other olectrcal accessories Do not tap accessories ito the engine harness Do not puncture wires for testing probing Do not reverse the battery leads Do not spice wires into the harness not route harness near sharp edges hot surfaces or moving parts Fasten cables away rom sharp edges fasteners or objects that could wear into the hamess or pinch the hames Avoid sharp bends in a data harness Minimum bend radius should be 76 mm 3 in for instalation Fasten hamesses to the boat at least every 457 cm 18 in using appropriata fasteners Donotattempt diagnostics without tho proper approved service Lois Disconnect all ine negative and postive battery cables each batte
48. MOO7OGES OCTOBER 2012 Section 3 On the Water 7 Precision Plot holds the compass heating the boat was following when the AUTO HEADING button was pressed and Auto Heading engaged Fer 1 45 m AUTOPILOT 8 To adjust your course while AUTO HEADING is engaged refer to Course Adjustment Using the Turn Buttons Joystick 8 To disengage Auto Heading refer to Disengaging Auto Heading 10 Press the AUTO HEADING bution a second fime Auto Heading goes to the standby mode and ights other than STANDBY tum off Course Adjustment Using the Tum Buttons or Joystick While in AUTO HEADING mode the TURN buttons course adjust buttons change the set course heading each time they are pressed Tapping the joystick left or right adjusts your course for each tap 1 Press the TURN button in the direction of the desired heading change Each press of the bution changes the desired heading by 10 Port TURN course adjust button b Starboard TURN course adjust button RESUME button 8 AUTO HEADING button 2 Defect and hold the joystick in the desired direction to make small adjustments in the chosen heading Each recognized movement adjusts the chosen heading by 1 GOBMOU ES OCTOBER 2012 Page Section 3 On the Water NOTE The joystick must move over 508 ofits travel and a beep wil sound for the movement to be recognized as input Adjusting heading to starboard To R
49. Welcome You have selected of the inest marine power packages available It incorporates numerous design features to ensure operating ease and durabilty With proper care and maintenance you wil thoroughly enjoy using this product for many boating seasons This manual isa supplement to the Operation Maintenance and Warranty Manual included with your engine package and provides information about the Zeus propulsion system To ensure maximum performance and carefree use we ask hat you thoroughly read this manual which contains speci instructions for using and maintaining your product We suggest hat his manual remain wih the product for reference whenever you are on the water Thank you for purchasing ane of cur Mercury Diesel products We sincerely hope your boating wil be pleasant Mercury Diesel Warranty Message The product you have purchased comes with limited warranty from Mercury Diese the terms of the warranty set orth in the Warranty Sections of this manual The waranty statement contains a description of what is covered what is not covered the duration of coverage how ta best obtain waranty coverage important disclaimers and Imitations of damages and other related information Please review tis important information Mercury Diesel products are designed and manufactured to comply wth our own high quality standards applicable industry standards and regulations as wol as certain emissions regulations Al Mercury Mar
50. West Pioneer Road P O Box 1999 Fond du Lac WI 54936 1939 Ship To Copy this form and print or type This is your shipping label Address City State Province ZIP or postal code Country Guantiy tem Stock Number Page 128 178110070803 OCTOBER 2012 Section 9 Predelvery Information Section 9 Predelivery Information Table of Contents Predeivay 720 Engines Running al he Dock 17 Dealer Predelvay Checkin for Zeus Produce E Dever to the Customer TO Afer On Waler Test E Botore Staring Key 10 Snook Equipped de Botore Starting On E OSMOUOESS my OCTOBER 2012 Page 129 Section 9 Predelvery Information Predelivery Information IMPORTANT socion of me Operation Maintenance and Warranty Manual guides our boat dealers and boat company rica personnel e propor tal rever service of o Mercy Diesel Zeus producte Dealer rede emos completed rior t f he produ cuter and i ot tue or ha Shades eed nthe manu you have ol bee rn n tno recommended servico proceres for ths product contact sauteed Merry ise Dati Donar 1a are Fe wl propr redee hada erecton or serang of Mercury Desi produc oud resin Garage he producto parsona y to hose Sang td perl e produ Dealer Predelivery Checklist for Zeus Products Before Delivery to the
51. a act ac WED ancy e ee Label in tho vicinity of ho transom boarding area IMPORTANT If ether of the labels cannot be located or are not legible they must be replaced before engaging Skyhook For replacement labels contact he manufacturer of your boat or a Mercury Diesel authorized faci Page 50 18110070852 wm OCTOBER 2012 Section 3 On the Water 1 Move the ERC levers to neutral and bring the boat to a sop Skyhook wil not engage until the boat sin neutral and at a speed slow enough or safe engagement 2 Inform passengers how Skyhook operates to stay out of the water and off the swim platform and to be alert for any sudden shifts in the boat positon 3 Check to soe no one is on the swim platform or in the water anywhere near the boat A rotating propeter a moving boat or device attached to a moving boat cause serious injury or death to people in the watar When Skyhook is engaged he propellers ratate and the boat moves lo maintain the postion of Ihe boat Stop the engines immediately whenever anyone is in tho water near he boat 4 Press tha SKYHOOK butan to eques pl PILOT pcm ment and operation Skyhook vh 44 SKYHOOK button 5 A safety popup warning screen app VesselView Read and observe the safety pop up PROPELLER INJURY HAZARD Do mot engage SKYHODK when are present Skyhook warning screen on V
52. above procedure then shift the transmission into neutral shut down the engine turn the key switch off and alternately push the port and starboard steering manual ovenida butions to rek spool Refer to the decal on the manifold bracket or on ho portada of the drive cover equipped for additonal information 6 Restart the engine At the helm staer the drive to the port and starboard to conim the fault has cleared the Steering Spool Stuck aut remains han shut down ihe engine and tum the key swich off on the unresponsive drive Operate on another engine and drive Refer to Port Engine Only Operation the starboard driva is shut down NOTE Boat speed and maneuverabilty wil be reduced Procedure for a Stuck Trim Tab Control Valve Determine the drive that is not responding tim control Shutdown the engine and tum the key switch oft Wait at least 30 seconds if possible Restart the engine Confirm the tim tab faut has cleared ft trim tab fault did not clear repeat the start stop routne up 1 three times f the trim tab fault does not clear using the above procedure then shift the transmission into neutral shut down the engine turn the key switch off and alternately push the trim up and tim down manualoveride buttons to release ne spool Refer to the decal an the manifold bracket or on the port side af the deve cover 4 equipped for additonal information 6 Restart the engine At the helm tm the tab up and down to confirm the fault ha
53. ack Wayport Precision Pilot Precision Pilot Trackpad Features General Information Precision Pot trackpad features includes 2 Precision Piot or Pt functors ar onto through the Pict vackpad ony Plot screens are located under the Environment chapter of VesseView The TURN buttons provide 107 course coracn far sach press ta the por or starboard Tre AUTO HEADING TRACK WAYPOINT and WAYPOINT SEQUENCE butions engage automatis course heading modes The tering wheel fos locked into delent when Alo Heading or rack Waypoint are engaged Manually overcoming ho detent fores of the stern wheel automaticaly puts imo Standby mode Standby The elements of the Standby sereen are In standby mode the shows a digital compass value and the angle ofthe drives The compass value the actual current heading fom Pot On the right side of the screen an icon labeled OFF indicates that Pilat is not engage OBMOU ES my OCTOBER 2012 Page 47 Section 3 On the Water NOTE Not all ofthe functions of Precision Piot work when DTS functions are engaged Disengage the DTS functions to use the functions of Precision Pio 8 2 FoF I 2 Standby screen on Vesselview AUTOPILOT OFF con b Heading Drive angle reference d Engine RPM Standby and Active Lights Precision Plot is disengaged off when the STANDBY ight is luminated You must press the button for Auto Heading T
54. act Information for Mercury Marine Customer Service For assistance cail fax or write lease include your daytime telephone number mail and fax correspondence United Sites Canada English 1 9209295040 iaa bene Fran ais 1 905 626 4751 a E Engish 1920 929 5893 Box 1939 i Francais 1 905 636 1704 Fond du Lac WI 54936 1939 Wels Wancmercunmarine com Paci Telephone 267397015622 Brunei Asia Pace Group Fax 61 39706 7228 41 71 Bessemer Drive Dandenong South Victoria 3175 Australia Europe Mile Eas Telephone CEEA Mame Eure Parc Industriel de Pett Rechain Fax 3207 31 1965 84800 Verviers Belgium Mexico Central America Sout America Caribbean Telephone 21954744350 Mercury Marne 11650 interchange North Fax 1 954 744 3635 Miramar FL 33025 USA Japan Telephone KIRE Co Ud 4 130 Kannabecho Sakai shi Sakai ku Fax 2336803 300984 Osaka japan Asia Singapore Telephone SE Brunswick Pac Group Mercury Marine Singapore Pte Lid Fax 65 65467789 29 Loyang Drive Singapore 508044 Customer Service Literature English Language Engish language publications available from Mercury Marine Atin Publications Department 16250 West Pioneer Road P O Box 1999 Fond du Lac WI 54935 1930 Outside the United Stat
55. amage can happen when water trapped in the seawater cooling system freezes For example after operating the boat exposure to freezing temperatures for even brief period of ime could result in freeze damage Corrosion damage is the resul of saltwater polluted water or water vith high mineral content rapped in the seawater cooling system Saltwater should stay in engine s coding system for even a brief storage ime drain and fush the Seawater cooling system after each outing Cold weather operation refers o operating the boat whenever the possibilty of freezing temperatures exists Likewise cold weather freezing temperature storage refers ta whenever ihe boat is not being operated and possiblity of reezng temperatures exists 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 more The length of ime varies depending on the geographic location of ihe boat in storage Seasonal storage precautions and procedures include all of the steps for cold weather freezing temperature storage and some addtional steps that must be taken when storage wil last longer than the short of cold weather freezing temperature storage Extended storage means storage for a period of time that may last for several seasons or longer Extended storage precautions and procedures ingude all of ihe steps for cold
56. andie in rough water To adjust the ERC handle datent tension 1 Remove the side cover of the handle needing adjustment 2 Tum the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension 3 Adjust lo tension desired To adjust ERC handle tension 1 Remove the side cover of the handle needing adjustment 2 Tum the adjustment screw clockwise Increase tension on the control handle and counterclockwise to decrease tension 3 Adjust to tension desired Starboard side cover removed port similar a Dotent tansion adjustment screw labeled En b Handle tension adjustment screw labeled i Basic Joystick Operation The joystick offers precise intuitive contral of your boat during low speed and docking maneuvers The joystick ansias the movement of the joystick into similar movement in the boat Engine speed is limited in is mode to prevent unacceptable boat namics during maneuvers While operation with the joystick is easy to learn we recommend that you drive the boat in the racional way unti you can spend ime in an apen area free of abstractions and traffic to leam how your boat responds to inputs Further we recommend you occasionally practice maneuvering in the aditional way to maintain your racional drive docking skils in case joystick contro is temporariy not available Electrical System Overload Protection Yan electrical overload occurs a fuse or a circuit break
57. are ficut inspect while the vessel is in the water and nol bo vile unti tho vessel is removed fron the wat Water condtons where the vessel moored may cause the anodes to erode quickly decreasing the corrosion protection for the pod drive An increase in water velocity through currents or tides Increases the corrosion rate of metals This is because flowing water puts more water In contact wih te metal and therefore more oxygen in contact wit the metal as wel Mercury Marine recommends visual inspection of the pod drive anodes every 30 days more ftn if ho vessels moored in swift currents or ides This inspection schedule may not be practical in certain situations You should consult the local authorized Mercury Marine repair facilty for options on inspecting the anodes of the pod drive Maintenance Log Record all maintenance performed your power package here Be sure to save all work orders and Page 178110070803 OCTOBER 2012 Section 5 Maintenance Engine Hours OSMOUOESS my OCTOBER 2012 Page 75 Section 5 Maintenance Drive Cover If Equipped Removing the Drive Cover NOTE The top of the dhive cover contains an access panel which provides access to the fi cap on the gear lube monitor and the transmission fd dipstick without removing tha cover Remove the tres upper screws port and starboard holding the side cover to the top cover Remove the two lower screws holding the po
58. arine to distribute product in the country in which the sale occured and then only afer ta Mercury Marine speci edpradelwery inspection process is completed and documented Warranty coverage becomes availabe upon proper registration of the product by the uthorzad dealer Corrosion prevention devices in he Operation Maintenance amp Warranty manual must be in use on boat and routine maintenance outined in the Operation Maintenance amp Warranty manual must be timely performed including without imitation he replacement of sacrificia anodes use of species lubricants and touch up of ricks and Scralchas in order to maintain warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance What Mercury Will Do Mercurys sole and exclusive obligation undar this warranty is mite o at our option repairing a corroded replacing such part or parts with new or Mercury Marne certified remanufactured parts or refunding the purchase price of ne Mercury Product Mercury reserves the right to improve or modify products rom time t time without assuming an obligation to modify products previously manufactured How to Obtain Warranty Coverage The customer must provide Mercury vith a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to serv
59. ater or in areas where the waters are suspected of having floating or underwater obstacles that could struck by the underwater dive components skegs or the Boat bottom IMPORTANT The most inportant thing you can do to help reduce injury or impact damage from striking a floating or underwater objoct ls control th boat speed Under these conditions reduce boat speed to minimum The folowing demonstrate some but not examples of what can happen the boat tres floating or underwater abject The boat could move in a new direction Such an unexpected change in direction or can throw occupants out other seats or of tne boat Arapid reduction in speed This can cause occupants to bo thrown forward even out of the boat Impact damage to the underwater drive components skeg or boat GOSMOUOESS my OCTOBER 2012 Page 25 Section 3 On the Water Keen in mind that one of the most important things you can do help reduce injury or impact damage in these situations is the boat speed when driving in waters known to have underwater obstacles Air striking submerged object sop the engine as soon as possible and inspect he drive systems for any broken or loose parts and fo hull for any damage If damage is present or suspected he power package should bo taken o a Mercury Diesel authorized repair faclily for a thorough inspection and any necessary repair The boat should be checked for hul
60. ble opportunity t repair and reasonable access to the product for warranty service The purchaser shal not Unless requested by Mercury Marine ship the product or parts of he product directly to Mercury Marine Termination of Coverage Warranty coverage may be terminated for used product obtained of the following ways Repossession from a retail customer Purchase at auction Purchase from a salvage yard Purchase from an insurance company that obtained the product as a result of an insurance claim Inaccurate warranty registration information What Is Not Covered This limited waranty does not cover the following Routine maintenance tems Adjustments Normal wear and tear Damage caused by abuse Abnormal use Use ofa propeller or gear ratio that does not alow the engine to run in its Maintenance amp Warranty manual Operation of the productin a manner inconsistent wih the recommended operation and duty cycle section of he Operation Maintenance amp Warranty manual Neglect o Accident submersion Improper installation proper instalation specfatons and techniques are set forth in the installation instructions for the product Improper service Use ofan accessory or part hal was not manufactured or sold by Mercury Marine and that damages the Mercury product Operation with or lubricants that are not suitable for use with the product see the Operation Maintenance amp Warranty manual
61. bs keep the boat on plane langer a lower speeds maintaining a level boat atitude Special Digital Throttle and Shift DTS Features The DTS system features several arate operational modes for tha electronic remote control ERC vers Most of ha sted features can be operated simataneousiy and can you wih Warming the engines Troling the vessel Docking the vessel GOBMOUOESS OCTOBER 2012 Page 5i Section 3 On the Water Synchronizing the engines Dual helm staton transfer ERC with DTS trackpad Conteh Funcion when he transmission irm ihe neural gear postion The lights Wash 4 meia ii When the engine is in votis only mode Trall reduces tha propeller speed o lower than thal of engine speed for the rar Ni 25 of lever tavel era for ont crio era dr Fai Dl ei 3 woe Reduces the throtle capaci to approximately 50 of normal tote c amar ls at engine RPM or warn wing T uu bles ol ans renal ange be aras Bye amm Ter otis apr te ETO tano ani team pres and NOTE Not all functions may be active Page DOEMOOTOGES OCTOBER 2012 Section 3 On the Water Troll and Throttle Response Troll mode allows the vessel to operate at very low speeds by controling the transmission The transmission is capable of ducing the propeller speed lower than the engine speed
62. cksiver Galvanic Isolator and the safety grounding lead This device wil also supply impressed current to the driva to aid in corrosion protection Improperly conducted AC shore power l an electric shock hazard that resul in damage and injury The AC grounding conductor green wire must be connected between the boats eect ca system and the shore power connection in order lo provide path for fault curent and to assist the MerCathode in preventing galvanic corrosion drive components Install a galvanic isolator or similar isolation device in the AC shore power system Inthe vessel Consu a qualified marine electrician Tor more information IMPORTANT If tho Galvanic Isolator alarm sounds and the monitor wil not respond to the rasat button AC fault current may be present and the shore power safely grounding conductor circuit to shore may be an open circuit Disconnect shore power immediately OBMOUOESS x OCTOBER 2012 Page 24 Section 2 Getting to Know Your Power Package Refer to Troubleshooting Galvanic Isolator for an explanation of the conditions or faulls that may bo displayed by the Normal Sate Galvanic Islator Monitor and conditons NOTE f your vessel is equipped with galvanic isolator from a manufacturer other than Quicksilver referto the instuctions provided by the manufacturers Page 2 178110070803 OCTOBER 2012 Section 3 On the Water Section 3 On the Water Table of C
63. d ERC lever into gez 5 The engine RPM raises and lowers simultaneously while the transmissions remain in the same gear To disengage the single lavar 1 Lever mode 1 Place both ERC levers in neutral 2 Press the 1 LEVER button The 1 LEVER bution light tums off Synchronizing the Engines The system features an automatic engine synchronization feature called Sync Syne engages automatically at key up The synchronization feature monitors the position of both ERC levers If both levers ara within 10 of one another the port engine Synchronizes to the starboard engines RPM VessalVisu shows an orange icon if tha RPM of the engines are not within 10 of each other and the icon turns green when they synchronize The icon tums grey when Sync mode is off To disengage Sync mode 1 Place the ERC levers n any detent 2 Press the SYNC button SYNC bution To re engage Sync mode press the SYNC button wy OCTOBER 2012 Page 45 Section 3 On the Water Cruise Control The VesselView system features integrated throttle cruise control called Cruise which allows the operator to mi the peak REM of choice below wide open throttle WOT Refer to the owners manual provided with your VesselView for operation These additonal notes are exclusive to your package You can change or disengage Cruise through the VessalView screen at any time Cruise resets when the key is tumed of Ifthe cruise m
64. d connections Test the MerCathode und output Inspect the electrical system for lose damaged or corroded fasteners Check for loose damaged or corroded wiring and connectors Inspect the cooing system components found on the drive for damage or leaks Check the hose camps on the hoses for ightness Check that tho water inlet openings on the seawater pickup are clean and not obstructed Inspect the exhaust system connections tne drive for damage or leaks Check the osa clamps the hoses for tightness Treat the power package components inside the boat wth Corrosion Guard to protect the product corrosion Every 1000 hours o operation or two years hichaver occus irat Replace the driveshaft ins Wneneverie VesselView fault code Fiter Fault or Fiter Clog Fault is splayed Change the hydraulic oil and fter for the steering and rim system Rafer to the information about Changing the steering actuator and tim BO BMDOTOSSS wy OCTOBER 2012 Page 73 Section 5 Maintenance Zeus Pod Sacrificial Anode Inspection IMPORTANT Sacrificial anodes are made of specifi types of metals or alloys Aluminum anodes are meant o corrode and sacro themselves in order to protect tha aluminum section of the power package hats in the water The sacrificial anodes a Zous pod dive must be Inspected periodically In most applications the sacrificial anodes the pod dive trim tab
65. d to reduce the possiblity of Serous engine damage Replacement Service Parts Avoid fre or explosion hazard Electrical ignition and fuel system components on Mercury Marine products comply with federal and Intemational standards to minimize risk of fre or explosion Do nol use replacement electrical or fel system components that do not comply with these standards When servicing the electica and fuel systems propery instal and tighten al components Marine engines are expected to operate at or near ful throttle for most of their e They are also expected to operate in bath fresh and saltwater environments These conditons require numerous special parts Exercise care when replacing marine engine pars because specifications are diferent from of the standard automotive engine For example one ofthe most importan special replacement parts i the cylinder head gasket Marine engines cannot use automotive haad gaskets because saltwater is highly corrosive A marine engine head gasket uses special materials to resist corrosion Because marine engines must be capable of running at or near maximum RPM much of the time thay also have special valve springs valve ars pistons bearings camshafts and other heavy duty moving parts Mercury MerCruiser marine engines have other special modifications to provide long and dependable performance Parts and Accessories Inquiries Direct any inquiries concerning Quicksilver replac
66. d with less than a one yaar Ima product warranty replacement parts parts purchased the Customer products used in a commercial application Commercial use is defined as any work or employment related use of product or any use of the product which generates income for any part of waranty period even f the product is oniy occasionally used far such purposes DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY Transfer of Warranty Te limited warranty is transferable to subsequent purchaser but only for the remainder of the unused portion of the limited warranty This wil not apply to products used for commercial applications To transfer the warranty to the subsequent owner send or fax of the bil of sale purchase agreement new owner s name address and engine serial number to Mercury Marine s Warranty Registration Depa
67. dering Literature United States and Canada Outside the United States and Canada 127 127 127 128 128 128 128 OSMOUOESS my OCTOBER 2012 Page 125 Section Customer Assistance Information Owner Service Assistance Local Repair Service Ifyou need service for your Mercury MerCniser powered boat take it to your authorized dealer Only authorized dealers specialize in Mercury MerCruiser products and have faciory rained mechanics special tois and equipment and genuine Quicksilver parts and accessories to properly service your engine NOTE Guiksier pars and accessories are engineered and by Mercury Marine specfcaly for Mercury MerCruiser lames and cade Service Away From Home you are away fam your local dealer andthe need arises for servion contac the nearest authorized dealer or any reason You cannot bli saca contact a nearest regional service cana Outside the Und Sats and Canada conta he Marne Power teatral sedes cate Stolen Power Package your power package olen mediate inform the local aures and Mercury Marne of e model and serial numbers mta whom the recovery to be reported This maintained in a database at Mercury Marne aid autores nd dealers in recovery of stolen power packages Attention Required After Submersion 1 Before recovery contact an authorized Mercury MerCruiser dealer 2 Ater recovery inmediate sence by an authorized Mercury MerCruiser dealer require
68. dous situation which f not avoided could resul in minor or moderate injury Indicates a situation which i not avoided could result in engine major component failure IMPORTANT Identifies information essential to he successful completion of the task NOTE Indicates information that helps in the understanding ofa particular stap or action Identification Information Drive serial number and model number The serial numbers the manufacturer s keys to numerous engineering datas that apply to your Mercury Diesel product When contacting Mercury Diesel about service aways speci model and serial numbers Pod Drive Models eries Zeus 3000 5 2013 Mercury Marine The serial number model number and other information needed for the identification record is located as shown Drive entation a Transmission identfeston piate b Drive identi cation decal e Pod location stamping m rto Section Control system identification if applicable SmartCraft 3 0 versions of the Zeus electronic conto system r 2 General Information have an electronics serial number ESN data tag located on he inside of the vessel interface panel UI doar The number is needed far the identification racord MERCURY MADE IN USA Engine serial number and model number Refer the engine operation and maintenance manual available from the engine manufacturer for he l
69. e Warmer lubricant ws more fee carias ay more purs and s to remove With the Boat in the Water 1 Plcedkabsorben wipes or material around the area to contain any spile ubican 2 Remove the land drain screw fom the steering actuator B _ Drop box model shown al sitar Fil and drain screw b Steering actuator 3 instal the special gear be adapter with washer into the threaded hol far the drain and f screw nut and washer b Adapter Threads into steering actuator 3 8 in 18 UNC Dasaripton Part Number Gear lube adaptar OT 2ATEOAT 2 0 83 wy OCTOBER 2012 Page 81 Section 5 Maintenance 4 Install a suitable double ended male adapter to the gear lube adapter n 4 Typical adapter pa Dore decimo sat E cms S 5 Atach the crankcase oil pump or a suitable gear ube pump Shown unattached for visual clarity Gear lube adapter and washer B Crankcase cil pump Doubie ended male adapter Eranicasa Pump EE CR as in the removal of drive gear ube without draining through the drive PP 8 Remove the gear lube marlior cap Shown without drive cover Gear lube monitor 1 cap 7 Operate the crankcase oi pump and remove the gear lube from the drive Pump the gear kibe into suitable container Properly dispose of the gear lube IMPORTANT If any water ex
70. e second after pressing the TRACK WAYPOINT button The display shows he digtal heading thatthe boat is traveling the anges of Ina drives and engine speed RPM Ses Mode Display in VesselView NOTE This display screen is activated during VasselView calibration The GPS system generates the displayed heading based on magnetic North 8 24 F eF 1 46PM AUTOPILOT Track Waypoint sereen NOTE Precision Piot wil nt initiate tums when Track Waypoint mode is engaged Tum features are only available in Auto Heading mode Disengaging Track Waypoint Mode 1 Disengage the Track Waypoint mode by one of the folowing methods GOBHOUOESS OCTOBER 2012 Page 57 Section 3 On the Water Press the TRACK WAYPOINT button on the Precision Plot keypad The TRACK WAYPOINT button light goes off and Piot goes lo Standby Tha STANDBY ight tus on Tum the steering wheel hard enough to overcame the force feedback and Pilot goes to Standby Move both ERC levers back to neutral and Pilot goes to Standby Press either TURN button and Pot goes Auto Heading mode Press he AUTO HEADING button and Pilot goes to Auto Heading mode Tum off the chart poter and Pict goes to Standby 2 You can resuma the Track Waypoint heading within minuta f the vessel has not tumed too far and the RESUME light is stil on or fasting Turn Buttons or Joystick in Track Waypoint Mode While in TRACK WAYPOINT mode using the left or right TURN b
71. eading Waypoint Sequence 1 Place the ERC lever or levers into forward WAYPOINT SEQUENCE does not engage ithe levers are in neutral or 2 Ifthe Track Waypoint button light is not press the TRACK WAYPOINT button wy OCTOBER 2012 Page 59 Section 3 On the Water 3 Press the WAYPOINT SEQUENCE button to engage Waypoint Sequence mode O PRECISION PILOT 7 pon e E e WAYPOINT SEQUENCE mode bution 4 A hom besp sounds on VesselViaw the gren cel icon tha Pilot screen wil display TRACK The TRACK icon tha VassaWView screen should Buminata 1 47 PM Waypoint Sequence TRACK icon 5 Ifyou are in a waypoint arva zone set by the chart plotter Waypoint Sequence mode informs Precision Pic is OK to proceed next waypoint Waypoint Sequence mode acis a waypoint acknowledge function and Precision Pot sounds a hom beep when inthe zone n some Precision Plot 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 watoreraf obstacles swimmers or underwater terrain Colson with these hazards could cause boat damage serious injury or death The operator must stay atthe helm ready to evade hazards and wam others of course changes 6 Press the enter button to acknowledge that itis OK to ur The enter button isin the up
72. efer to To Resume Heading Ifyou do not wish to resume the course press the AUTO HEADING button once to engage Standby and press it again to tum the Auta Heading mode LL D ose inccator OFF or AUTO AUTOPILOT b Current heading 2 Drive positions d Engine RPM 4 Ifthe ERC handles were moved to neutral the AUTO HEADING button ight tums off and the STANDBY light comes You cannot resume your course by pressing the RESUME button Refer to To Resume a Heading 5 if Auto Heading disengaged because the AUTO HEADING button was pressed the AUTO HEADING button ight tums fand the STANDBY ight comes on Press the AUTO HEADING boton a second time and tna STANDBY ight goes Auto Heading is disengaged and the mode is OFF Response Button 1 Press the RESPONSE button to increase or decrease how aggressively the vessel reacts to programmed changes when in he Piot modes How aggressively the vessel reacts equals response seting in VesselView GOSMOU ES OCTOBER 2012 Page 58 Section 3 On the Water NOTE Each time you press the RESPONSE button the button fight binks to indicate you changed the response seting pa mod O Precision PLOT e E Response bution 2 Press the RESPONSE button again to increase how aggressively the vessel reacts to programmed changes The initial bution press shows the curent response seting Pressing the bution as many as
73. ement parts and accessories to your local authorized dealer The dealer has he necessary information to order parts and accessories for you Only authorized dealers purchase genuine Quicksilver parts and accessories from the factory Mercury Marine does not sell to unauthorized dealers or retail customers When nqueing about parts and accessories dealer requires the engine model and serial numbers lo order tne correct paris Resolving a Problem Satisfaction wih your Mercury MerCruiser product is important ta your dealer and to us If you ever have a problem question or concern about your power package contact your dealer or any authorized Mercury MerCruiser dealership If you need additonal assistance 1 Talk with the sales manager or service manager Contact the owner of the dealership if the sales manager and savice manager have been unable to resolve ho problem 2 your question or problem cannot be resolved by your dealership please contact a Mercury Marine Service Office for assistance Mercury Marine wil work with you and your dealership to resolve all problems The folowing information wil be needed by Customer Service Your name and address Daytime telephone number Page 125 178110070803 OCTOBER 2012 Section 8 Customer Assistance Information Model and serial numbers for your power package The name and address of your dealership Nature ot the problem Cont
74. en operating your boat in this emergency mode On the drive with he manually engaged gear you must tum that engine cff to stop the propeller ram turning or providing thrust NOTE Puting the drive with the gear manually engaged into reverse stops the engine 10 Immediately take your boat to a Mercury Diesel authorized repair faciity and inform them that the drive pear has b manually engaged Steering and Trim Manual Override The steering and tim system operate using a hydraulic manifoid tad with control valves If a malfunction occurs in the manifold for tne steering and rim system VesssiView should display fault code The steering actuator tim cinder or both not respond t helm contral resulting in the loss of steering ar tim control A tuit Be ong av rn coral vale il tempora caus maras of dawg or Hm ham Sorti on he acid ve roma et rin COR icr eed opr e cal Tre ato proide a mati of ted ve and in ab omn e event ofa maluncton or aur Oi Tab Tx raa cots Bi TP e dao Pr T uan any gt Sa Sake sig Spa Ss Fau made percentage is engine shui ot exceed Weiss CERE contol valve Tab Spool Stuck Faut Stuckin any No effect on engine operating speed within he duty E made E OBMOU ES OCTOBER 2012 Page 63 Section 3 On the Water an emergency if a stee
75. en the seawater return seacock if equipped Rotate handie in the direction indicated by the arrow Drive cover removed for clarity a Handle positon b Seawater retum overboard quipped E i the hande in the direction indicated by the arrow Typical inet seacock port orientation starboard similar Seacock for seawater inlet b Handie in open poston 6 Former position closed 4 Open the seacock f equipped for any accessory equipment NOTE When the key swich is turned to the position the nautra LED lights on the ERC trackpad fash on and off iF he ERC handles are not in the neutral positon Before starting the engines the ERC handles must in the neutral positon 5 At the active standard helm move the ERC handles to the neutral position NOTE Ask your dealer for the location of the key switches the key switches aro nat located at the heim Fag 32 18110070852 y OCTOBER 2012 Section 3 On the Water 8 Tum the key switch to the on position for each engine o be started 7 Verify itis safe to start the engines 8 Inthe engine room locate the VIP for each engine IMPORTANT The sario such or SMARTSTART switch on a VIP wil start the corresponding engine regardless of which helm station active or previously active Inside the VIP or triple or quad installations turn the engine selector switch to the desired engine or engines 10 Press and release the startistop switch
76. enger label is properly displayed forthe passengers a Supply the customer wih Skyhook Operation DVD Very that the Skyhook Quick Reference Guide is attached to the heim Dealer Check Checklist tem Page 132 18110070803 OCTOBER 2012
77. er Drive Gear Lube Drive Gear Lubrication Checking Filing Changing Gaar Drive Lubricant itn he Boat in the Water With the Boat Out of the Water Steering Actuator and Hydraulic Checking Fling Changing Transmission Oi Fig and Fiter Checking the Transmission Oi Level Filing m 2 2 76 76 76 76 19 r1 r1 E E E E Ei Changing Seawater System Draining the Seawater System Boat cut ofthe Water Boat nthe water Checking the Seawater Pickup onthe Drive Flushing he Seawater System Battery Electrical System Cooling System and Exhaust System Lubrication Driveshaf ipini Driveshaft Uoints Propeler Shaft Corrosion and Corrosion The Causes of Corrosion Corrosion Protectan Anodes and MerCathode System ar 97 ar x it E E E E i se 5 ite it i Reference Electrode Wire of the MerCathode System MarCaihode Anode Checking Replacing MerCalhode System Tasting Trim Tab Anode Checking Replacing Continuity Circus Inhibiting Corrosion Painting the Boat Propellers Propel Propel Propel 107 108 108 108 1 1 108 108 no 110 m m m T 112 7 0 8 OCTOBER 2012 Page 68 Section 5 Maintenance Product Responsibilities Owner and Operator Responsibilities tis the operators responsi to perform
78. er procedure is started Ta remove the fault codes it may be necessary to cycle the key swich off and on and then restart the helm transfer procedure Ensure that other contr and navigation inputs are performed after helm transfer is complete o avoid seting fault codes aS RE pees ST PAL To avoid damage use extra care when attempting a helm transfer while the vessel s close to docks piers or other fred tems or when near other vessels Requesting Helm Transfer NOTE Any movement of the joystick or ERC levers afer pressing the TRANSFER button terminates the haim transfer equest A single boop sounds and transfer button ots f igang the end of the taser request To reques the transfer of vessel control om one he o another 1 heim you are requesting be made active and with the ERC levers in neutral press the TRANSFER button ane time Aner ihe TRANSFER button pressed tne transfer button igh tums on and one beep wil sound confrming ine mc arta r3 TRANSFER button Page 48 BOEMOOTOGES OCTOBER 2012 Section 3 On the Water NOTE Ifthe ERC levers at ha helms are not in neutral the neutral lights wil flash Move al he ERC levers to neutral and fe neural ight shouid then be 2 Wih the TRANSFER button ight and neutral ight on press the TRANSFER button a second time to complete the helm transfer 3 When the helm transfers complet another beep sounds and the transfer buti
79. er opens Find and correct the cause for the electrical overload before placing the fuse or resting ihe circuit breaker OBMOUOESS OCTOBER 2012 Page 2i Section 2 Getting to Know Your Power Package NOTE In an emergency when you must operate the engine and cannot locate or correct he cause for the electrical overload high curent dw tum or disconnect the accessories connected o the engine and instrumentation wiring Reset he ruit breaker or replace the fuse If the remains open electrical overload has not been eliminated Contact your Mercury Diesel authorized repair facilty to check the electrical system Circi breakers and fuses provide protection for tna electrical system as indicated crcit breakers and fuses are located in various locations throughout the boat Have your dealer show you the location and deny the that they protect After finding and correcting the cause of the overload reset the circuit breaker by pressing the reset button Vessel Interface Panel VIP Overload Protection The vessel interface panel VIP contains five circu breakers that help protect he transmission hamess engine harness vessel sensor harness and helm harness NOTE A VIP for each engine is located in the engine oom oa Main circuit breaker 25 amp iut b VIP diagnostic circuit breaker 10 amp G Helm crit breaker 10 ene idea 8 SiMivessel circuit breaker 10 a
80. ering details hat apply to your drive Drive seri number locations Transmision serial number plate b Drive serial number decal and stamping Refer to the engine owner s manual supped with the engine for the location af the engine data tag that contains the engine serial number and model number Features and Controls Instrumentation VesselView Your power package may be connected to a SmartCraft Vesselview display The interactive VesselView display continuousiy reports realtime information about speed performance engine fault codes fuel status water temperature and depth and ther operating data When VeaselView delete problem with any connected system i displays an alarm message lo the boat operator VesselView VesselView may also be connected to other vessel systems such as GPS generators and cabin environmental controls This vessel integraton allows the operator to manor and control a wide range of vessel systems from a single display Refer to your VessalView operations manual for dete instructions on how to operate this display Page 12 178110070803 OCTOBER 2012 Section 2 Getting to Know Your Power Package SmartCraft Speedometer and Tachometer Digital Gauges The SmariCraft instrument package if equipped augments the information provided by VesselView The instrument display Engine RPM Boat speed Coalant temperature Ol pressure Batte
81. ero Effort Zeus and 1 On tha Water are registerad trademarks of Brunswick Corporation Mercury Product Protection is a registered service mark of Brunswick Corporation The operator driver is responsible for the corect 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 fom this product contains chemicals known to the state of Calfomia to cause cancer birth defects or olher reproductive harm TABLE OF CONTENTS Section 1 Warranty Warranty information 2 Conditions That Must Be Met to Obtain Warranty Warranty Registration Unted States and 2 Coverage 5 Warranty Regiataton Outside the United Stats and What Mercury Marine Wil Do 5 Canada 2 How t Obtain Warranty Coverage Warranty Diesel Models 2 Termination of Coverage 6 HIGH OUTPUT RECREATIONAL USE WORLDWIDE ratis Not Covered LIMITED WARRANTY 2 Zeus Drive Limited Warranty Against Corrosion 7 Wate Covered 2 Wat Is Covered 7 Duration of Coverage 2 Duration of Coverage 7 Twa Year Limited Warren mid Waraniy Contone Trat Muet Be Nat io Obi Wananiy Coverage 3 Coverage 7 Extended Major Components Limisd 73 Wat Mercury Wii
82. es and Canada contact the nearest Mercury Marine or Marine Power Intemational Service Centar or futher information When ordering be sure to ROBMOUOESS wy OCTOBER 2012 Page 127 Section 8 Customer Assistance Information List your product model year and serial numbers Check the Iterature and quantities you want lt Enclose full remittance in check or money order NO COD Other Languages To obtain an Operation Maintenance and Warranty Manual in anther language contact tha nearest Mercury Marine or Marine Power International Service Canter far information A tst part numbers or ber languages s provided wi your power package Ordering Literature Before ordering lerature have the following information about your power package available Ses Number Horsepower Year United States and Canada For addtional iterare for your Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Mercury Marine 820 9295110 920 920 4804 Ali Publications Department USA only USA oniy P O Box 1930 du Lac WI 54935 1939 Outside the United States and Canada Contact your nearest Mercury Marine authorized service center to order aditional teratura that is available for your particular power package Mercury Marine Submit he folowing Atm Publications Department order form with payment WE250
83. esselView 6 Press the Xbuton on VesselView to close the safety pop up NOTE Pressing the SKYHOOK button wil also cose safety pop up and then disengage Skyhook 7 The Skyhook system engages and second sold hom beep sounds once The trackpad SKYHOOK button ight stops blinking and remains indicating Skyhook is engaged NOTE Some boat manufacturers include additonal secondary systems of sounds lights or other sources to alert you and your passengers that Skyhook is engaged Sea your boat manufacturer for information about additonal Skyhook otfcaton systems equipped 8 The VesselView SKYHOOK screen displays green circle wih the word ON when Skyhook engages Refer to The Skyhook Screen VesselView NOTE The boat may reverse automaticaly it passed the positon it was asked to hold where the SKYHOOK button Was frst pressed OBMOU ES my OCTOBER 2012 Page Section 3 On the Water 8 When Skyhook engaged you must remain at the helm and maintain vigilant watch Disengags Skyhook f anyone enters ho water or approaches the boat from he wate 10 Press the SKYHOOK button second ime to put Precision Pilot in standby ght other than STANDBY tum of 11 To disengage Skyhook refer to Disengaging Deactivaing Skyhook Disengaging Deactivating Skyhook IMPORTANT Both engines and drives must be operational for Skyhook to function f the necessary reference signals from an eng
84. esume a Heading The RESUME bution lignis on ithe previous course heading is available to resume IMPORTANT The previous heading only be resumed within one minute of the auto heading being disengaged or i the steering wheel has boen tumed no mora than 90 Press the RESUME button to resume the previous heading if you Turned the steering wheel and disengaged auto heading Pressed of the TURN course adjust butions with auto heading engaged 8 Port TURN course adjust bution b Starboard TURN course adjust button RESUME button 8 AUTO HEADING button Disengaging Auto Heading 1 Disengags the auto heading mode with any af the folowing actions Place the ERC handles for boh engines in neutral The AUTO HEADING bution ight tums off and the standby light Turn the steering wheel beyond the electronic detent The AUTO HEADING button light turs off and the resume light comes Page 54 BOEMOO7OGES OCTOBER 2012 Section 3 On the Water Press the AUTO HEADING button on the Precision Plot trackpad Tha AUTO HEADING button light tums off and the standby ight comes on Button ight A single hom beep sounds and the mode indicator changes fron AUTO to OFF 3 I Auto Heading disengaged because the steering wheel was tumed the resume buon ight turns on While the resume button light is on you can press the RESUME button to resume tne course in Auto Heading R
85. et at al times while in the boat Prepare other boat operator Instruct at least one person aboard in the basics of starting and operating the engine and handing the boat in case the driver becomes disabled or als overboard Do not overload your boat Most boats are rated and cet for maximum load weight capacities Refer to your boat capacity plate Know your boat s operating and loading limitations Know if your boat wil feat if fuil of water When in doubt contact your authorized Mercury Marine deslriditibutor or the boat manufacturer Ensure that everyone in the boat is properly seated Do not alow anyone to sit ride an 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 fisting seat anywhere that sudden unexpected acceleration sudden stopping unexpected lass of boat contral or Sudden boat movement could cause a person to be oum overboard or into boat Ensure that all passengers have proper seat and are in it before any boat movement Never be under the influence of alcohol or drugs while boating It is the law Alcohol or drugs impairs your judgment and greatly reduces your to react quicky Know your boating area and avoid hazardous locations Be alert The operator of the boat is responsible by law to maintain proper lookout by sight and hearing The operator must have an unobstructed view particularly to t
86. etween the paint and drive anodic blacks trim tab anodes or MerCathade system by lowing minimum of 40 mm 1 1 2 in unpainted area the hull of the boat around these ems and as shown in the folowing figure Unpainted area Minimum unpainted 40 mm 1 12 in area around the interface ring seal grommet on models with a molded in tunnel opening or round the bolt on interface rng 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 instaling or removing a propeller remove the key from the Key switch placa tno divo in neutral and engage the E stop switch to prevent the engine from starting 1 Place block o wood between the rear propeller blade and the trim tab 2 the rear propeller nut counterclockwise to remove the nut Block af wood Trim tab L E mes 3 Side the propeller and thrust hub off of the propeller shaft 2 0 83 wy OCTOBER 2012 Page Tit Section 5 Maintenance Using the propeller nut tool tum the ron propeller nut counterclockwise and remove the nut Block of wood b Propeller nut tool 4 GEZE Frapar Nut Toot Aids in the removal and installation of the tront propeler nut 5 Side the font propeller and te front rust hub off the propeller shaft io Propeller
87. eus drive Mercury Parts Manual 90 879150112 Getting Started Break In Period New or With Replacement Gears Always perform these proceduras on new drive units This break in procedure allows the proper seating of drive unit gears and related components which great reduces the of problems o Avold ful throtle starts Do nat operate at any one constant speed for extended periods of ime Donat exceed 75 of full hate during the frst five hours During the next ive hours operate at intermittent ful throttle Shift the drive into forward gear a minimum of 10 times during breakin with runin time at moderate RPM after cach shift Afar the frst 25 hours and not to exceed 30 hours change the transmission fluid and fiter including the transmission fuid in he drop if equipped Afer the frst 25 hours and not to exceed 30 hours replace the drive gearcase fuid with High Performance Gear Lube DC Voltage Regulator Switch If Equipped Ifthe vessel is equipped wih 24 system a DC votage regulators required to supply 12 volt power to the VIP and the her 12 alow regulator lo med on and vi provided bythe boat manufacturer The nfs separate Switching he power provides regulated power to the VIP and other 12 alow the vessel o sari Switching the DE voltage regulator prevents regulator om drawing power when vessel operated GOBMOUOESS
88. fractures transom fractures and water leaks Operating a boat or engine with Impact damage can result in product damage serious injury or death If the vessel experiences form of impact have an authorized Mercury Marina dealer inspect and repair the vessel or power package Operating with damaged underwater drive components or boat bottom could cause additonal damage to other parts of the Power package could affect control of he boat If continued operation is necessary do at grealy reduced speeds Zeus Drive Impact Protection IMPORTANT Ahough he design of Zeus dive provides some impact protection no design can ensure total protection from impact damage under ai conditons The Zeus dive has some protecion by dein since the drive is mounted in a tunnel above the bottom o the hul the re az losing or submerged object whe the Baat moving fa skeg is designed bresk away absoring some of the pod and possibly reducing damage o the praeler and lower part f neve eremo canes large feed or fading objects siruck ia skag and Ih exposed over part af the dive may caus he Lower pat f dre a shear of shearing ofthe lower part of the arive i a design feature o protect th hul and dive syst NOTE e lower part of tte drive shears off due to a severe impact make immediate ote of the GPS locaton to assist in covery recovery ofthe damaged parts of he drives pos
89. ge COLD FILL LEVEL old ful ine Page 85 18110070803 OCTOBER 2012 Section 5 Maintenance NOTE After the drive has been operated and the gear lube is hot the fuid expands and may ba up tothe MAX OPERATING LEVEL hot ful ne MAX OPERATING LEVEL noL full ine IMPORTANT if any water is visible at the bottom of the gear lube monitor or if the gear lube appears discolored contact your Mercury Diesel authorized repair act immediately These conditions may indicate a water leak in te drive 4 Ifthe level is ower than the COLD FILL LEVEL col ful line rafer to Filing NOTE Premium Gear Lubricant used during the breakin period is brown in color and must changed after the 25 hour breakin The olor of High Performance Gear Lube used after breakin is blue Do mot mi the gear lubricant 8 Ifthe cap was removed ensure that the gasket for the gear lube monitor cap is property positioned and install the cap Do nat overtighten 8 Gear lube monitor b Instali the civ cover if removed Refer to Installing the Drive Cover 7 i your modelis equipped with a drive cover instal the access cover Insert the molded cip on the end of the access cover under the indented of the cove a Accoss cover b Molded indented edge 8 Align the access cover with the opening in the top cover BO BMDOTOSSS wy OCTOBER 2012 Page Bi Section 5 Maintenance
90. ge With the Boat in the Water 5 Deve Senses Pari Locations n Wa the Boat Out Waar E Starboard 71 Steering Actuator and Hydraulic FI Port Checking E Top 2 Fang E Drop Box 72 Changing E Maintenance Schedules 72 Transmission Gi Pid and Fite E Replication 72 Checking the Transmission Oil Level 90 Routine Naiienance Fang 2 Scheduled Maintenance 73 Chango Zeus Pod Sacra Anode inspection 74 Seawater System E Maintenance Log 74 Draining the Seawater System Drive Cover WEnuppad out of the Water 97 Removing the Drive Cove Boat in the water E Clearing and Inspecting the Dive Cover 78 Checking the Seawalar Pickup on he Drive 101 Instating ine Drive Cover TS Fusing tho Seawater System Deve Gear Lube 79 Bater 102 LI 1080070083 OCTOBER 2012 crcl System 02 Replacing 108 Goong System and Exhaust Sys 102 MerCathose Sys Testing Lubre 100 Tm Tab Anoda E rera Sip lani 102 Checking 108 Driveshaft ome E Replacing 100 Propeller Shaft 105 Continuity mo Corrosion Protection 198 Inhtitng Corrosion mo he Causes Corrosion 106 Paiming the Boat m Corrosion Protection 108 Proper 11 Anodes and MerCathode System 108 Propeller Removal m Reference Elecrde Wire of tie MerGathedo Sala 107 Propeller Repair MarCathods Anode 108 Propelerinsalaton n2 Checking 108 Section 6 Storage Storage Descriptions 116 Recommissioning
91. ge Mercury Marine reserves the ight fo make any warranty coverage contingent upon proof of proper NOTE The product application must be reviewed and approved by Mercury Marine What Mercury Marine Will Do Mercury Marine s sole and exclusive obligation under this warranty is imitadi to at our option repairing a defective replacing such part or parts with or Mercury Marne certified remanufactured parts or refunding purchase price of the Mercury Marine product Mercury Marine reserves the right to improve or modify products from ime to time without assuming obligation o modiy products previously manufactured GBGSWOUTOBSS wy OCTOBER 2012 Page 3 Section 1 Warranty How to Obtain Warranty Coverage Warranty claims must be made trough a Mercury Marine authorized repair faciity The customer must provide Mercury Marine wi a reasonable opportunity t repair and reasonable access to the product for warranty service The purchaser shal not Unless requested by Mercury Marine ship the product or parts of he product directly to Mercury Marine Termination of Coverage Warranty coverage may be terminated for used product obtained of the following ways Repossession from a retail customer Purchase at auction Purchase from a salvage yard Purchase from an insurance company that obtained the product as a result of an insurance claim Inaccurate warranty registration information What Is Not Covered This
92. gin to tha dv BO BMDOTOSSS OCTOBER 2012 Page B5 Section 5 Maintenance 11 Continue to pump gear lube into the drive unt the gear ube appears in the ge ine Donat over yr lobe monitor at the COLD FILL LEVEL COLD FILL LEVEL Ine 12 Remove the gear lube pump and adaptar assembly Quickly install the steering actuator fil and drain washer and screw Tighten the fil and drain screw to specification Description Nm ER Seeing actuator drain sew 87 LJ Ifthe level is low il the gear ibe manitor to the COLD FILL LEVEL ins Refer to Filling 14 Ensure that the rubber gaskat is inside the cap for the gear lube monitor and install the cap Do not overtighten 15 Recheck the gear lube level at the gear lube monitor afer the frst use Rafar to Checking IMPORTANT Tho gear lbs level in the gear lube monitor rises and falls during drive operation always check the gear b level when to drivo is cool and tho engine te shut down With the Boat Out of the Water Rotating propellers can cause serous Injury or death Never operate the boat out of the water wih a propeller Installed Before instaling removing propeller remove the kay from the key switch plaoe ta drive In neutral and engage the switch o prevent tho engine from staring 1 Remove the drive propellers Refer to Propellers 2 Remove the gearcase fil and drain screw and sealing washer
93. h ERC levers to forward neutral or reverse detent 2 Press the DOCK button Dock mode disengages and the DOCK button ight tums of Throttle Only To engage Throtle Only mode 1 Piace both ERC levers in neutral 2 Press the THROTTLE ONLY button located on the DTS trackpad THROTTLE ONLY button 3 The THROTTLE ONLY button light iluminalas and the neutral ights blink 2 Piace either ERC lever into gear 5 The RPM ofthe engines can be raised while the transmissions remain in neutral To disengage Throttle Oniy mode NOTE Pressing the THROTTLE ONLY button whe the ERC levers ar in gear tums of the button but the boat remains in Throttle Only mode unti you place the levers in neutral 1 Bring both ERC levers to neural Only wil not disengage unless the ERC levers ara in neutral 2 Press the THROTTLE ONLY button The THROTTLE ONLY button ight tums of 3 Notice that the neutral lights remain on Single Lever 1 Lever Operation The Zeus single ever 1 Lever feature simpliies engine management during rough ses conditions by allowing you to grasp a single lever to command both engines simultaneously To engage the single lever 1 Lever mode 1 Piace both ERC levers in neutral Page 44 BOSUDIDGSS OCTOBER 2012 Section 3 On the Water 2 Press the LEVER button located on the OTS trackpad attached to the ERC levers 3 The LEVER button light tums on 4 Place the starboar
94. he drives 3 Retum to dock at reduced speed 4 Contact a Mercury Diesel authorized repair faciliy if impact damage is found or suspectas 1 Shutdown engines Tum off and remove keys 3 Check propellers for damage If damaged retum to a Mercury Diesel authorized repair facility for repair or replacement Page 122 BOEMOOTOGES OCTOBER 2012 Section 7 Troubleshooting Battery Will Not Charge Posso Cause Remedy Excessive curent draw rom battery Tarn af nonessential acoassoree ike the air conditioning and Rol water henter Loose or dirty electrical connections or damaged wiring Check al associated connections and wires especialy batery cables Clean and tighten faulty connections Repair or replace damaged ens Ensure area around he ground connections s clean and making good metalto metal contact Wlemsiordrve ba ose or in poor condi Replace or adjust bell Unacceptable battery condon Test baten Battery charge swich off Turn he battery charge Si on Shore power Check the condition of the connections cables and shore power Supp Repair or replace as necessary Gauges and Instrumentation Possible Cause Remedy Gauges not working Key aff and kay on Contact a Mercury Diesel repair Galvanic Isolator Symptom Possis Cause Remedy Rad ight One bink rom green Wah
95. he outboards sterndrives and inboard engines that propel boat as well as ine generators fal power varous boat accessories Carbon monoxide s a deadly as thats odorless colorless and tasteless Early symptoms of carbon monoxide poisoning wich should not be confused with seasickness or intoxication include headache dizziness drowsiness and nausea Carbon monoxide poisoning lead to unconsciousness brain damage or death Keep te boat well vontlatod wie at rest underway and avoid prolonged exposure to carbon monoxide Good Ventilation Ventlate te passenger area open the side curtains or forward hatches to remove fumes Example cf desired air low through the boat Poor Ventilation Under certain conditions permanently enclosed or canvas enclosed cabins or cockpits with insuficient venation may draw in carbon manok Install or mare carbon monoxide detectors in your boat Although the occurrence s rare on a vary calm day swimmers and passengers in an open area of a stationary boat that contains oris near operating engine may be exposed taa hazardous sve of carbon monoxide 1 Examples of poor ventilation while boats stationary a Operating the engine when the boat moored ina confined space eese b Mooring close to another Boat wih ts engine operating a Operating the boat with the angie of the bow too high meresse1 b Operating Pa boat vith no 9 e forward ha
96. he ront No passengers load or fishing seats should block he operators view when operating the boat above idle or planing transitan speed Walch for others keap your eyes on the water and be aware of your wake Never drive your boat directly behind a water skier in case the skier falls As an example your bost traveling 40 kih 25 mah wil overtake a fallen skier who was 61 m 200 in front of you in seconde Watch fallen skiers When using your boat for waterskiing or similar activities always keep fallen or down skier on the operators side of ba boat wile reluming to attend to the skier The operator shouid always have the down sider in sight and never back up to the skier or anyone inthe water Page 25 8010070883 OCTOBER 2012 Section 3 On the Water lt Report accidents Boat operators are required by law to boating accident report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 ferais loss of ife probable los of ifa 2 nere i personal injury requiring medial treatment beyond fes aid 2 here ie damage to boats or other property where the damage value exceeds US 500 00 4 there is complete loss of he boat Seek further assistance om local law enforcement Be Alert to Carbon Monoxide Poisoning Carbon monoxide is present in the exhaust fumes of all intemal combustion engines including t
97. ice the product purchaser cannot deliver the product to such a dealer writen notice must be given o Mercury We wil hen arrange for he inspection and any covered repair Purchaser in that case shall for all related transportation charges andlor trave ime Ifthe service provided is not covered by this warranty purchaser shall for all related labor and material and any other expensas associated with that service Purchaser shal not unless requested by Mercury ship ihe product or parts of the product directly o Mercury Poof of registered ownership must be presented to the dealer at he time warranty service is quested in order to obtain coverage wy OCTOBER 2012 Page 7 Section 1 Warranty What Is Not Covered This mated waranty does not cover electrical system corrosion corrosion resulting from damage corrosion which causes purely cosmetic damage abuse or improper service corrosion to accessories instruments steering systems damage duo to marine growth product old with less than a yea Imited product warranty replacement parts parts purchased by the Customer products used in a commercial application corrosion damage as a result of improper paint application see Operation Maintenance and Warranty manual for acceptable paint applications Commercial use is dened as any work or employment related use of the product or any use of the product which generates income for any pa
98. iesel authorized repair for additonal information 4 Lubricate the driveshaft U joints through the grease i equipped with approximately 3 4 pumps from a handheld mechanical grease gun Driveshat joint with grease tings Page 107 18110070803 OCTOBER 2012 Section 5 Maintenance Tube RefNo Descipion Were Used Pa o pao ad Drives so jon nd joins pm 5 adhesiva to tne renis of he es aed TERN vena helm Tuba Reto Desciplon Where sed Paris fer Disesha retaining screw anda Loealy Install the top and bottom driveshaft shields on he transmission end as Shown Tighten he driveshaft shield retaining screws and nuts to specifications Bottom shield Driveshaft shield upper ower retaining mut and washer 2 Top shiek Driveshaft shield retaining soraw and washer 4 a Description m en C 5 E Driveshaft shield retaining screw transmission end GS models a E Driveshaft shel upperio lower rearing screw and rui ransmisson end 17 7 Insta the engine end driveshaft shield Tighten the screws o specication cw Driveshaft shield Screw wo on each side e Engine end Description m en BF Driveshaft shi screw engins end E Propeller Shaft 1 Remove the propellers Refer to Propellers OSMOUOESS my OCTO
99. iis changed while the levers are at WOT Cruise gradually changes to the new speed Crise does not disengage i he ERC levers are at a higher engine speed than the actual RP Bring the levers back to the forward detent hen use VesselView ta disengage Cruise Skyhook does not function Cruise is engaged Helm Transfer Some boats are designed to alow control of the vessel from more than location These locations are commonly refered to as helms stations Heim transfer is a term used ta describe the method of transfering contra fom one helm or staton o another helm Avoid serious injury or death from loss of boat control The boat operator should never leave the active station while engine is in gear Helm transfer should only bo attempted whie both stations are manned One person helm tansfer should only be performed while engine is in neural The helm transfer function allows the boat operator to select which helm is in contral of the vessel Before a transfer can be inated the ERC levers at ine active helm and at the helm tended for he transfer must ba in na neutral postion NOTE Ifyou attempt to transfer eim control when the ERC levers are notin neutral a beep wil sound and the helm transfor hil not succeed unti the levers at the helms are moved fo neutral transfer is requested Some faut codes may appear VesselView if other control or navigation functions are attempted after the helm transf
100. ine every engine operated and tested before itis boxed for shipment o make sure that the productis ready for use In tin certain Mercury Marine products are tested in controlled and monitored environment for up to 10 hours of engine run ime in order to very and make a record of compliance with applicable standards and regulations A Mercury Marina product sold as new receives the applicable limited waranty coverage whether the engine participated in of the test Programs descrbed above or not Read this Manual Thoroughly IMPORTANT If you do not understand any portion o this manual contact your desler for demonstration of tho actual starting and operating procedures Notice Throughout is publication and on your power package dangers wamings cautions and noticas accompanied by the Intemational Hazard Symbol may be used to aer the installer and user to special instructions conceming a paricular service or operation hat may be hazardous if performed incorrect or carelessly Observe them careful These safety alerts alone cannot eliminato the hazards that they signal Insalers must comply stictly with these special Instructions and should exercise common sense during operation to prevent accidents DANGER Indicates a hazardous situation which I not avoided wl result in death or serious Injury Indicates a hazardous situation which not avoided could resul In death or serious injury Indicates a hazar
101. ine or drive become unavalablo Skyhook automaticaly disengages 1 To disengage the Skyhook do one of the folowing Press the SKYHOOKC button on the Precision Plt trackpad Move any ERC lever out of neural Move the joystick NOTE In each method the ight on the Precision Piot trackpad for the SKYHOOK button wil turn oft 2 A single hom beep sounds when the feature dsengages Auto Heading Auto Heading allows the boat to automatically maintain a compass heading while the boat is underway Engaging Auto Heading 1 Piace at least one running engine in forward gear NOTE Auto Heading does not function withthe ERC levers in neutral or reverse 2 Steer the boat to the desired compass heading 3 Press the AUTO HEADING button to engage the Auta Heading moda The button urinates and single hom beep sounds acknowledging engagement A double horn beep sounds f Auto Heading does not engage 8 Port TURN course adjust button b Starboard TURN course adjust button 62 RESUME button 4 AUTO HEADING bution 4 Display the AUTOPILOT screen on VessalView Refer to Mode Display in VesselView On the VesselView screen for autopilot the mode indicator changes from OFF to AUTO 6 The steering wheel wl sel certer and be hek in electronic delent poston NOTE ff you must tum the steering wheel for any reason you wil need to apply sufficient force to overcome the electronic dete Page 52 BOE
102. ing With the Boat in the Water and fll the drive through the steering actuator Checking IMPORTANT The gear lube level in the goar lube monitor rises falls during drive operation aways check the gear lube level when the drive ls cool and he engine ls shut down NOTE Iis normal to add a amount of gear lube between change intervals IMPORTANT If he gear ube level is below the COLD FILL LEVEL ine when checked especially after the frst couple of times the boat is operated for a long period orf ear lube must be added frequenty there could be a lubricant os such as leak Leaks result in a lack of lubrication that wi damage ha drive Inspect tre diva i lubricant los occurs Contact Your Mercury Diesel authorized acy UBOSWOUTOBSS OCTOBER 2012 Page 75 Section 5 Maintenance 1 On models equipped with a driva cover Inspect the gear lube level in the monitor Port side cover b Gear iube monitor Access cover Oy 5 e 2 b If necessary remove the access cover rom tha drive cover Xem Remove the cap rom the gear lube monitor 2 To check the drive gear lube with the optional drive cover removed refer o Removing the Drive Cover 3 Inspect the gear lube level in the gear lube monitor The gear ube level should be between the COLD FILL LEVEL cold fal and he MAX OPERATING LEVEL pot ful ne a Access cover b Molded cip indented ed
103. ing engine regardless of which station active or previously 9 Inside the VIP for triple quad installations turn the engine selector switch to the desired engine or engines OSMOUOESS my OCTOBER 2012 Pags 17 Section 2 Getting to Know Your Power Package 10 Press and release the start stop switch cr green SMARTSTART start stop switch on the VIP corresponding to the engine being started The control system automaticaly controls the starter to achieve a successful start a E STOP switch tor emergency use only STARTISTOP switch G ec Typical 3 0 VIP for triples Engin selector switch B switch c ve Typical SmartCra 3 0 VIP for quads Engine selector switch port and por center Staristop switch ve Engine selector switch starboard center and starboard switch IMPORTANT To avoid excessive exhaust aeration of tno seawater do not operate ho engines over 1500 RPM when the vessel io ares 11 Ifyou must operate the engines above 1500 RPM put the vessel underway with aight throttle load until the engines reach normal operating temperature Stopping the Engine Using the VIP SmartStart Switch You may desire o stop an engine from the engine room or under certain circumstances the engine control system may not be ble to automatically stop engine The engines can
104. ion forces resulting from accidental or unintended slop switch actvaton The boat aparator should neve leave the operator s station without frst disconnecting the stop vite lanyard from tha operator Vessel Interface Panel VIP Overload A vessel interface panel VIP is typically mounted in the engine compartment The VIP contains circuit breakers hat help protect the syst wiring Ou Main crcut breaker 25 amp 5 Vidagposi cost breaker 10 amp any oral of circuit breaker 10 amp EX eo 8 SiMvessel circuit breaker 10 amp we Starting and Stopping the Engines Your Zeus power package is equipped with a SmartStart system that includes a sar stop button for emergency use that is remotely mounted in he vessel interface panel VIP The VIP is usualy located in the engine room In normal circumstances start and slop the engine rom the helm using the bution of the SmartStart system The seawater pumps on vessels equipped with Zeus pod drives be damaged by excessive exhaust aeraton due to Inadequate water flow To ensure adequate water fow across the seawater inlets make sure that the vessel is underway before exceeding 1500 RPM Page 16 1078110070803 OCTOBER 2012 Section 2 Getting to Know Your Power Package Starting an Engine Using the VIP SmartStart Switch You may desire to start an engine from the engine room or under certain circum
105. ission cooler and hoses may drain into the transmission causing an o level slightly above he maximum mark CChecking dipstick resting on top of threaded hole Maximum mark b Minimum mark Top of threaded hole d 5 ithe level is correct install the dipstick Ithe level is low add the specified transmision through the dipstick threaded hole to bring the level up to the maximum mark on the dipstick Dasaripton Fluid Par Number yel Power Steering Fad SAE Transmission and drop box NOTE the transmission level is extremely low contact your local Mercury Diese authorized repa facit ROBMOUOESS x OCTOBER 2012 Page 9i Section 5 Maintenance IMPORTANT For a more accurate measurement operata he engine at 1500 RPM for tree minutes immediately before checking the ol level Tho seawater pumps on vessels equipped wih Zeus pod drives can bo damaged by excessive exhaust aeration duo to Inadequate water fow To ensure adequate water flow across the seawater inlets make sure that the vessel is underway before exceeding 1500 RPM 7 Start ihe engine and operata a 1500 for three minutes o fl all the hydraulic arcus To avoid excessive exhaust aeration of he seawater do operate the engine above 1500 RPM 8 Stop the engine and quickly check the oi level 9 ifthe o tevel is ow add the specified
106. its the f and drain hole or Ifthe gear lube appears milky the diva is leaking Contact your Mercury Diesel authorized repair immediately 8 Remove the crankcase ol pump and the two adapters 8 the specified gear ube pump or equivalent Locate the adaptar provided with the gear hube pump Page B4 1078110070883 OCTOBER 2012 Section 5 Maintenance Description Part Number Quksiver Lube Pump DE Assemble the sealing washer spacer and sealing washer on the threaded end ofthe adapter NOTE The spacer is required to prevent the adapter rom treading in past the orifice in the fi and drain hole of the Steering actuator The adapter should thread approximately 7 mm 14 in into the actuator housing a Adapter b Sealing washer ay Descartan Part Number 3 Spacer 25406545 T Sealing washer EXE e Instal and hand ighten the adapter assembly into the f and drain hole of he steering actuator IMPORTANT Use Mercury or Quicksilver High Performance Gear Lube in tne drive d Attach the gear lube pump to container of he specified gear lube Adapter assembly b Gear lube pump Fld Capacity peludos Drive Model drive and the gear Fluid Type Fluid Part Number Tube monitor 1 Hah Performance Gear _ 927858064 TL TUS qj Sie BM otl Un Lue 92858065001 951 25 US gal 10 Opera The gear lube pump and be
107. iva gearcase and gear lube monitor In the vessel have been filed wih breakin gear Breakin gear ube must be changed 25 hours and not to exceed 30 hours of oparaton to prevent premature gear wear The color of Drain the drive and goar lube monitor of the breakin goar lube and fil with the specifi gear lubricant Rafer to Drive Gear Task interval Maintenance to Performed Atter the fest 25 hours of operation and not to exceed 30 hours of operation hange e vansmissin ol Ri and Mr including the transmission alin he drap box if equipped Change the gear ube in the drive gearcase and gear lube monitor The task be performed wilh the vessel in the water Every 250 hours af operation or once a yaar whichever occurs fest Tian the drveshal connecting bats and ruso specication Inspect and lubricate the driveshaft spin Inspect the driveshaft lubricate if equipped with grease Figs Change the gear lube in the drive gearcase and gear lube monitor Change the transmission fuid and fiter including the transmission in the drop box if equipped Every 500 hours of operation or once a yaar whichever occurs frst Lubricate the propeller shaft spines and gian the propeller nuis o specication Inspect the hydraulic system ftings and hoses found on the drive for leaks or damage Check the hose fitings far tightness Check the banding continuity cireult for ose or damage
108. k b Gear lube monitor fll Exhaust bow d Drivashat shield screws g Transmission fiter h Anodes Maintenance Schedules Application The folowing schedules apply to the Zeus drive and driveshaft connection not to the engine For the engine maintenance schedule and procedures refer to the Operation and Maintenance Manual avaiable rom the manufacturer of the engine NOTE the maintenance lists the ward check means to visually inspect and than accordingly replace or repair the task item Routine Maintenance Task eral Maintanance tbe Performed Check the actuar and tim tab fuid leve Each day start and when Check the gear lube level in the gear lube monitor refusing Check the transmission fuid level Page 72 18110070803 OCTOBER 2012 Section 5 Maintenance Task interval Maintenance to be Performed Every two months of operation heck the battery connections and fuid level Treat the power package components inside the boat wth Corrosion Guard to protect the product corrosion Ensure that the gauges and the wiring connections are secure Clean the gauges every wo months or every 50 hours whichever cecus frst operating in saltwater ne interval is reduced every 25 hours or 30 days whichever occurs irat Scheduled Maintenance breakin gear lube ls brown Lube IMPORTANT The dr
109. les and booster battery to start the engine can cause serious Injury or product damage from fre or explosion Remove the battery from the boat and recharge in ventlted area away om sparks or fames Electrical System 1 Check for loose damaged corroded fasteners 2 Check fr loose damaged or corroded wiring and connectors Cooling System and Exhaust System 1 Inspect the cooling and exhaust systems for damage or leaks 2 Check the coating and exhaust system hose clamps for tightness Lubrication Driveshaft Slip Joint The driveshaft has slip joint that must be lubricated through a grease fiting Part of he protective driveshaft shield must be temporary removed foraccess o grease ting 1 Remove the driveshaft shield on the engine end Shield on engine end Driveshaft shield b Serew two on each side Engine end Page 107 18110070803 OCTOBER 2012 Section 5 Maintenance 2 Lubricate the driveshaft spjcint through the grease Ring Driveshaft Grease fiting Tube Raf No Description Whore Used Parth up Gimbal z ED Bearing Grease Driveshaft pin 1 2 NOTE cup plug is installed in the canter of the nearest universal joint on the driveshaft si joint The plug retains grease n spine cavity A hole in the canter of the plug acts as a pressure reli for grease in he spine cavity 3 Pump grease into the grease fiting for
110. low speeds he drive system is capable of directing th thrust to produce more responsive turning of the vessel The Zeus drive system features countersotaing propels that do not produce any sideways motan when accelerating or slowing down NOTE During sow speed tuming with the wheel the drive the inside tums as much as 42 to create vary ight turs traditional boats to gan 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 wy OCTOBER 2012 Page 35 Section 3 On the Water To Steer the Boat in Tight Tums at Low Speeds 1 To tum the boat in tight tums at low speeds tum the wheel in the direction of the 2 To increase the tum rate of the boat after the wheel is completly tumed you may increase the power to the inside dive To Spin the Boat on its Axis at Low Speeds Center the steering wheel To spin to the right place the starboard engine in reverse and the port engine in forward To spin to the left place the port engine in reverse and the starboard engine in forward To increase the rate of tum simultaneously adjust each ERC lever for trot Maneuvering with the Joystick The joystick provides single lever interface to maneuver the vessel Operating the vessel with the joystick is well suited for close quarter operations and when docking
111. lt iion he rin secre 12 On modets with ro box and engine mounted transmision oil cooler V ATH sentio ba treads oe anode pug A Desorption Where Used Pai so Jasa Anode plage STO ial plas Tighten anode plugs to specication TZ 7 Ancla rin pica S i E m en ode pg z Recomec he Pose Tran dual ss camps ecl 14 Ay sean to the trends of ha dri scr fo o return ECT Where Used Doo asa Pags 100 18110070883 OCTOBER 2012 Section 5 Maintenance 15 instali the cri screw on the tum seacock Tighten the screw securely Dual hose clamp b Primary cooler c Seawater hose Drain screw Water trapped in the seawater section of the cooing system can cause corrosion or frezo damage Drain the seawater section ofthe cooling system immediately afiar operation or before length of storage in freezing temperatures the boat is in he water koop the seacock closed unti restarting the engine to prevent water from flowing back into the cooing system Ifthe boat snot ited with sescock leave the water niet hose disconnected and plugged 16 Place a tag al the helm and in the engine compartment stating hal he seacocks are closed and must be opened afier all drain plugs and hoses are installed prior to starting the engines Checking the Seawater Pickup on the Drive 1 Ensure that
112. mal usage However boats connected to AC shore power require addtional protectin to prevent destructiva low voltage galvanic currants passing trough the shore power ground wee A Quckaiver Galvanic isolator be installed o block the passage of ness wile providing path to ground for dangerous fault shock currents Rafar to Diesel Parts and Accessories Guide 0 92645008 or he Mercury Accessories Guide 30 8M0062697 for numbers IMPORTANT f AC shore power is not Isolated boat ground the MerCathode System and anodes may be unable to handie the increased galvanic corrosion potential Anodes and MerCathode System Anodes help protect against galvanic corrosion by sacrifcing ther metal to be slowly eroded instead of the melal components te drive or vessel Corrosion protection for the drive is provided by sacrificial anodes installed on the tim tabs Other anodes may be mounted on the vessel to ensure against corrosion of vessel components IMPORTANT Sacrificial anodes must be Inspected periodical Replace the sacri anodes N they are eroded 50 percent or more Refer to Scheduled Maintenance Page 106 178110070883 OCTOBER 2012 Section 5 Maintenance Description Location Faure Trim tab anode Mounted on the trim tab plates The MarCalhodo system uses a reference electrode and an anode as MerCathode controle is mounted on tha transmission Tho system
113. mational Waranty See Table of Contents IMPORTANT Registration ists must ba maintained by the factory and dealer in some countries by law Itis our desira to have ALL products registered at te factory shouid it ever be necessary to contact you sure your Mercury Marino distributor or Mercury Marine authorized dealer fils out tno warranty registration card immediatly and sends te factory copy to the Marine Power International Servico Center for your area Warranty Policy Diesel Models HIGH OUTPUT RECREATIONAL USE WORLDWIDE LIMITED WARRANTY What is Covered Mercury Marine warrants each new Zeus drive system Product to be free of decis in material and workmanship during the period described folowing Duration of Coverage The warranty period begins on the date the product is frst sold to a recreaiona us retail purchaser or the date on which the productis frst put into service whichever occurs frst This Limited Warranty provides coverage for 24 months or 1000 hours of usa whichever occurs frst Commercial use of he product voids waranty Commercial use defined as any work or employment related use of the product or any use of the product which generates income during any part of the warranty Period even if the product is aniy occasionally used for such purposes The repair or replacement of parts or the performance of service under this warranty does not extend the term of his warranty beyond its original expiration dae Unex
114. mp Luml Ten Great Breaker Rating Protection Location on VIP ELY Tower if VIP diagnostics Upper left 3 10 Upper ight H TUA EN Towar ight A Gear Lower center Overload Protection for the DC Voltage Regulator System If Equipped Ifthe vessel is equipped with 24 volt system a DC voltage regulators required to supply 12 volt power to the VIP and the ther 12 al circuits The power package manufacture provides protective fuse for the 24 DC lo 12 01 DC voltage regulator system if equipped The spade st in ine fuse is located in the harness Between Ine voltage regulator and ne Zicvottbatery system The fuse protect the wing and he regulator against overloads Page 22 178110070803 OCTOBER 2012 Section 2 Getting to Know Your Power Package NOTE For addtional information on the on off wich or the voltage regulator refer to your owner s manual uc a DC votage regulator b Wiring t DC voltage regulator 30amp fusa and holder d To 24 volt battery system positive 8 To 24 01 battery estem negative The boat manufacturer may replace the fuse and holder with circuit breaker Have your boat manufacturer or dealer show you location and identity the fuse cirouit breaker for your reference Overload Protection for Other Circuits Other circuits may be protected by creuit breakers or fuses installed by
115. n for Other Circuli a Stating and Stopping the Engines 18 Galvanic Isolator and Monitor a Section 3 On the Water Safe Boating Suggestions 2 While the Boat is Moving Be Aler to Canon Monova Wle the Boat is Sonar 29 Good Vensiation Wave and Wake Jumping 29 Poor Venison 27 impact wih Underwater Hazards 29 Basi Boat Operation 27 Zeus Drive Impact Protection 3 Gold WeanerFreczing Temperatura Seasonal Storage Zeus Dive Alignment and Extended Storage 27 Conditions Affecting Boat Operation 3 Drain Pug and Bige Pump 28 Weight Distribution Passengers and Gear Inside the Proecing People in the Waler 25 3 GBOSWOTOESS OCTOBER 2012 Page i Bottom Of Boat 30 Precision Piot 47 Cavitation 51 Precision Pii Trackpad Festres Ventiaton E General Infomation a Propeller Salen El Standby Geting Started El Standby and Active gis 48 Breakin Period New or Win Replacement Gears 31 Power con 2 DC Voltage Regulator Swich I Equipped 31 if Equipped Staring and Stopping te Engines 2 Engaging Activating Skyhook E Starting en Engine Using the VIP SmartStart Disengaging Deactvating Skyhook E a2 Auto Heading 52 Engaging Auto Heading 52 p P Course Adjustment Using the Tum Butons racional tiancuveriog win Sisering and Taal 38 Joystick E To Maneuver tns Boat in Forward 35 To Resume Heading Steer the Boat in
116. n m en Drop box drain 56 3 15 metal he wanamsion dram plug wi a new seaing washer Tighten the drain plug is specication a Drain lug and seating washer b Transmission Description m em or TTranemiasion dran plug E NOTE The drop box fils with oil when the transmission is filed The transmision may have o be operated ofl he angine mounted cooler Aways use the dipstick to determine the quantity of ol required 16 Fil the transmission drop box and engine mounted cooler if equipped to the proper level with the specified cil Refer to Filing 17 Afer frst start up check for leaks leaks exist stop operation immediately Check the components and repair as needed 18 Instali the drive cover f equipped Refer to Installing the Drive Cover Seawater System Draining the Seawater System IMPORTANT The vessel must be as level posse to ensure completo draining of the cooling system Drain the seawater system of the power package before flushing or before cold weather freezing temperatura seasonal storage or extended storage IMPORTANT The engine must not be operating during to draining procedure Boat out of the Water 4 Remove the boat from the water 2 Open the seawater inlet seacock and seawater retur overboard seacock 3 Drain the seawater 4 On models with a drop box and engine mounted transmision cooler remove the two anode plugs a
117. nd drain the Tp gt b Transmission oll cooler 770883 OCTOBER 2012 Page 07 Section 5 Maintenance 5 On models with a drap box and drive mounted transmission oil cooler as shown remove the drain pug Drain the a Drain plug b Transmission cocer 8 On models equipped wih a seawater strainer rafer to Seawater Strainer Depending on equipment apply sealant to the transmission cooler drain plug or anode plugs before installation Tighten 7 the drain plug securely or ne anode pugs to speciation Tube RefNo Description Where Used Pa o psp pese Drain plug and anode plugs 2 34227002 Description Nm ER z3 Anode plugs EJ 22 8 Place a tag athe helm and in the engine compartment stating that the seacocks are open and must be closed and all plugs and hoses installed prior to placing the boat in the water Boat in the water Water can ener the bilge when draining the seawater system damaging the engine or causing the boat to sink Remove the boat from the water or close the seawater inlet and discharge seacocks and operate the bige pump when draining Do nol operate the engine when draining the seawater system models using a through he hul seawater inlet rafer to your boat manufacturer for instructions and close the seawater vial inlet sacok Rotate the handle in the direction 1 inet valve or snac
118. ng not available in this condition However Zeus features redundant AutoPilot systems so Auto Heading and Track Waypoint mode are sl available during single engine operation Gear Engagement Emergency Procedure Fa transmission or electrical system is damaged or has experienced a condition resulting in a fault such that a transmission oes not respond to the helm controls itis possible to manualy engage a gear In an emergency you can manualy place a transmission into gear by using a suitable wrench to actuate the appropriate gear shifing solenoid Note the folowing Mtis better to use one drive that works propery than locking and operating the drive that is functioning properly This procedure is for when both dives not responding o helm control Auto Heading and Track Waypoint wil work when emergency gear engagement is in use Moving the ERC handle into reverse stops the engine Locking the transmission in gear using tho emergency procedure renders fno heln s shifing control Inoperable Drve careful with the gear lock engaged To shift out of gear um 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 Nuits are hot and can causo serious injury or death Allow the engine to cool before removing any components or opening uid hoses 3 Remove the cover of the affected transmission
119. ngines 4 When the engines are running press and release the start stop switch or the green SMARTSTART start stop switch for sach engine you want to slop a E STOP suitch or emergency use only b STARTISTOP switch Typical SmartCra 3 0 VIP for triples Engine selector switch Starlstop switch c ve Page 34 OSUDIDGSS OCTOBER 2012 Section 3 On the Water B 1 Typical SmariCrat 3 0 VIP or quads Engine selector switch port and center 8 Starstop switch 4 Engine selector switch starboard center and starboard Slaristop switch 8 Turn the key switch to the off position for each engine that was stopped lose the seawater retum seacock if equipped Rotate the handle in the direction indicated by the arrow Drive cover removed for Seawater return seacock if equipped b Handle closed poston 7 Close the seaceck for the seawater inlet Rotate the handle in the direction indicated by the arrow Typical ilo enacock port orientation starboard simian Seacock for seawater inet b Former position open 2 Handle in closed position Traditional Maneuvering with Steering and Thrust You can maneuver your Zeus equipped vessel much tke a traditional inboard boat However the Zeus drive system expands maneuvering capability of your vessel at both slow and planing speeds At s
120. o retard corrosion Without suficient cooing water he engine the water pump and othar components wil overheat and suffer damage Provida a sufficiant supply of walar to tho watar Iles during operation Open the seacocks 3 Ifthe boat is not in the water supply cooling water to the water inlet openings 4 Start the engine and closely observe the instrumentation and system view panel Ensure that all systems are functioning correctly Refer to the Marine Operation and Maintenance Manual for your engine available from the engine manufacturer and carefully inspect the engine for fuel ud water and exhaust leaks 6 Carefully inspect the drive for lubricant Mud water and exhaust leaks Check the steering system the ERC shit control and trot control and the joystick for proper operation 8 Check all lubricant and fud levels afer frst use GOSMOUOESS my OCTOBER 2012 Pags 117 Section 6 Storage Notes Page 118 18110070803 OCTOBER 2012 Section 7 Troubleshooting Section 7 Troubleshooting Table of Contents Diagnosing Elscroncally Controlla Fuel System Problems 120 Eicirica Connections 120 Troubleshooting Chart 120 Troubieshooing Engine Related Problems 120 Check VesselView First 120 Poor Performance 120 am Electronic Remate Controls Steering System Trim Tabs Boat Response Changes Battery Wil Not Charge Gauges and instrumentation Galvanic
121. o ensure no is in the water near the boat and thatthe passengers are secure Compliance with this practice is even more important when Skyhook is engaged Before engaging activating Skyhook the operator must Inform passengers how Skyhook operates to stay of the water and the swim platform and to be alert for any sudden shifts in the boat positon Check to no one is the swim platform or in the watar anywhere near the boat GOBMOUOESS OCTOBER 2012 Page 16 Section 3 On the Water When Skyhook is engaged the operator must Remain atthe helm and maintain a vigilant wah Disengage deactivate Skyhook if anyone enters the water or approaches the boat from the water The capabilty of Skyhook to maintain the postion of the boat in a curent is dependent on the characteristics of the boat If you notice your boat din sideways wd Skyhook s engaged move the bow or stem more direc into the curent to help rede the affects of he curent When the Skyhook is engaged the boat stays in presat postion however Skyhook can disengage unexpectedly When Skyhook disengages the boat does not hold the preset postion and may drit causing the potential of damage or personal Injury The helm operator must be able to take control of he boat when using Skyhook Skyhook raes on an operational GPS receiver and operational heading sensar Occasionally due to imperfect satelite communications the
122. oat in that direction maneuver the boat with te joystick 1 Move both electronic remote contral ERC levers to the neutral positon 2 Move the joystick in the direction that you want the boat to move or twist the joystick in the direction thal you want the boat to rotate Tho joystick can be moved and rotated at the same ime Joystick Input and Boat Response Table Movement Joystick Input Boat Response shown from light gray to dark gray e Boat at rest 1 Page 36 BOSUDIDGSS OCTOBER 2012 Section 3 On the Water Joystick input Boat Response Movement shown from light gray to dark gray E Boat moves forward A Boat moves aft Boat moves to starboard without rotating A 2 Boat moves to part without rotating A wy OCTOBER 2012 Page 37 Section 3 On the Water Movement Rad chown trom ight gray to dark gray Boat moves dagonaly forward and tothe V4 atar without E this maneuver move and ist the tor yaw corecton requie Boat moves diagonal forward and rotates Starboard for yaw correction A aoa without tang N Boat moves dagonaly at ant the port bot rotating Page 35 BOEMOOTOGES OCTOBER 2012 Section 3 On the Water Movement
123. ocation of the engine data tag that contains the engine serial number and model number needed in he ident cation record Jdontficaton Record Please record ho folowing information Drive Location Zeus Drive Serial Number Zeus Drive Model Number Transmission Serisi Number Starboard Gamer Starboard Canter Port Cantar Engine Serial Number Saree Starboard Canter Cantar Pt Cantar Engine Model and Horsepower Propeller Part Number Pih Boat Hull identification Number HIN Purchase Date 7 Boat Manufacturer Boat Model Boat Length Exhaust Gas Emissions Certificate Number Europe Oniy Electronic Control Serial Number Trademark and Copyright Information The description and specifications contained herein were in effect at tha ime this guide was approved for printing Mercury Marine whose policy is of continuous improvement reserves he ight to discontinue modes at any time orto change specifications or designs without noice and without incuring obligan Mercury Marine Fond du Lac Wisconsin USA Printed in USA 2013 Mercury Marine Alpha Axius Bravo One Bravo Two Bravo Three Circle wth Waves Logo K lanes Mariner MerCathode MerCruiser Mercury Mercury with Waves Logo Mercury Marine Mercury Precision Parts Mercury Propellers Mercury Racing MolorGuide OptiMax Quicksilver SeaCora Skyhook Smarcra SprtJet Verado VesselView Z
124. ock 2 On models using the throughhe div seawater inlet lose the acad hear Fa port handle Bere 5 Forner paston open Hande in closed postion 18110070803 OCTOBER 2012 Page 96 Section 5 Maintenance cn indicated by the arro Drive cover removed for clarity seacock b Handle closed poston 4 Tuman the bige pump NOTE In the folowing sep lower or bend the hose as necessary to alow the seawater to drain completa Remove the hose from the seawater niet seacock Drain the seawater T Tipica conecten Poni b Dual hose clamps Hose 6 Remove the seawater hose from the outst end of the primary cooler for the hydraulic Drain the seawater 7 Remove the drain screw onthe seacock Drain the seawater Dual hose clamps b Primary cooler c Seawater hose d Drain screw Ze res 770883 OCTOBER 2012 Page 09 Section 5 Maintenance 9 On models with a drap box and drive mounted transmission cooler as shown remove the drain plug and drain fhe a S donor y 10 On models equipped via sema sir rer Strainer 11 On addu vh ho dive mound ario coca App sealant th ren fh dan plor ha Transmision cil cooler Tube Ratha Where Used so eser 3234227002 E ial di plz
125. on The Skyhook feature can hold your boat near stationary for example while you wait for a space a the fuel dock or while for a bridge to open You also use Skyhook to maintain your boats poston when the water co desp fran ancha To unlock and be able to use this feature you will have to contact your authorized Mercury Diesel repair facit Skyhook should not be used when the boat is next to dock or any other object including other anchored boats Because Skyhook holds the boat in approximate posto not precise one t cause your bost to wih objects cose the boat causing damage to the boat and the nearby objects Occasionaly the Skyhook system may apply a brief surge in power Rong a postion Ts may cause a parson standing near he edge fe boat loose balance and a A rotating propoter a moving boat or a device attached to a moving boat can cause serious injury or death to people in the water When Skyhook is engaged he propellers rotate and the boat moves to maintain the postion of the boat Stop the engines immediatly whenever anyone inthe watar near ha boat To engage Skyhook the drives must be shifted into neutral However after engaging Skyhook the drive response is not the as with drivas normally sid into neutral The propellers will tum when Skyhook is activated and propeller rotation may Pot be obvious As in all boats when the engines ara running it is imporlant t
126. on 5 Draining the Seawater System 3 Place a caution tag at the helm advising the operator to open the seacocks before operating the boat Seasonal and Extended Storage Instructions IMPORTANT Mercury Diesel strongly recommends that this service bo performed by an authorized repa act 1 Remove the boat fom the water possible 2 Read all precautions and perform all procedures found in Cold Weather Freezing Temperature Storage section 3 Perform al maintenance specified for completion under the interval of Every 500 Hours or Once a Year Whichever Occurs First in Maintenance Schedules NOTE For seasonal or extended storage we recommend flushing the seawater cooling system to avoid salt or sit buildup Contact your Mercury Diesel authorized rear facilty for addtional information 4 Clean the outside of the drive and engine Paint any areas as required with the specified primer and spray paint Ater the paint has dried coat the outside of the drive and engine wih the specified corrosion bing or equivalent Description Where Used Part Number Light gray primer of engine and d ve 924287852 Guia cire components when parte mM Marce Cloud White Outside of angine CA Carrion Guard Outside of engine and ave ES Page TIE 178110070803 OCTOBER 2012 Section 6 Storage Battery Storage Whenever the battery wil be stored for an extended period of me be sure the calis a
127. on light tums off NOTE Ifthe hm transfer fs not completed in ten seconds the request is automaticaly cancelled and a double beep sounds Conta wil remain at the existing active hain Press the TRANSFER button again to restart helm transfer 4 The helm where the transfer request was initiated is now active and controls tha vessel Helm Transfer and Precision Pilot Transfering control fom an active helm to an inactive helm one station to another station affects the functionality of Precision Piot modes Some of the effects are listed Auto Heading mode is disengaged when the ERC levers are moved to neutral for helm transfer You must engage Auto Heading at the newly active helm Requesting a heim transfer causes Pilot to go to Standby mode You wil need to input information at the new heim in conta engaged Skyhook wil disengage when the TRANSFER button is pressed tne second ime You must engage Skyhook atthe the nowy active helm The Resume feature for Auto Heading does nat transfer automatically Afer engaging the previous Auto Heading course at the newly active helm the resume feature works the same as at any active station In Track Waypoint mode the contral of the route and display of route data on your chart platter does not automatically transfer to the chart plotter at the requested helm You must tum an the chart plotter at the newly active helm input he waypoint or waypoint route 1o be wacked and re engage Tr
128. onic helm steering operates using electrical signals A computer controlled electric mator attached to the steering wnaei simulates the resistance feedback found in hydraulic steering systems We recommend that you drive carefully in an open area clear of obstructions or other boat affe unti you are familiar with the systers handing characteristics and the boat s response The electronic steering may provide faster steering response than expected To confirm your steering range from lock ta lock ensure that the starboard engine key switch is on Tha engines do not have to be running Turn the wheel starboard unti the wheel stops at the starboard lock or end stop The and stop is electrocicaly Set bythe electric motor attached to the steering wheel Begin turning the wheel to port and count the number af revolutions Until the wheel stops at the port lock The number of wheel ravolutons you counted moves the drivas from the maximum Starboard angle to maximum port angle with the center straight ahead position being 0 The maximum steering angles are controled wihin the vessel personaly developed by the drive manufacturer and the boat OEM In certain situations the electronic end stops of the whee are not felt The absence of noticeable end stops does not affect the steering The drives wil stil stop when they reach the tum position at each lock The absence of end stops can be the result fn starboard key switch in ihe ff poston starboa
129. onnectors or Fayed wiring Blackigraen continuity wire be Nut Bonding stud 4 At the specified interval with the boat out of the water lower the trm tabs and inspect the continuity wire locat between the rim ab and the hinge block Hinge block Tre tab In addition to the corrosion protection devices folow these steps to inhibit corrosion 1 Paint your power package Refer to Painting the Boat 2 Spray power package components on the inside of the boat annually with Corrosion Guard to protect the finish trom duling and comoson 3 Koop all lubrication points wel lubricated Page TIO 18110070803 OCTOBER 2012 Section 5 Maintenance Painting the Boat IMPORTANT The limited warranty does not cover corrosion damage as a result of improper paint aplication IMPORTANT Paint renders anodes and the MerCathode system ineffective as inhibitors of galvanic corrosion When painting the boat hul with antifouling paint observe the following Use high qualiy antfouling paint designed for marine use Avoid using antifouling paint that contains copper material which could conduct electrica current Wusing copper based orlinbased paints is necessary ensure that you comply with and federal laws prohibiting their use Do nat paint drain holes or items as specified by the boat manufacturer Donat paint any anodes or the MerCathode system components Avoid any electrical interconnection b
130. ontents Safe Boating Suggestions Alen to Carvon Monoxide Poisoning Good Ventilation Por Venison Basic Boat Operation Gold Weather Freazing Temperature Seasonal Storage and Extended Storage Drain Pug and Bilge Pump Protecting People in the Water While the Boat is Moving While the Boat is Stationary Wave and Wake Jumping Impact with Underwater Hazards Zeus Drive Impact Protection Zeus Drive Alignment Conditions Affecting Boat Operation Weight Distribution Passengers and Gear insida the Boat Bottom OF Boat Cavitation Ventilation Propeller Selecion Gating Started Breakin Paria New or With Replacement Gears DO Voltage Regulator Switch If Equipped Starting and Stopping the Engines 2 20 20 20 30 E E E 30 31 a EI a E Starting an Engine Using the VIP SmartStart Swiich Siopaing the Engine Using the VIP Sania Sue Traditional Maneuvering wih Sisering and Trust To Maneuver the Boat in Forward Steer the Boat in Tight Turns at Low Speeds o Spin the Boal on is Anis al Low Spade Maneuvering with the Joystick ran Tabs Automate Manual Control Using Tab Otet Special Digtal and Shit OTS Features Troll and Response E 36 40 40 E Dock Only Single Lover 1 Laver Operation Synchronizing tne Engines Crise Control Heim Transfer Requesting Holm Transfer Heim Transfer and Precision Pi
131. or green SMARTSTART start stop switch on the VIP coresponding o the engine being started control system automatically controls he starter to achieve a successful start O ESTOP EU b STARTISTOP switch se D Typical Smaricrat 3 0 VIP for tiles Engine selector switch b Starstop switch e Typical Smartcraft 3 0 VIP for quads a Engine selector switch port and center b Slaristop switch e d Engine selector switch starboard center and starboard Slaristop switch IMPORTANT To avoid excessive exhaust aeration of the seawater do not operate ho engines ovar 1500 RPM when tho essai at rost wy OCTOBER 2012 Page 34 Section 3 On the Water 11 Ifyou must operate the engines above 1500 RPM put the vessel underway with aight throttle load the engines reach normai operating temperature Stopping the Engine Using the VIP SmartStart Switch You may desire lo stop an engine from the engine room or under certain circumstances the engine control system may not be ble to automaticaly stop an engine The engines can be stopped using the SMARTSTART start stop switch on the VIP for ach engine 1 Move the ERC handles to the neutral postin 2 Locate the VIP for each engine in the engine room 3 Inside the VIP for triple or quad installations tum the engine selector switch to the desired engine e
132. ot Precision Piot Precision Piot Trackpad Features General Information Standby Standby and Adve Power lon Skyhook Equipped Engaging Activating Skyhook Disengaging Deac vating Skyhook Auto Heading Engaging Auto Heading Course Adjustment Using the Tum Bulions or To Resume Heading Disengaging Auto Heading Response Sutton Track Waypoint Engaging Track Waypoint Made Disengaging Track Waypoint Mode Tum Buttons or Joystick in Track Waypoint Mode Auto Heading Button in Track Waypoint Mode Acknowtedging a Tum During a Waypoint val Waypoint Sequence Contingent Operations Steering Emergency Alismaive Method Port Engine Only Operation Gear Engagement Emergency Procedure Steering and Trim Manual Override Procedure for a Stuck Steering Conral Vaive Procedure for Stuck Trim Tab Contro Valve End of First Season Checkup wy OCTOBER 2012 Page 25 Section 3 On the Water Safe Boating Suggestions In order to safely enjoy waterways familiarize yourself wih local and all other governmental boating regulations and restrictions and also consider the folowing suggestions Mercury Marin strongly recommends that al powerboat operators complete boating safely course Courses are offered in the USA by he US Coast Guard Auxiliary the Power Squadron the Red Gross and your state or provincial boating aw enforcement agency Inquiries may be made o the Boa
133. overage The warranty period begins on the data tha products first sol to an intermitent commercial use retai purchaser or the date on which tn product is frst put into service whichever occurs frst This Limited Warranty provides coverage for 24 months or 3000 hours of use whichever occurs frst The repair or replacement of parts or the performance of service under this warranty does nat extend the fe of he warranty beyond orginal expiration date Unexpired warranty coverage cannot be transfered Intermittent Commercial Rating Intermittent Commercial apples to variable load applications whore fut power is limited to two 2 hours out of every eight 8 hours of operation Reduced power operation the 6 hours out of 8 hours in which the engine is not operated at full power must be at or below cruise speed Cruise speed is dependant on the engine s maximum engine ated speed RPM Full Power Engine Rated Speed RPM Cruise Speed Full Power is dead as an RPM that excoeds rulo speed Reduction from Engine Rated Speed RPM 2000 2800 RPM 200 RPM 2800 3500 RPM 300 RPM 300 4500 REM 400 RPM Commercial use is defined as any work or employment rated use of this product or any use of the product which generates income for any part of the warranty peris even if tha product is only occasionally used for such purposes Operation of the product in excess af the intermittent commereialuse specifications wil void the wa
134. per right comer of VesselView and has a check mark symbol Once acknowledged Plot racks to the waypoint route Page 60 8010070883 OCTOBER 2012 Section 3 On the Water 7 Stay alert tha boat tums automaticaly in this mode The operator must know fitis safe to tum when the vessel is entering a waypoint arrival zone Inform passengers that tha boat automatically ums o thay be prepared D 1 47 PM AUTOPILOT Please acknowledge that it is safe for the vessel to turn onto the now course Waypoint acknowledge screen 8 Ifyou are notin a previously set waypoint arrival zone WAYPOINT SEQUENCE mode starts auto sequencing to the waypoints in the route Acknowledge that you understand the information presented by the pop up screen warning and press the enter bution the button with a check mark symbol 1 47 PM COLLISION HAZARD Pop up sereen waring 9 Press the TRACK WAYPOINT button The WAYPOINT SEQUENCE button light tums on and a singe hom beep sounds 10 Press the TRACK WAYPOINT button a second ime to put Precision Pio in Standby mode A lights other than STANDBY tum of Contingent Operations Steering Emergency Alternative Method Ifthe electronic steering wheel ceases to operate the engine throttie handles ERC handles tim abs and the vessel joystick shoud operate Engine freies and im tabs can be used as an emergency atemative for steering in open water where here aro
135. pired waranty overage can be transfered from one recreational use customer o a subsequent recreational use customer upon proper registration of Ine produet Page 2 BOEMOOTOGES OCTOBER 2012 Section 1 Warranty Two Year Limited Warranty Limited Warranty Coverage This mid waranty provides coverage for 24 months or 1000 hours of use whichever occurs first for the base drive warranty Coverage Category Monins Hours Parts and Labor Travel Base deve 24 1000 Yes Yes Extended major components 28 2000 Yes Yes Extended Major Components Limited Warranty The Extended Major Components Limited Warranty takes effect when the Base Drive Limited Warrant expires The Bas Drive Limited Warranty expires after 24 months or 1000 hours in service whichever occurs frst The Extended Major Components Limited Waranty covers warrantable ars of a folowing drive pars or casings for 48 mon or 2000 hours Extended Major Components Limited Warranty Coverage Marine gear housing casing Marine gear box housing casing Steering actuator housing casing Dre midsection casting Lower gear housing casing underwaler impact damage excluded Tim tab casting underwater impact damage excluded Bearing cariar casing underwater impact damage excluded venal U ins excluded TIntermodiala shaft underwater impact damage excluded rings Skog unde
136. proper ool shouid attempt major repair Your safely is our concern Always read and understand the Cautions Warnings Important Notices and Notas Do not attempt repairs unless spacificaly trained in that procedure Reference the correct service manual for the product Do not attempt repairs unless qualified Special tools and equipment are required to perform certain repairs Failure to use the correct special and equipment resul in severe damage to the product Always have Mercury Diesel authorized repair faciily service your power package and do periodic maintenance inspections o help provide safe and trouble free boating General Inspection of Power Package Inspect your power package at regular intervals to help maintain top operating performance and avoid potential problems Before they occur Check the entre power package careful including all accessible engine and drive parts For engine inspection information refer to ha appropriate manual 1 Check for loose damaged or missing parts hoses and clamps Tighten or 2 Check electrical connections and leads for damage 3 Remove and inspect the propellers f nicked bent or cracked contact your Mecury Diesel authorized repair faci 4 Repair nicks and corrosion damage on the power package exterior finish Contact your Mecury Diese authorized repair facii While inspecting the power package and drive certain components can be damaged by the weight of an indi
137. r side cover to the center section Remove the one lower screw holding he 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 drive cover Upper screw 6 b Lower screw 3 6 Port side cover Top ofthe drive cover Starboard side cover 1 Tep screw 2 Cleaning and Inspecting the Drive Cover 1 Clean and wax the cover assembly ofen using marine canas and waxes 2 Inspect he individual cover parts for cracks or damage place f cracked or damaged Installing the Drive Cover 1 Carefully install the top cover on the drive Align the cover with the two threaded holes in the transmission where the iting rg were removed E a rop cover 82 Trancas holes 2 Install ane large washer on each of the top cover screws Page 76 178110070883 OCTOBER 2012 Section 5 Maintenance 3 Install the two screws Tighten the screws to specication a Top cover screw b Washer Torque wrench Dascriplon Ca cover screw Li 4 Insta the starboard ade cover using four straws Starboard cover Screw 4 8 Align and insert the starboard cover into the groove ofthe section on the port cover 0770883 wy OCTOBER 2012 Page 77 Section 5 Maintenance 8 Install the por side cover using five screws Typical
138. rack Waypoint or Si hook lo engage a mode When the ACTIVE is illuminated one mode of Precision Pilot is engaged on PRECISION PILOT E LE oo Page 48 BOEMOOTOGES OCTOBER 2012 Section 3 On the Water Power Icon poner on OD locale on the buttons Sook Auto Heating and Track Waypoint data hat the butions can rose or gags Meca Pt c y pam Buttons with Power icons SKYHOOK button 7 AUTO HEADING button TRACK WAYPOINT button O Precision PLOT C Myou press a buton that has the power icon when that button ight is on he ght tums of for hat button and he STANDBY ighi you pres a buton that has the power icon QD wien hat buton ight is oft tha ight tums on for tat button a single beep Sounds and Pa ACTIVE igh urinate another meda is cumanii activa I another mode curan acie press dra bution on aive mods o tan pres a button far he new mode you press a button with tne power icon when that button is of tne ight tums on o hat button a single beep sounas MR AINE iit ur Skyhook if Equipped Your vessel may be equipped with staton keeping feature called Skyhook Skyhook automatically maintains the heading and positon ofthe Boat within about 3 m 101 of a set postion The control system for Skyhook uses GPS and compass heading information automaticaly control si tote and steering to keep the boa in approximately one posit
139. rd battery voltage or a steering wheel molor fault Your vesers personality as developed by the vessel manufacturer in partnership with tha drive manufacturer determines the number af turns lack to Typically this is approximately 2 34 revolutions of the wheal The OEM may request diferent lock to lock setings for other boat models Dual Handle Electronic Remote Control ERC Features and Operation Operation The electronic remote control ERC handie controls the operation o shift and throttie Push the control handle forward from neutral to the frst detent or forward gear Continue pushing the handle forward to increase speed Pull he control handle from the forward positon to he neutral poston o decrease speed and eventual stop Pull he control handie back rom neutral ta the frst detent for reverse gear Continue puling the handie back o increase speed in reverse Page 20 18110070883 OCTOBER 2012 Section 2 Getting to Know Your Power Package NOTE in certain modes gear position is determined by the position of the shit valves on the transmission not the postion of he ERC levers When using the joystick or while in Skyhook the computer movas the transmission in and out of gear even though tha handles are n neutral Neural b Forward 2 Reverse d Bow of boat The amount of foree needed to move the ERC handles and to move the ERC handles through the detents is adjustable to help prevent unwanted mation of the h
140. rdian fault codes Fat cause engine power reduction If found have the system checked by a Mercury Diesel Authorized repair Joystick doas not wark No fault code set contol engaged Disengage cruise contol Electronic Remote Controls Symptom Remedy ERE electronic remate contro levers tao hard or too easy to get out of neutral detent Adjust detent tension Rafer to Section 2 Dual Handle Electronic Remote Control ERC Features and Operation ERC lever moves too hard or too easy rough range of mation Adjust handle tension screw Refer to Section 2 Dual Handle Electronic Remote Control ERC Features and Operation ERC lever increases engine RPM but does not engage gears and boat does not move Key and key Cheek Thrlle Only bulion on DTS trackpad Put ERC levers in neutral and push the button to disengage he Baht is Check transmission ua Tevel and fil necessary Refer to Section 5 Maintenance Engage gears manually Refer to Section 3 Gear Engagement Emergency Procedure Contact a Mercury Diesel authorized repai facii ERC lever controis engine and drive but does not reach wide open toti T engine reachas 50 of WOT check DOCKING buon on DTS trackpad Put handles in neutral and push bution to disengage ight on CheckVesseiView lo ses crues corro enabled Disable puse E Check propaler for damage
141. re ful of water and the battery is charged and in good operating conctton shouldbe clean and tres of leaks Fotow the battery manufacturers instructions for Storage Recommissioning Engine NOTE Discharge of propylene glycol into the environment may be restricted by law Contain and dispose of propylene gyel in accordance wih federal state and cal and guidelines 1 On engines that ware prepared for cold weather freezing temperatura or seasonal storage drain the propylene glycol into a sable container Dispose of the propylene in accordance with federal siate and local laws and guidelines 2 Refer to the appropriate service manual for recommissoning procedures specified by the Mercury Diesel Drive 1 Perform all maintenance specified for completion under the interval of Every 800 Hours or Once a Year Whichever Occurs First in Section 5 Maintenance except ems that were performed at the ime of driva layup 2 Check all id levels before first use Power Package Disconnectig or connecting tho battery cables In he incorract order can cause jury rom electrical shock or can damage electrical system Awaya disconnect the negative battery cable frat and connect h last 1 Instal fuly charged battery Clean the battery cable clamps and terminals Reconnect he cables see the CAUTION above Secure each cable camp when connecting Coat terminais with a battery anl corosion spray t
142. reezing temperatures for even a brief period of ime could resultin freeze damage Corrosion damage is the result of saltwater polluted water oF water with high mineral content trapped in the seawater cooling system Saltwater should not stay in an engines cooling system for even bre storage time drain and flush the seawater cooling system after each outing Freezing weather freezing temperature operation refers to operating the oat whenever freezing temperatures are possible Likewise Freezing weather storage refers to whenever the boat is not being operated and freezing temperatures are possible In such cases the seawater section of the cooling system must be completely drained immediately afer operation Seasonal storage refers to when the bost is not being operated for one month or The duration varies according to the geographic location Seasonal storage precautions and procedures include all the steps for freezing weather storage and some additional stepa that must be taken when storage wil last longer than the short ime of freezing weather storage Drive Storage Cold Weather Freezing Temperature Storage IMPORTANT Mercury Marne song recommends that his service peromed by an authorized repair Damage caused by ring not covered Lined Waray 1 Remove the boat from the water f possible 2 Drain the seawater section of the cooling system Read al precautions and perform al procedures found in Secti
143. rice of the Mercury Product Mercury reserves tna right o improve or modi products rom ma o time without assuming an obligation to modify Products previously manufactured Page amp 8010070883 OCTOBER 2012 Section 1 Warranty How to Obtain Warranty Coverage The customer must provide Mercury vith a reasonable opportunity o repair and reasonable access to the product for warranty service Warranty claims shall bo made by delivering the product for inspection to a Mercury dealer authorized to service the product purchaser cannot deliver the product t such a dealer writen notice must be given o Mercury We will hen arrange for he inspection and any covered repair Purchaser in that case shall for all related transportation charges andlor trave irme Ife service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expensas associated with that service Purchaser shal not unless requested by Mercury ship the productor parts of the Yoduct directly lo Mercury Proof of registered ownership Rust presented to the dealer at he ime warranty service is quested in order to obtain coverage What Is Not Covered This imited waranty does not cover electrical system corrosion corrosion resulting ftom damage corrosion which causes purely sosmet damage abuse or improper service corrosion to accessories Instruments steering systems damage due lo marine grow product soi
144. ring or trim control valve is stuck it may be possible to clear tha steering fault code by manualy overriding the system A decal with information about the location of specife control values ffs to the drive cover f equipped and on the bracket attached loo steering manifold on all models Rafer o the Procedure for a Stuck Steering Control Valve or the Procedure fora Stuck Trim Tab Control Valve for additional information a Decal Hyirauic manifold for steering and irm ManuaLovortdo buttons on tront of manifold a Stoero staboard override button b Trim down override bution Hydraulic manifold Manvial overide buttons roar of manifold a Hydraulic manifold b Trip override bution Steer to port override button Accidental engine staring can cause serious injury or death Remove the key rom the ignition switch and engage the lanyard or Esto switch to prevent ho engine from starting when pororming serie or maintenance on the power package Page 8i 8010070883 OCTOBER 2012 Section 3 On the Water Procedure for a Stuck Steering Control Valve Determine the drive that is not responding steering control Shut down the engine and tum the key switch oft Wait at least 30 seconds if possible Restart the engine Conf the steering fault has cleared Ifthe stering fault did not dear rapeat the sarstop routine up to three times Ifthe steering fault does not clear using the
145. rment In the United States and Canada malo Mercury Marine Warranty Registration Department 6250 W Pioneer Road P O Box 1999 Fond du Lac WI 54936 1930 920 929 5054 Fax 1 920 907 6063 Urge processing the waster of waranty Mercury Marine wil send region ventana new owner of he product by There is charge for this service For products purchased outside the United States and Canada contact the distributor in your county or the Marine Power Saree Center closest to you wy OCTOBER 2012 Page d Section 1 Warranty Notes Page 0 18110070803 OCTOBER 2012 Section 2 Getting to Know Your Power Package Section 2 Getting to Know Your Power Package Table of Contents csi 2 Seed A E sa d Corea HE o em prier Festung Ope m rnm 2 ede 7 Op 2 pes Ete tr ad RE Sai ia Gags su 2 A 1S Grab Rois Lang Sp Saen E 2 Verre oa vad Sharan then ita E Storing ana Sep e Ere S canan kantar and Manor 5 Stating an Engine Using tne VIP SmartStart Switch 7 0 8 OCTOBER 2012 Page Section 2 Getting to Know Your Power Package General Information Models Covered Models Covered Seral Number Zeus 3000 Series Pod Uri MESITA and above Drive Serial Number and Decal Placement numbers are the manufacturer s key to numerous engine
146. rode wee and decrease the corrosion protection a Anode b Reference electrode nat visible in his view MerCathode Anode Checking Inspect the MerCathode anode and replace the anode if damaged Anode b Reference electrode nat visible in his view Replacing Contact your Mercury Diese authorized repair acit MerCathode System Testing Ifthe boat is equipped with a Quicksilver MerCathode system test the system to ensure that itis providing adequate output to protect the underwater metal pars on te boat The test should be made where ins boat is moored using a Quiksilver Reference Electrode and Test Meter Reference DON senses the electrical curent Use to check hul potenti the water when testing the MerCathode system Contact a Mercury Diesel authorized repair facilty for testing or Trim Tab Anode Checking 1 inspect the trim tab anodes Page 108 178110070803 OCTOBER 2012 Section 5 Maintenance 2 Replace the anode i eroded 50 percent or more T m tab anodes Replacing IMPORTANT Te vim tab cylinder is equipped with a check valve to avoid the lowering of the rm tab after shut down When serio ie required lower ori tab before suting he engine down 1 Completa lower the tim tab 2 Remove the five tim tab anode attaching screws each anode fom the bottom of the wim tab 3 tek loc my oc meting zos a y coo 2 Remove and
147. rranty Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage is available only to rta customers that purchase from a dealer authorized by Mercury Marine to distribute product in the country in which sale occured and then only afer Ins Mercury Marine speci edpradelwery inspection process is completed and documentad Warranty coverage becomes available upon proper registration of the product the authorzad dealer Routine maintenance outined in he Operation Maintenance amp Warranty Manual must be imely performed order to obtain waranty coverage Mercury Marine reserves the right 10 make any waranty coverage contingent upon proof of proper maintenance NOTE The product application must be reviewed and approved by Mercury Marine What Mercury Marine Will Do Mercury Marine s scie and exclusive obligation under this warranty is ited to at cur option repairing a defective placing such par or parts with new or Mercury Marine caia remanufactured parts or refuting e purchase price of the Mercury Marine product Mercury Marine reserves the right to improve or modify products from ime to time without assuming obligation o products previously manufactured wy OCTOBER 2012 Page 5 Section 1 Warranty How to Obtain Warranty Coverage Warranty claims must be made trough a Mercury Marine authorized repair faciity The customer must provide Mercury Marine wi a reasona
148. rt of the warranty period Even ifthe product is only occasional used for such purposes DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATESICOUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY 3 Year Limited Warranty Against Corrosion Diesel Models Recreational Use Only What Is Covered Mercury Marine warrants that each new recreational use engineldrive package Product wil not be rendered inoperative as a rect resul of corrosion forthe period of ime described in the folowing Duration of Coverage This corrosion warranty provides coverage for three 3 years rom ether the date the product is frst sold or the date on which the product is frst put into service whichever occurs frst The repair and replacement of parts or the performance of Serves under this warranty does nat extend the ofthis warranty beyond its original expiration date Unexpired warranty coverage can be transferred to subsequent
149. rwater impact damage excluded High Output Rating A High Output Rating applies to variable load applications and requires ful power to be limited to one 1 our out of every ight 6 hours of operation Reduced power operation he 7 hours cut of B hours in which the engine is not operated at full power must be at or below cruise speed Cruise speed is dependant on the engines maximum engine rated speed RPM Full Power Engine Rated Speed RPM Cruise Speed Full Power is defined as an RPM that exceeds cruise speed Reduction from Engine Rated Speed RPM 2000 2800 RPM 200 RPM 2800 3500 RPM 300 RPM 3500 4500 RPM A00 RPM Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage available only to rta customers that purchase a dealer authorized by Mercury Marine to distribute product in the country in which the sale occured and then only afar the Mercury Marine specified predelivary inspection process is completed and documented Warranty coverage becomes available upon proper registration ofthe product by the Authorized dealer Inaccurate warranty registration information regarding recreational use or subsequent change of use from resbional to commercial unless propery reregistered may vod the warranty at he sole discretion of Mercury Marine Routine maintenance outined in tne Operation Maintenance amp Warranty Manual must be timely performed in order to obtain warranty covera
150. ry before elec arc welding tne vessel Attach tho welder ground cable no more han 0 81 m 2 from the par boing welded Do nol connect he ground cable of the weider to any ECM cooling pate or ECM To avoid damage to the engine rive and related components welding on the engine drive or engine and drive mounted component i not recommended Troubleshooting Charts Troubleshooting Engine Related Problems Troubleshooting engine related problems may require information not found in these troubleshooting charts Additional troubleshooting Information can ba found in the owners manual for he engine Refer ta he appropriate Marine Recreational High Output Propulsion Units 058 or QSC Operation and Maintenance Manual provided with he engine Check VesselView First Your VesselView display is the primary information source for the various functions of your beat Consult the VesselView splay if you suspect something is wrong VesselView displays faults and other information that can be helpful in determining the current status of varous systems at could be causing your concer and the solution to the problem Poor Performance Symptom Remedy Chak tat he Cruise Control disengaged Thratle nat operating properly Tum off Tra or Dock functions on DTS control pad Refer to Special Digital and Shit OTS Features Damaged ar improper propeller _ Replace the propeller Ses a Mercury Diesel authorized repair
151. ry voltage Fuel consumption Engine operating hours Smartraf tachometer and speedometer a Tachometer b Speedometer LCD display Jeba The SmartCraft instrument package also aids in identifying the fault codes associated wih the engine audio warning system SmartCraft instrument package displays engine alarm data and ether potential problems on its LCD display For basic operation information on the SmarCrat instrument package and for details on e warming functions monitored by the system refer lo he manual provided wih your gauge package System Link Digital Gauges Some instrumentation packages include gauges that augment the information provided by VesseView and the SmarCrat tachometer and speedometer Tha owner and operator shouid be familar with al the instruments and the functors on the bost Because of ine large variety of instrumentation and manufacturers ave your boa dealer explain the gauges and normal ings that appear on your boat The folowing types of digital gauges may be included with your power package ANS System Link digital gauges Tem Gauge dates Dl pressure gauge Engine of pressure Votar Battery voltage Water temperature gauge Engine operating temperata ENLIT Quantity of fus in tank OBMOUOESS x OCTOBER 2012 Page 13 Section 2 Getting to Know Your Power Package Switches Four Position Key Switch OFF In the
152. s eur he damaged parts to your authorized Mercury Diesel repas or possible reuse Wan pac occurs and damage is present or suspected f the bost does not respond as i shouid or if water is present in the ear lube monitor boe have your inspected at he nearest Mercury Diesel authorized repa acit Operating in reverse gear offers less impact protection Use extreme caution when operating in shallow water or where underwater objects known to be present Use extreme care fo prevent striking submerged objects whe operating in Zeus Drive Alignment The Zeus drives are aligned by the boat manufacturer and must not be adjusted by anyone other than your Mercury Diesel authorized service and repair fact Zeus drives wil automatically recalibrate to this seing at each startup The drives do ol need to be realigned undar normal use Conditions Affecting Boat Operation Weight Distribution Passengers and Gear Inside the Boat Shing weight to the rear stern Causes the bow lo bounce in choppy water Increases the danger of a folowing wave splashing nto the boat when coming aff plane Can cause the boat to porpoise at extremes Shifing weight to the front bow Improves ease of planing o Improves rough water ride Can cause the boat to veer back and forth bow steer at extremes Bottom Of Boat To maintain maximum speed the boat bottom should be lt Clean and free of barnacles and marine growth
153. s cleared I the Tab Spool Stuck fault remains than shut down the engine and turn the key switch aff on the unresponsive driva Operate on another engine and Give Refer io Port Engine Only Operation he starboard drive is shutdown NOTE Boat speed and maneuverailty wil be reduced Oversize or oat listing may occur with tab in the down postion End of First Season Checkup Atthe end of the frst season of operation contact authorized repair faciity to discuss or perform scheduled maintenance Stems If you are in an area where the productis operated continuously year round you should contact your dealer at the end of the frst 100 hours of operation or once yearly whichever occurs frst OBMOU ES my OCTOBER 2012 Page 85 Section 3 On the Water Notes Page 85 178110070803 OCTOBER 2012 Section 4 Specifications Section 4 Specifications Table of Contents De Gear Labra SE Approved Pam r1 Transmission Approved i erro Acusir and Tm OSMOUOESS my OCTOBER 2012 Page 87 Section 4 Specifications Drive Gear Lubricant Fica m rad do zo Pu Pat under per REL Ger season Transmission TMPORTANT Alaya use he disk detain the exact of icant i ee Transmission Without Drop Box oO ETE Fa Pa br Transmission WIh Drop Box Pesce 7 Transmission and drop box 5 14 L 5 1 2 US ql
154. smission cooler equipped T ios 5 Dispose of the transmission cil propery Clean the exterior of the transmission around the fiter assembly 7 Use a Allen wrench and remove the fiter assembly screw Fluid fiter assembly b Assembly scrow Remove the fiter cover assembly UBOSWODTOSSS OCTOBER 2012 Page 95 Section 5 Maintenance 9 Remove and decani the fiter element and the O rings Assembly crew Washer Cover Fiter cover assembly Fiter element Seal 1 Oipie 10 Coat the new O ings wit transmission 11 Instali the new O rings and ftr element Improper installation o the transmission fuid fter assembly may causo th fluid to foam or leak out resulting In decreased fancy and damage to the transmission Proper seat transmision fu fite during instalation 12 instal the fiter assembly in the Transmission cavi by uring the assembly clockwise during instalation 13 Using a 6M Allen wrench tighten the fiter assembly screw to specication a Assembly screw b Fluid itr assembly Descripion Tn a Filer assembly screw 52 IMPORTANT Use new sealing washers to avoid leaks 14 On models with a drop box instal the drain cap Tighten the drain cap to specification a Drop box b Drain cap Page 08 178110070883 OCTOBER 2012 Section 5 Maintenance Dasaipio
155. speed RPM wih Jess tnan a 100 Uso tne Vessel delay to engine RPM and percent ca Its the responsi of the boat manufacturer or the seling dealer to equip the power package with the correct propellers Rafar to the engine information data tag located an the engine for tha specified engine rated spoed RPM Information for the location of the engine data tag can found in the engine owners manual IF full hott engine RPM is below the engine rated speed RPM the propellers will have to be changed to prevent loss of performance and possible engine damage Afr iniiai propeller selection certain issues may require propeller with a lower pitch They include Operating with increased load adaitonal passengers or gear Shiting the center of gravity of the vessel 22 The ad n of towers or canvas Fouing of the hull and running gear High ambient temperatures Operating at high elevation Its the responstlty of the boat owner to ensure that the correct propellers ara installed at delivery and maintained over the fo of he boat Because of the many variablas of boat design on tasting wil determine the best propeler for a particular boat Ifthe engine not able to reach the engine rated speed RPM contact your boatbul r boat dealer or an authorized Mercury Diese repair facit for assistance in propeller selection A ist of propellers for the Zeus drive can located in the Zeus drive parts manual Refer to the Z
156. stances the engine control systems may not be abie to automatically start an engine The engines can be started using the SMARTSTART switch on he VIP for Sach engine 1 Perform the checks and steps listed in the engine s operation and maintenance manual available fortis package NOTE Some vessels are not equipped with a seawater retum seacock 2 Open the seawater retum seacock f equipped Rotate the handie in the direction indicated by the arrow Drive cover removed for Handle in open postion b Seawater return overboard seacock if equipped Typical inlet seacock port orientation starboard similar a Seacock for seawater inlet b Handle in open positon Former pasion closed 4 Open the seacock if equipped for any accessory equipment NOTE When the key swich is tumed to the on position the neutral LED lights on the ERC trackpad fash on and offir the ERC handlas are nof in neutral positon Before starting engines the ERC handles must be neutral posito active standard helm move the ERC handles to the neutral position Ask your dealer for the location of the kay switches the kay switches are not located at the heim 8 Tum the key switch the on position for each engin to be started Verity itis safe to start the engines 8 in the engine room locate the VIP for each engine IMPORTANT The staristop switch or SMARTSTART switch on a VIP wil start the correspond
157. te engine mounted transmission 3 Fluid OW 30 IMPORTANT For more accurate measurement operate the engine at 1500 RPM for throe minutes immediately before checking the ol level NOTE transmission may ba required to fil empty cavities in the transmission filer and coolers afer hanging the transmision o Aways use the dipstick to establish the correct ol eve The seawater pumps on vessels equipped with Zeus pod drives can be damaged by excessive exhaust aeration due to Inadequate water fow To ensure adequate water fow across the seawater inlete make sure that ho vessel is underway before exceeding 1500 RPM 4 Start the engine and operate at 1500 RPM Tor ree minutes Io Ia of the hydraulic and amply caves To avad excessive exhaust aeration of the seawater do not operate the engine above 1500 RPM 5 Stop the engine Quickly unscrew and remove the dipstick TS OCTOBER 2012 Page 03 Section 5 Maintenance 8 Check the oil level Refer to Checking a Maximum mark b Minimum mark c Top of threaded hole d Dipsick yal up to the maximum mark on the dipstick T Ifthe o tevel is ow add the specified transmission i to bring the ke 3 Install the dipstick 8 Install the access cover onto the drive cover it was removed 30 install the drive covert was removed Refer to Installing the Drive Cover
158. tes open station wagon afec Basic Boat Operation Cold Weather Freezing Temperature Seasonal Storage and Extended Storage IMPORTANT Mercury Marino soni recommends that tie servo bo performed by a Mercury Diesel authorized epar tac Damage caused by not covered by ha Mercury Marne mitad Warrant wy OCTOBER 2012 Page 27 Section 3 On the Water Water trapped in the seawater section of the cooing system can cause corrosion or freeze damage Drain the seawater section of he cooling systam immediately operation or before any length of sorage In freszing temperatures If tho boat isin the water the seacock closed unt restarting the engine to prevent water from flowing back into the cooling system Ifthe boat not fed wi a seacock lave Ino water inlet hose disconnected and plugged NOTE As a precautionary measure attach a tag to the key switch steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water iet hase before staring he engine A boat is considered to be in storage whenever itis not in operation The amount of ime that the power package i not peated may be for a brief parod such as during a day overnight fara season or or an extended period of me Certain precautions and proceduras must be observed protect the power package from freeze damage corrosion damage or both pes of damage during storage Freeze d
159. the boat manufacturer and can vary in appearance and locato For example tha MerCathode system has 20 amp in ine fuse in the wire that connects from the positive battery terminal to the postive terminal on he controlar Ifthe fuse is defective open system wil not operate resting in a loss of corrosion protection Have your dealer show you the location of and service procedures for the fuse Ask your dealer for the locaton and operation instructions of all overioad protection devices Galvanic Isolator and Monitor These power packages feature anodes as standard equipment to help protect them fram galvanic corrosion under moderate conditions The MerCathode Systam and sacrical anodes provide corrosion protection under normal usage Boats connected to AC shore power require addtional protection to prevent destructive low voltage galvanic currents rom passing through the shore power ground wre A Quicksilver Galvani lator or equivalent isolation device is recommended to Dock passage of these currents providing a path to ground for dangerous fault shock currents IMPORTANT I AC shore power is not isolated from boat ground the MarCathode System and anodes may be unable to handle the increased galvanic corrosion potential A Quicksiver Galvanic Isolator kt includes an audio and visual monitor to alert you to faults that occur The monitor is micoprocassor controlled salid state device that wil test ihe integrity of fhe Qui
160. the warranty registration and lim program for your area 2 The warranty registration card idas your name and address product model and serial numbers date of sale of use and the seling distibutors and dealer s code number ama and address The distributor or dealer also ceras th you ara the anginal purchaser and user of the product 3 A copy ofthe waranty registration card designated as tha purchaser s copy must be given lo you immediately after the card been completely fled out by the seling distributor or dealer This card represents your factory registration idantficati and shoud 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 waranty registration card to verly date of purchase and use the information on the card to prepare the waranty aim forms 4 In some countries the Marine Power Center wil issue you a permanent pias warranty registration card win 30 days after receiving the factory copy of the warranty registration card your distributor or dealer If you receive plaste waranty ragistraton card you may discard the purchasers copy that you received fram the distributor or dealer When you purchased the product Ask your distributor dealer i this plastic card program applies lo you 5 For further information concerning the warranty registration card and ts relationship to Warranty Claim processing the Inte
161. ting Safety Resource Center vm usegbcatins or the Boat U S Foundation www bcatus comiccurseina Know and obey all nautical rules and laws of the waterways Perform safety checks and required maintenance Follow a regular schedule and ensure that al repas are propery made Check safety equipment onboard Haro are some suggestions of the types of safety equipment to carry when boating Approved fire extinguishers Padi or oar Sional devices fashiight rockets ar fares and whistle or hom E Transistor rado E Tools necessary for minor repairs E Fits kit and instructions Anchor and extra anchor ine Waterproof storage containers Manual bige pump and extra drain plugs E Spare operating equipment batteries bulbs and fuses Dining water Compass and map or chart of the area Watch for signs of weather change and avoid foul weather and rough sea boating Toll someone where you are going and when you expect to retum Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back str ofthe boat Shifting the drive uni into neutral is not sufficient Use personal flotation devices Federal law requires that there ba aU S Coast Guard approved wearable type Ife jacket personal fotabon device correctly sized and rendi accessible for every person aboard plus throwable cushion or rng We strongly advise that everyone wear a Ife jack
162. top switch the E stop switch tums off al of the engines Typical E stop switch Activation of an E sop switch stops the engine or engines immediately but the boat can continue to coast for some distance depending upon the velocity and degree ol any turn at shuldown While ihe boat is coasting it cause injury 1o anyone inthe boats path as seriously as the boat would when under power We recommend instructing ther occupants on proper starting and operating procedures should they need io operate the engine in an emergency Accidental or unintended activation of the switch during normal operation is also possibla which can cause any or all ofthe following potentially hazardous situations Occupanis can be thrown forward due to unexpected loss of forward motion and passengers in the front af the boat could be ejected over the bow and possibly struck by ine propulsion or steering componente The operator can lose power and directional control in heavy seas strong curent or high winds The operator can lose control of the vessel when docking Restarting engine using the key switch or start button after an E stop shutdown without frst turing the key switch to the off position for at least 30 seconds wil restart the engine but cause fault codes to be set Unless you are n a potentially hazardous Situation tum the key swich off and wait at least 30 seconde before restarting the engine or engines If afiar restarting some
163. torage 118 Ore Seasonal and Extended Storage Instucions 116 Power Package Battery Storage 17 n7 GOBMOUOBSS s OCTOBER 2012 Page 115 Section 6 Storage Storage Descriptions IMPORTANT We strongly recommand that tis service be performed by a Mercury Marine authofzd repal Damage tnd by teeing covered by a Mercury Marne Lined Waray Water trapped in the seawater section of the cooing system can cause corrosion or freeze damage Drain the seawater section of the cooling systam immediatly operation or before any length of storage in feazing temperatures If tho boat is in the water keep the seacock closed unt restarting the engine to prevent water from flowing back into he cooling system Ifthe boat not ed witha seacock leave the water inet hose disconnected and plugged NOTE As a precaution attach tag to the key switch or steering whee ofthe boat to remind the operator to open the seacock or unplug and reconnect the water iet hase before starting the engine The power package must be protected from freeze damage corrosion damage or both pes of damage during storage Storage is any length of time the product is not operated Based an the length of storage certain precautions and procedures must be observed to protect the power package Freeze damage can happen when water trapped in he seawater cooing system freezes For example after operating the boat exposure to f
164. tters approved by Mercury Diesel Waypoint data needs to be provided to VesseVew by third party chart plotter Refer to your chart plotters user manual for delais The accuracy of the feature can ba affected by environmental conditions and incorrect use Observa the following information using Track Waypoint and Waypoint Sequencing feature Waypoint data distance setings Between waypoints Greater than 10 nautical mile 1 15 mil alarms No less than 0 1 nautical mile 0 12 mie Page 58 BOEMOOTOGES OCTOBER 2012 Section 3 On the Water Engaging Track Waypoint Mode engage the Track Waypoint mode of Precision Pilot 1 Tum on the char plotter and select single waypoint or waypoint to be tracked 2 Place at least one ERC handle in forward gear Track Waypoint does not funcion both handles are in neutral or reverse 3 Manually steer the boat to the direction af the frst waypoint and hold the boat steady at a safe operating speed 4 Press the TRACK WAYPOINT button onthe Precision Pilat keypad The TRACK WAYPOINT bation ight tums and a single hom beep sounds indicating Track Waypoint engaged Pilot racks to the frst waypoint on tha chart plier course Tu ham beeps sound f Track Waypoint does not engage C O e Gp c e TRACK WAYPOINT button 5 The VesselView TRACK WAYPOINT screen displays on VesselView for on
165. ul coid mark a Cap and dipstick b Fuleoid mark Lowcold mark d dd o 5 ifthe level is low see Filing 6 Ifthe level is correct insert the cap and dipstick into the neck of the reservoir Push down and tum the reservoir cap in the close direction Cap and dipstick b Open direction Close direction Filling 1 Using clean intres cloth wipe the dirt and debris away from the and exterior of the steering actuator and tim fuid NOTE The direction ta rotate the to apen or cese is imprinted on the top of he cap 2 Remove the cap and dipstick Push down and tum the reservoir cap and dipstick about 1 3 tum nthe open direction Reservoir cap and dipstick b Open direction Close direction IMPORTANT Always use the dipstick to determine the exact quant of o required wy OCTOBER 2012 Page 80 Section 5 Maintenance 3 FIL the hycrauscresorvir with the specified lo bring the level up 1o the fulkcold mark Do not ovrt a Cap and dipstick b F licod mark Low cold mark Where Used Patio cp eic Power Steering eT FBR rr sar oo Hydraulic sys 4 Inger he and dipstick the neck af he reservar Push down amd lun reservo cap nthe close rectos Changing You do not need to change the steering actuator and tim system and fiter unless they become contaminated with water or debris
166. ut lubrcant is visible Filing the monitor to the specified level whenever lubricant is stil visible in the monita is correct In some events such as seal leaking the gear lubricant level may have dropped low enough that no lubricant is visible in the monitor In these situations the operator should have received an audible or visual alarm of a ow gear lubricant laval If there has been an audible or visual alarm for low gear lubricant level and the monitor is found empty ing he system trough the gear iube monitor when no lubricant s visible in the monitor is not correct requires ational staps as outined in the Event Summary tabla IMPORTANT Ifthe gear lube monitor is empty alr may be trapped in the drive lubrication system by attempting to f tho monitor through the opening in the monitor Trapped air may cause the lubricant level to appear correct in the monitor but stil be low or insuficiente system The steps for correct maintenance of the drive gear lubrication level can be summarized by the following tabe Event Summary Table Event Task Tow an Taw Wik an gear lube monitor to the specified level Refer to Filing low but visible in monitor Remove the ive side cover equipped Pressure the dive ui through he steering Monitor empty and with an actuator unti the gear lube appears in the gear lube montor at the COLD FILL LEVEL line aam Refer to the appropriate staps in Chang
167. uttons on the keypad or using the joystick changes the mode to AUTO HEADING Auto Heading Button in Track Waypoint Mode While in TRACK WAYPOINT mode pressing the AUTO HEADING button causes Pilot to change to AUTO HEADING mode Acknowledging a Tum During a Waypoint Arrival IMPORTANT Track Waypoint moda does not automatically tum the boat upon arival at a plotted waypoint 1 When the boat enters a waypoint arrival zone as indesled by the chart plotter a short hom beep sounds and tha WAYPOINT SEQUENCE button ight starts blinking to inform the operator to make atum Q PRECISION PILOT 9 o aS 24 WAYPOINT SEQUENCE button Page 58 DOEMOO7OGES OCTOBER 2012 Section 3 On the Water 2 the Waypoint Sequence mode has not been engaged the WAYPOINT SEQUENCING icon ight Binks at the arrival 2 Fo 1 47PM AUTOPILOT Waypoint Sequencing con light 3 VesselViaw displays pop up screen warring The operator must determine is safe to tum the boat If so press the WAYPOINT SEQUENCE button to acknowledge hat its safe for Pilat lo automaticaly turn the boat and maneuver to the B24 F eF 1 47PM AUTOPILOT A Pop up screen warming 4 Ifthe waypoint is not acknowledged the boat continues on its current heading 5 the end af the Track Waypoint course input new route or take control of the boat Otherwise the boat reverts to Auto Heading mode and continues on its last course h
168. vidual and mus mol bo used as stap Decals on top of the drive components indicate where step is allowed Do not step on components wih a decal place as necessary Decal placed where no step is allowed Page 70 178110070803 OCTOBER 2012 Section 5 Maintenance The Zeus drive cover protects and separates some components afier 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 to hoses such as being stepped on during service or maintenance Keep the drive cover installed except when removed for service Typical dive cover For information removing the drive cover refer to Drive Cover If Equipped Drive Service Point Locations Starboard Seawater return discharge valve f equipped b Transmission fud drain plug Hydraulic oil cooler d Exhaust outlet connection Engine seawater retum outlet f Mutter seawater bypass g Seawater inlet seacock h Hydraulic drain plug 1 Gearcase drain plug J Hydraulic oil reservoir Seawater inlet seacock f drive mounted D Driveshaft under shield f equipped Driveshaft shield d Gear lube monitor fit Hydraulic uid fatar f Tim tab and anode plates 8 Propeller shaft OBMOUOESS OCTOBER 2012 Page Section 5 Maintenance a Transmission dipstic
169. ward visit and use less power As the boat comes on plans in automatic control the tim tabs are brought up so the boat does not run withthe bow too far dcum For the best performance asthe boat comes on plane in manual control the port and starboard tim tabs must be adjusted so the boat does not run with the bow too far down In automate control the rm tabs can be usted offset with the port and starboard rm tab switches for best performance when the boat conditions are temporary outside he normal operating conditions avoid an uncomioriahisJaring ride in certain sea conditions adjust the im abs using ether automatic control or manual control As tha wave throws tha bow up trim tabs dampen the boats Smoothing the Ride reaction leveling and smoothing the ride In a folowing sea put tna trim tabs up This allows the Dow ta lit offzeting the waves wivch sf tne stem In mider water some Boats gently porpoise Lower he tim tabs atte at 2 me unt the disappears Gating on Plane A boat ist leaning 1o port or starboard can be caused by unbalanced load or several sea and Correcting a List Weather Using fe por starboard trm tab switches individual m tab adjustments can be made in control or manual control to correct a Tst Tn controled speed zones many boats start to fall of plane as speed decreases hereby reducing Low Speed Trim visti In automatic contral or manual contral lowered tm la
170. with the removal e replacement of boat parlons or other material in order to gain access tothe product are not covered by this waranty No individual ar including Mercury Marine authorized dealers has been given authority by Mercury Marine to make any affirmation representation or warranty regarding the product other than those Contained in his limited warranty If such affirmation representation or warranty s made not enforceable against Mercury Marine Page 4 BOEMOO7OGES OCTOBER 2012 Section 1 Warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY INTERMITTENT COMMERCIAL USE WORLDWIDE LIMITED WARRANTY Products Included in this Coverage Mercury Marine warrants each new Zeus drive system Product to be free of defects in material and workmanship during the Period as described in the folowing Duration of C
171. y A spinning propel moving boat or any solid device attached to tho boat can causo serious injury or death to swimmers Stop the engine immediately whenever anyone In the water is near your boat Shift into neural and shut off the engines before allowing people t swim or be in the water near your boat Do rot alow people to swim around the boat with the Skyhook Electronic Anchor engaged The Skyhook Electronic Anchor causes ha dives to move andthe propellers to turn witout notice Having ta engines in neutral does not protect he swimmers Swimmers in the area of the propellers are at risk of geting 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 posse Operating recreational boats over waves and wakes is a natural of boating However when this activity is done wilh enough speed to force the boat hull paria or completly out of he water certain hazards arise particularly whan the boat entera ina 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 lo leti veer in a new direction Such a sharp change in direction or can cause occupants to be thrown out of thelr seats or out of he boat Impact with Underwater Hazards Reduce speed and proceed with caution whenever you are driving boat in shallow w

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