1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Engine
  5. Zeus 3000 Series
  6. User manual

Mercury Zeus 3000 Series User Manual

Cmd pod drive models
Hide thumbs
Table of Contents

Advertisement

Quick Links

Identification Record
Please record the following information:
The serial numbers are the manufacturer's keys to numerous engineering details
that apply to your Cummins MerCruiser Diesel product. When contacting Cummins
MerCruiser Diesel (CMD) about service, always specify model and serial numbers.
Refer to the engine operation and maintenance manual available from the engine
manufacturer for the location of the engine data tag, which contains the engine serial
number and model number.
Engine Model and Horsepower
The description and specifications contained herein were in effect at the time this
guide was approved for printing. CMD, whose policies are based on continuous
improvement, reserves the right to discontinue models at any time or to change
specifications or designs without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.
©2009, Mercury Marine
a
Drive serial number locations
a -
Transmission serial number plate
Please record the following information:
Drive Serial Numbers
Port
Starboard
/
Propeller Information
Front
Rear
Boat Hull Identification Number (HIN)
Boat Manufacturer
.
Exhaust Gas Emissions Certificate Number (Europe Only)
b -
Drive serial number decal and
stamping
Zeus Drive Serial Number Transmission Serial Number
Engine Serial Number
Port
Starboard
Propeller Part Number
‑
‑
Boat Model
/
b
41269
Pitch
Purchase Date
/
Boat Length

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Zeus 3000 Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Mercury Zeus 3000 Series

Summary of Contents for Mercury Zeus 3000 Series

  • Page 1 CMD, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation. Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A. ©2009, Mercury Marine...

  • Page 2: Read This Manual Thoroughly

    Bravo, Bravo Two, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, VesselView, Zeus, Axius, Total Command, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all trademarks or registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
  • Page 3 CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 - Limited Warranty Warranty Information..........2 Intermittent Commercial Use World‑Wide Warranty Registration—United States and Limited Warranty..........7 Canada.............2 Zeus Drive Limited Warranty Against Corrosion Warranty Registration—Outside the United (Worldwide)............10 States and Canada........... 2 Emission Warranty.........11 High Output Recreational Use World‑Wide Transfer Of Warranty........11 Limited Warranty..........3 Section 2 - Getting to Know Your Power Package...
  • Page 6 Trim Tabs............43 Engaging Auto Heading......58 Automatic Control........43 Course Adjustment Using the Turn Buttons or Manual Control..........44 Joystick............59 Using Trim Tab Offset.........44 To Resume a Heading .......60 Special Digital Throttle and Shift (DTS) Disengaging Auto Heading......60 Features............45 Response Button...........
  • Page 7 Filling............104 The Causes of Corrosion......122 Changing............106 Corrosion Protection........122 Seawater System..........110 Anodes and MerCathode System ....123 Draining the Seawater System.....110 Reference Electrode Wire of the MerCathode Boat out of the Water.........110 System............124 Boat in the water........112 MerCathode Anode........124 Checking the Seawater Pickup on the Drive 115 Checking............124 Seawater Strainer.........116 Replacing...........124...
  • Page 8 Customer Service Literature.......145 Andre språk...........146 English Language..........145 Outros Idiomas..........147 Other Languages...........146 Otros idiomas..........147 Andre sprog...........146 Andra språk...........147 Andere talen..........146 Allej glþssej............147 Muut kielet.............146 Ordering Literature..........147 Autres langues..........146 United States and Canada......147 Andere Sprachen...........146 Outside the United States and Canada..147 Altre lingue.............146 Section 9 - Pre-Delivery Information Pre‑Delivery Information........150 Before Starting—Key On.......151...

  • Page 9: Section 1 - Limited Warranty

    Section 1 - Limited Warranty Section 1 - Limited Warranty Table of Contents Warranty Information..........2 Intermittent Commercial Use World‑Wide Warranty Registration—United States and Limited Warranty..........7 Canada............2 Zeus Drive Limited Warranty Against Corrosion Warranty Registration—Outside the United (Worldwide)...........10 States and Canada.........2 Emission Warranty........11 High Output Recreational Use World‑Wide Transfer Of Warranty........11...

  • Page 10: Warranty Information

    Warranty Registration—United States and Canada The CMD warranty registration center will coordinate warranty registration for both CMD/Cummins and Mercury Marine products, only one Warranty Registration Form is required to be filed for each engine/drive system. 1. To ensure that your warranty coverage begins promptly, your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product.

  • Page 11: High Output Recreational Use World-Wide Limited Warranty

    High Output Recreational Use World‑Wide Limited Warranty Engines and Drive Systems Included in this Coverage Marine Propulsion Zeus 3000 Series Pod Drive Products Warranted This limited warranty applies to new Engines and Drive Systems sold by Cummins MerCruiser Diesel LLC.
  • Page 12 Section 1 - Limited Warranty Base Engine and Drive Limited Warranty This limited warranty covers any failures of the Product, under normal use and service, which result from a defect in CMD material or factory workmanship (Warrantable Failure) Underwater impact damage is not a warrantable failure.
  • Page 13 Failure when performed during normal business hours. All labor costs will be paid in accordance with Cummins and Mercury Marine's published Standard Repair Time guidelines. When it is necessary for mechanics to make on‑site warranty repairs, CMD will pay reasonable travel expenses, including meals, mileage and lodging, for mechanics to travel to and from the repair dock.
  • Page 14 Marine‑approved rebuilt or repaired parts. CMD is Not responsible for failures resulting from the use of Parts not supplied by Cummins/Mercury Marine. A new Cummins/Mercury Marine part or Cummins / Mercury Marine‑approved rebuilt part used to replace a Warranted Part assumes the identity of the Warranted Part it replaced and is entitled to the remaining coverage hereunder.

  • Page 15: Intermittent Commercial Use World-Wide Limited Warranty

    Failure when performed during normal business hours. All labor costs will be paid in accordance with Cummins and Mercury Marine's published Standard Repair Time guidelines. When it is necessary for mechanics to make on‑site warranty repairs, CMD will pay reasonable travel expenses, including meals, mileage and lodging, for mechanics to travel to and from the repair dock.
  • Page 16 Section 1 - Limited Warranty Owner Responsibilities During the Base Engine and Drive Limited Warranty Owner is responsible for the cost of lubricating oil, antifreeze, filter elements, and other maintenance items replaced during warranty repairs unless such items are not reusable due to the Warrantable Failure. Owner is responsible for the operation and maintenance of the Product as specified in the applicable Cummins, MerCruiser, or CMD Operation and Maintenance Manual.
  • Page 17 Section 1 - Limited Warranty Consumer Products The warranty on Consumer Products in the United States is a limited warranty. CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied warranties applicable to Consumer Products terminate concurrently with the expiration of the express warranties applicable to the Product. In the United States, some states do not allow the exclusion of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to you.

  • Page 18: Zeus Drive Limited Warranty Against Corrosion (Worldwide)

    Cummins MerCruiser Diesel and Mercury's sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part, replacing such part or parts with new or CMD / Mercury Marine‑certified, remanufactured parts, or refunding the purchase price of the CMD / Mercury product.

  • Page 19: Emission Warranty

    CMD distributor, an authorized dealer or a repair location approved by CMD, and may elect to use parts other than new genuine Cummins/Mercury Marine or Cummins / Mercury Marine‑approved rebuilt parts and assemblies for such maintenance, replacement or repair; however, the cost of such service or parts and subsequent failures resulting from such service or parts will not be covered under this emission control system warranty.
  • Page 20 Section 1 - Limited Warranty Notes: Page 12 90-866938081 MAY 2009...
  • Page 21 Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents General Information..........14 Electronic Helm Steering.......17 Models Covered..........14 Dual‑Handle Electronic Remote Control (ERC) Drive Serial Number and Decal Placement —Features and Operation......17 ..............14 Operation ..........

  • Page 22: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package General Information Models Covered Models Covered Serial Number Zeus 3000 Series Pod Drive 0M963371 and above Drive Serial Number and Decal Placement Serial numbers are the manufacturer's key to numerous engineering details that apply to your drive.

  • Page 23: Instrumentation

    Section 2 - Getting to Know Your Power Package Activation of an E‑stop switch stops the engine, or engines, immediately, but the boat can continue to coast for some distance depending upon the velocity and degree of any turn at shutdown. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

  • Page 24: System Link Digital Gauges (If Equipped)

    Section 2 - Getting to Know Your Power Package • Battery voltage • Fuel consumption • Engine operating hours • And more 24575 Typical SmartCraft tachometer and speedometer Tachometer Speedometer LCD System View display The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system.

  • Page 25: Electronic Helm Steering

    Section 2 - Getting to Know Your Power Package Item Gauge Indicates Oil pressure gauge Engine oil pressure Voltmeter Battery voltage Water temperature gauge Engine operating temperature Fuel gauge Quantity of fuel in tank Electronic Helm Steering The Electronic Helm Steering is a true drive‑by‑wire system that controls the steering through electronic signals.

  • Page 26: Basic Joystick Operation

    Section 2 - Getting to Know Your Power Package 2. Turn the adjustment screw clockwise to increase tension on the control handle and counter‑clockwise to decrease tension. 3. Adjust to tension desired. To adjust ERC handle tension: 1. Remove the side cover of the handle needing adjustment. 2.

  • Page 27: Vessel Interface Panel (Vip) Overload Protection

    Section 2 - Getting to Know Your Power Package Circuit breakers and fuses provide protection for the electrical system as indicated. The circuit breakers and fuses are located in various locations throughout the boat. Have your dealer show you the location and identify the circuit that they protect. After finding and correcting the cause of the overload, reset the circuit breaker by pressing the reset button.

  • Page 28: Overload Protection For Other Circuits

    Section 2 - Getting to Know Your Power Package NOTE: For additional information on the on‑off switch for the DC voltage regulator, refer to Section 3—Getting Started . 37994 DC voltage regulator To 24‑volt battery system positive ( +) Wiring to DC voltage regulator To 24‑battery system negative (–) 30 ampere fuse and holder The boat manufacturer may replace the fuse and holder with a circuit breaker.
  • Page 29 Section 2 - Getting to Know Your Power Package A Quicksilver Galvanic Isolator kit includes an audio and visual monitor to alert you to faults that occur. The monitor is a microprocessor controlled, solid state device that will test the integrity of the Quicksilver Galvanic Isolator and the safety grounding lead.
  • Page 30 Section 2 - Getting to Know Your Power Package Notes: Page 22 90-866938081 MAY 2009...

  • Page 31: Section 3 - On The Water

    Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions........25 Special Digital Throttle and Shift (DTS) Features Be Alert to Carbon Monoxide Poisoning..26 ..............45 Good Ventilation ........26 Troll and Throttle Response ....46 Poor Ventilation ........

  • Page 32: Section 3 - On The Water

    Section 3 - On the Water Procedure for a Stuck Trim Tab Control End of First Season Checkup......73 Valve ............73 Page 24 90-866938081 MAY 2009...

  • Page 33: Safe Boating Suggestions

    Section 3 - On the Water Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions, and also consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Cummins MerCruiser Diesel strongly recommends that all powerboat operators complete a boating safety course.

  • Page 34: Be Alert To Carbon Monoxide Poisoning

    Section 3 - On the Water • Ensure that everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat;...

  • Page 35: Poor Ventilation

    Section 3 - On the Water 1. Example of desired air flow through the boat. mc79553-1 POOR VENTILATION Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.

  • Page 36: Drain Plug And Bilge Pump

    Section 3 - On the Water • At the end of each daily operation, completely drain the seawater section of the cooling system to protect against damage by freezing. • At the end of each daily operation, drain the water from the water separator, if equipped.

  • Page 37: While The Boat Is Stationary

    Section 3 - On the Water WHILE THE BOAT IS STATIONARY WARNING A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers. Stop the engine immediately whenever anyone in the water is near your boat.

  • Page 38: Zeus Drive Impact Protection

    Section 3 - On the Water IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed. Under these conditions, reduce boat speed to a minimum. The following demonstrate some, but not all, examples of what can happen if the boat strikes a floating or underwater object: •...

  • Page 39: Zeus Drive Alignment

    Section 3 - On the Water Zeus Drive Alignment The Zeus Drives are aligned by the boat manufacturer, and must not be adjusted by anyone other than your Cummins MerCruiser Diesel Authorized Service and Repair Facility. The Zeus drives automatically recalibrate to this setting at each startup. The drives do not need to be re‑aligned under normal use.

  • Page 40: Getting Started

    Authorized Cummins MerCruiser Diesel Repair Facility for assistance in propeller selection. A list of propellers for the Zeus drive can be located in the Zeus drive parts manual. Refer to the Zeus drive Mercury Parts Manual—90-879150112. Getting Started Break‑In Period (New or With Replacement Gears)

  • Page 41: Starting And Stopping The Engines

    Section 3 - On the Water 1. Turn the switch on before attempting to start the engine. 2. Leave the switch on when the vessel is operating. 3. Turn the switch off when the vessel is not operating. Starting and Stopping the Engines Your Zeus power package is equipped with a SmartStart system, as well as an engine start and stop system for emergency use , that is remotely mounted on the VIP for each engine.
  • Page 42 Section 3 - On the Water 4. Open the seacock for the seawater inlet. Rotate the handle in the direction indicated by the arrow. 41197 Typical inlet seacock—port orientation Seacock for seawater inlet Handle in open position Former position (closed) 5.

  • Page 43: Normal Stopping

    Section 3 - On the Water NORMAL STOPPING 1. Move the ERC handles to the neutral position. 2. Corresponding to the engine you want to stop, and depending on your equipment, do one of the following: • Press and release the "START/STOP" switch, if equipped with optional SmartStart switch panel.
  • Page 44 Section 3 - On the Water 3. Open the seacock for the seawater return. Rotate the handle in the direction indicated by the arrow. 41198 Drive cover removed for clarity Handle in open position Seawater return (overboard) seacock 4. Open the seacock for the seawater inlet. Rotate the handle in the direction indicated by the arrow.

  • Page 45: Stopping The Engine Using The Vip Smartstart Switch

    Section 3 - On the Water 10. Press and release the green "SMARTSTART" (start/stop) switch on the VIP corresponding to the engine being started. The control system automatically controls the starter to achieve a successful start. 33930 Typical VIP Red "E‑STOP" switch—for emergency use only Green "SMARTSTART"...

  • Page 46: Traditional Maneuvering With Steering And Thrust

    Section 3 - On the Water 5. After stopping the engines you may close the seacocks. Rotate the handles in the direction indicated by the arrows. 41199 Drive cover removed for clarity Seacock for seawater return Handle in closed position 41196 Typical inlet seacock—port orientation Seacock for engine seawater inlet...

  • Page 47: To Spin The Boat On Its Axis At Low Speeds

    Section 3 - On the Water TO SPIN THE BOAT ON ITS AXIS AT LOW SPEEDS 1. Center the steering wheel. 2. To spin to the right, place the starboard engine in reverse and the port engine in forward. 3. To spin to the left, place the port engine in reverse and the starboard engine in forward.
  • Page 48 Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves forward 25928 24705 Boat moves aft 24706 25927 Boat moves to starboard without rotating 25929 24707 Boat moves to port without rotating 25931 24708...
  • Page 49 Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves diagonally forward and to the starboard without rotating 25926 24709 NOTE: In this maneuver move twist joystick correction, if required. Boat moves diagonally forward and rotates starboard for yaw...
  • Page 50 Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves diagonally forward and to the port without rotating 25925 24712 Boat rotates clockwise 25921 24713 Boat rotates counter clockwise 25920 24714 Boat moves diagonally forward and to the...

  • Page 51: Trim Tabs

    Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves diagonally forward and to the starboard while rotating counterclockwise 25918 24718 Boat moves diagonally forward and to the port while rotating counterclockwise 25917 24719...

  • Page 52: Manual Control

    Section 3 - On the Water Manual trim tab control is available to allow trim tab adjustment when not using the automatic trim tab control feature. See Manual Control. 26318 Typical automatic and manual trim tab switches NOTE: The port or starboard manual trim tab rocker switches allow some control of the attitude of the vessel.

  • Page 53: Special Digital Throttle And Shift (Dts) Features

    Section 3 - On the Water In controlled speed zones, many boats start to fall off plane as speed decreases, thereby reducing visibility. In automatic control or manual control, Low Speed Trim lowered trim tabs keep the boat on plane longer at lower speeds while maintaining a level boat attitude.

  • Page 54: Troll And Throttle Response

    Section 3 - On the Water TROLL AND THROTTLE RESPONSE Troll mode allows the vessel to operate at very low speeds by controlling the transmission. The transmission is capable of reducing the propeller speed lower than the engine speed. Lever control is adjusted so that trolling occurs within the first 25% of lever travel.

  • Page 55: Dock

    Section 3 - On the Water DOCK Dock mode reduces the percent of throttle throughout the range by 50%. This allows better control of engine power in close quarter situations. 31464 "DOCK" button To engage Dock mode: 1. Place both ERC levers in neutral. 2.

  • Page 56: Single Lever (1 Lever) Operation

    Section 3 - On the Water 2. Press the "THROTTLE ONLY" button, located on the DTS trackpad. 31465 "THROTTLE ONLY" button 3. The "THROTTLE ONLY" button light illuminates and the neutral lights blink. 4. Place either ERC lever into gear. 5.

  • Page 57: Synchronizing The Engines

    Section 3 - On the Water 3. The "1 LEVER" button light turns on. 4. Place the starboard ERC lever into gear. 5. The engine RPM raises and lowers simultaneously while the transmissions remain in the same gear. To disengage the single lever (1 Lever) mode: 1.

  • Page 58: Helm Transfer

    Section 3 - On the Water Helm Transfer Some boats are designed to allow control of the vessel from more than one location. These locations are commonly referred to as helms or stations. Helm transfer is a term used to describe the method of transferring control from one helm (or station) to another helm.

  • Page 59: Helm Transfer And Precision Pilot

    Section 3 - On the Water NOTE: If the ERC levers at the helms are not in neutral, the neutral lights will flash. Move all the ERC levers to neutral and the neutral light should then be on. 2. With the "TRANSFER" button light and neutral light on, press the "TRANSFER" button a second time to complete the helm transfer.

  • Page 60: Standby And Active Lights

    Section 3 - On the Water • On the right side of the screen, an icon labeled "OFF" indicates that Pilot is not engaged. NOTE: Not all of the functions of Precision Pilot work when DTS functions are engaged. Disengage the DTS functions to use the functions of Precision Pilot. 31408 Standby screen on VesselView "OFF"...

  • Page 61: Power Icon

    Section 3 - On the Water POWER ICON The power icon located on the buttons for Skyhook, Auto Heading, and Track Waypoint indicate that the buttons can engage or disengage the Precision Pilot function they perform. 27696 Buttons with Power icons "SKYHOOK"...
  • Page 62 Section 3 - On the Water Skyhook should not be used when the boat is next to a dock, or any other object, including other anchored boats. Because Skyhook holds the boat in an approximate position, not a precise one, it can cause your boat to collide with objects close to the boat causing damage to the boat and the nearby objects.

  • Page 63: Engaging (Activating) Skyhook

    Section 3 - On the Water Skyhook performance is largely dictated by the performance of the onboard Zeus GPS system. The Zeus GPS system is accurate within 3 meters (10 feet) when receiving a Wide Area Augmentation System (WAAS) correction. WAAS is a system of satellites and ground stations that provide GPS signal corrections, allowing for more accurate positioning of your GPS.
  • Page 64 Section 3 - On the Water WARNING A rotating propeller, a moving boat, or a device attached to a moving boat can cause serious injury to people in the water. When Skyhook is engaged, the propellers rotate and the boat moves to maintain the position of the boat. Stop the engines immediately whenever anyone is in the water near the boat.

  • Page 65: The Skyhook Screen In Vesselview

    Section 3 - On the Water 9. When Skyhook is engaged you must remain at the helm and maintain a vigilant watch. Disengage Skyhook if anyone enters the water or approaches the boat from the water. 10. Press the "SKYHOOK" button a second time to put Precision Pilot in standby. All lights other than "STANDBY"...

  • Page 66: Auto Heading

    Section 3 - On the Water NOTE: In each method, the light on the Precision Pilot trackpad for the "SKYHOOK" button will turn off. 2. A single horn beep sounds when the feature disengages. Auto Heading WARNING In some Precision Pilot modes—"Auto Heading," "Track Waypoint," and "Waypoint Sequence"—the boat navigates a preset course.

  • Page 67: Course Adjustment Using The Turn Buttons Or Joystick

    Section 3 - On the Water 31409 9. To adjust your course while "AUTO HEADING" is engaged, see Course Adjustment Using the Turn Buttons or Joystick. 10. To disengage Auto Heading refer to Disengaging Auto Heading. 11. Press the "AUTO HEADING" button a second time, Auto Heading goes to Standby mode and all lights other than "STANDBY"...

  • Page 68: To Resume A Heading

    Section 3 - On the Water NOTE: The joystick must move over 50% of its travel for the movement to be recognized as input. 24707 Adjusting heading to starboard TO RESUME A HEADING The "RESUME" button light is on if the previous course heading is available to resume. IMPORTANT: The previous heading can only be resumed within one minute of Auto Heading being disengaged or if the boat has not turned more than 180°.
  • Page 69 Section 3 - On the Water • Press the "AUTO HEADING" button on the Precision Pilot keypad. The "AUTO HEADING" button light turns off and the Standby light comes on. 27700 "TURN" button "RESUME" button "AUTO HEADING" button 2. A single horn beep sounds and the mode indicator changes from "AUTO" to "OFF". 3.

  • Page 70: Response Button

    Section 3 - On the Water Response Button 1. Press the "RESPONSE" button to increase or decrease how aggressively the vessel reacts to programmed changes when in the Pilot modes. How aggressively the vessel reacts equals a response setting in VesselView. NOTE: Each time you press the "RESPONSE"...

  • Page 71: Engaging Track Waypoint Mode

    Section 3 - On the Water • It must not be used as the sole source of navigation. IMPORTANT: Track Waypoint can only be used with chart plotters approved by CMD. Waypoint data needs to be provided to VesselView by a third party chart plotter. Refer to your chart plotter's user manual for details.

  • Page 72: Disengaging Track Waypoint Mode

    Section 3 - On the Water NOTE: This display screen is activated during VesselView calibration. The GPS system generates the displayed heading based on magnetic North. 31413 Track Waypoint screen NOTE: Precision Pilot will not initiate turns when Track Waypoint mode is engaged. Turn features are only available in Auto Heading mode.
  • Page 73 Section 3 - On the Water 1. When the boat enters an waypoint arrival zone as indicated by the chart plotter, a short horn beep sounds and the "WAYPOINT SEQUENCING" button light starts blinking to inform the operator to make a turn. 27703 "WAYPOINT SEQUENCE"...

  • Page 74: Waypoint Sequence

    Section 3 - On the Water 3. VesselView displays a pop‑up screen warning. The operator must determine it is safe to turn the boat. If so, press the "WAYPOINT SEQUENCE" button to acknowledge that it is safe for Pilot to automatically turn the boat and maneuver to the new course. 31414 Pop‑up screen warning 4.
  • Page 75 Section 3 - On the Water 4. A horn beep sounds on VesselView and the green circle icon on the Pilot screen will display "TRACK." The "TRACK" icon on the VesselView screen should illuminate. 31411 Waypoint Sequence TRACK icon 5. If you are in a waypoint arrival zone set by the chart plotter, Waypoint Sequence mode only informs Precision Pilot it is OK to proceed to next waypoint.

  • Page 76: Contingent Operations

    Section 3 - On the Water 7. Stay alert; the boat turns automatically in this mode. The operator must know if it is safe to turn when the vessel is entering a waypoint arrival zone. Inform passengers that the boat automatically turns so they can be prepared. 31414 Waypoint acknowledge screen 8.

  • Page 77: Port Engine Only Operation

    Section 3 - On the Water To maintain steering and course heading, closely observe the amount of engine speed used with each throttle handle. Trim tabs can be adjusted to assist in steering the vessel. An operator should regularly practice steering the vessel in this manner to be familiar with using their vessel's throttles and trim tabs for steering.

  • Page 78: Gear Engagement-Emergency Procedure. 69 Steering And Trim-Manual Override

    Section 3 - On the Water 4. Locate the forward gear solenoid on the port side of the affected transmission (the wire is tagged "Forward Gear"). NOTE: Do not disturb the reverse gear solenoid on the starboard side of the transmission (the wire is tagged "Reverse Gear").
  • Page 79 Section 3 - On the Water CAUTION A fault in the steering control valve or trim control valve will temporarily cause a malfunction of the steering or trim helm controls on the affected drive. If you lose normal steering or trim control, reduce speed to operate the boat safely. The table provides a matrix of related drive and trim tab information in the event of a malfunction or failure.

  • Page 80: Procedure For A Stuck Steering Control Valve

    Section 3 - On the Water 41307 Manual‑override buttons on front of manifold Steer‑to‑starboard override button Trim‑down override button Hydraulic manifold 41309 Manual‑override buttons on rear of manifold Hydraulic manifold Trim‑up override button Steer‑to‑port override button WARNING Accidental engine starting can cause serious injury or death. Remove the key from the ignition switch and engage the lanyard stop or E‑stop switch to prevent the engine from starting when performing service or maintenance on the power package.

  • Page 81: Procedure For A Stuck Trim Tab Control Valve

    Section 3 - On the Water PROCEDURE FOR A STUCK TRIM TAB CONTROL VALVE 1. Determine the drive that is not responding to trim control. 2. Shut down the engine and turn the key switch off. Wait at least 30 seconds, if possible.
  • Page 82 Section 3 - On the Water Notes: Page 74 90-866938081 MAY 2009...

  • Page 83: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Drive Gear Lubricant........... 76 Approved Paints..........76 Transmission............76 Approved Lubricants........... 76 Steering Actuator and Trim Oil......76 90-866938081 MAY 2009 Page 75...

  • Page 84: Drive Gear Lubricant

    (6–6‑1/3 US qt) 92‑858077K01 1 L (1 US qt) 0W‑30 Approved Paints Description Part Number Marine Cloud White (CMD part number: 4918660) Obtain locally Mercury Light Gray Primer 92‑80287852 Mercury Phantom Black 92‑802878Q1 Approved Lubricants Tube Ref No. Description Where Used Part No.
  • Page 85 Section 4 - Specifications Tube Ref No. Description Where Used Part No. U-joint and Gimbal Bearing Driveshaft slip-joint 92-802870A1 Grease Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shafts 92-802867Q 1 90-866938081 MAY 2009 Page 77...
  • Page 86 Section 4 - Specifications Notes: Page 78 90-866938081 MAY 2009...

  • Page 87: Section 5 - Maintenance

    Section 5 - Maintenance Section 5 - Maintenance Table of Contents Product Responsibilities........80 Boat out of the Water ......110 Owner and Operator Responsibilities...80 Boat in the water ........112 Dealer Responsibilities........80 Checking the Seawater Pickup on the Drive Do‑It‑Yourself Maintenance Suggestions..80 ..............115 Inspection............81...

  • Page 88: Product Responsibilities

    Section 5 - Maintenance Product Responsibilities Owner and Operator Responsibilities It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation, and to return the unit to a Cummins MerCruiser Diesel Authorized Repair Facility for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner or operator and as such, are not considered defects in workmanship or material within the terms of the warranty.

  • Page 89: Inspection

    Section 5 - Maintenance It is recommended you have the Cummins MerCruiser Diesel Authorized Repair Facility do periodic maintenance checks on your power package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating season when you want trouble‑free boating pleasure.

  • Page 90: Drive Service Point Locations

    Section 5 - Maintenance Drive Service Point Locations Starboard 41394 Seawater return (discharge) valve Muffler seawater bypass Transmission fluid drain plug Seawater inlet seacock Hydraulic oil cooler Hydraulic oil drain plug Exhaust outlet connection Gearcase drain plug Engine seawater return outlet Hydraulic oil reservoir Port 41381...

  • Page 91: Top

    Section 5 - Maintenance 41460 Transmission dipstick Upper exhaust clamps Gear lube monitor fill cap Lower exhaust clamps Exhaust elbow Transmission filter Driveshaft shield screws Anodes Drop Box 35639 Drain plug or cap Maintenance Schedules Application The following schedules apply to the Zeus drive and driveshaft connection, not to the Cummins engine.

  • Page 92: Routine Maintenance

    Section 5 - Maintenance Routine Maintenance Task Interval Maintenance to be Performed • Check the steering actuator and trim tab oil (fluid) level. Each day start and when • Check the gear lube level in the gear lube monitor. refueling •...

  • Page 93: Maintenance Log

    Section 5 - Maintenance Task Interval Maintenance to be Performed • Change the transmission oil (fluid) and filter, including the transmission After the first 25 hours of oil in the drop box, if equipped. operation and not to exceed 30 hours of operation •...
  • Page 94 Section 5 - Maintenance Date Maintenance Performed Engine Hours Page 86 90-866938081 MAY 2009...

  • Page 95: Drive Cover, If Equipped

    Section 5 - Maintenance Drive Cover, If Equipped Removing the Drive Cover NOTE: The top of the drive cover contains an access panel which provides access to the fill cap on the gear lube monitor and the transmission fluid dipstick without removing the entire cover.

  • Page 96: Installing The Drive Cover

    Section 5 - Maintenance Installing the Drive Cover 1. Carefully install the top cover on the drive. Align the cover with the two threaded holes in the transmission where the lifting rings were removed. 39497 Top cover Threaded holes 2. Install one large washer on each of the top cover screws. 3.
  • Page 97 Section 5 - Maintenance 6. Install the port side cover using five screws. NOTICE Push-T rim Down Push-T rim Up Push- Push- Steer to STBD Steer to POR T Steering a nd Trim Manual Override Buttons. Refer to Operation manual for procedure. 8M0041040 41329 Typical port side cover...

  • Page 98: Drive Gear Lube

    Section 5 - Maintenance Press down evenly on the front end of the hatch cover. The hatch cover snaps into its installed position. 39514 Completing the hatch cover installation Drive Gear Lube Drive Gear Lubrication NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law.

  • Page 99: Checking

    Section 5 - Maintenance Event Task Remove the drive side cover. Pressure fill the drive unit through the steering actuator Monitor empty and until the gear lube appears in the gear lube monitor at the "COLD FILL LEVEL" line. with an alarm Refer to the appropriate steps in Changing—With the Boat in the Water and fill the drive through the steering actuator.
  • Page 100 Section 5 - Maintenance 3. Inspect the gear lube level in the gear lube monitor. The gear lube level should be between the "COLD FILL LEVEL" (cold full line) and the "MAX OPERATING LEVEL" (hot full line). 41471 "COLD FILL LEVEL" (cold full line) NOTE: After the drive has been operated and the gear lube is hot, the fluid expands and may be up to the "MAX OPERATING LEVEL"...

  • Page 101: Filling

    Section 5 - Maintenance Insert the molded clip on the aft end of the hatch cover under the indented‑edge of the cover. 39506 Hatch cover Molded clip Indented‑edge Align the access cover with the opening in the top cover. Press down evenly on the front of the access cover. A click‑sound can be heard when the access cover snaps into final position.

  • Page 102: Changing

    Section 5 - Maintenance 2. Fill the gear lube monitor with the specified gear lube so that the gear lube is level with the "COLD FILL LEVEL" line (cold full line). Do not overfill. 41468 "COLD FILL LEVEL" line (cold full line) Tube Ref No.
  • Page 103 Section 5 - Maintenance 2. Remove the fill and drain screw from the steering actuator. 41463 Drop box model shown, all similar Fill and drain screw Steering actuator 3. Quickly install the special gear lube adapter fitting into the threaded hole for the drain and fill screw.
  • Page 104 9. Pump the gear lube pump and begin to fill the drive with the specified gear lube. IMPORTANT: Use only Mercury or Quicksilver High Performance Gear Lube in the drive. 10. Continue to pump gear lube into the drive until the gear lube appears in the gear lube monitor at the "COLD FILL LEVEL"...

  • Page 105: With The Boat Out Of The Water

    IMPORTANT: If any water exits the fill and drain hole, or if the gear lube appears milky, the drive is leaking. Contact your Cummins MerCruiser Diesel Authorized Repair Facility immediately. IMPORTANT: Use only Mercury or Quicksilver High Performance Gear Lube in the drive. 90-866938081 MAY 2009 Page 97...
  • Page 106 Section 5 - Maintenance 6. Install a suitable gear lube pump into the gearcase fill and drain hole. Fill the drive with the specified gear lube. 28391 Fill and drain hole Gear lube and pump 7. Continue to pump gear lube into the drive until the gear lube appears in the gear lube monitor at the "COLD FILL LEVEL"...

  • Page 107: Steering Actuator And Trim-Hydraulic Oil

    Section 5 - Maintenance NOTE: After the drive has been operated and the gear lube is hot, the fluid will expand and may reach the "MAX OPERATING LEVEL" line (hot full line). 41467 "MAX OPERATING LEVEL" line (hot full line). Steering Actuator and Trim—Hydraulic Oil The steering actuator and trim system use a common hydraulic pump, filtering system, and hydraulic oil storage reservoir for lubrication and pressure.

  • Page 108: Filling

    Section 5 - Maintenance 4. Inspect the fluid level, which should be at the full‑cold mark. 40243 Cap and dipstick Low‑cold mark Full‑cold mark 5. If the level is low, see Filling. 6. If the level is correct, insert the cap and dipstick into the neck of the reservoir. Push down and turn the reservoir cap in the close direction.
  • Page 109 Section 5 - Maintenance 2. Remove the cap and dipstick. Push down and turn the reservoir cap and dipstick about 1/3 turn in the open direction. 40235 Reservoir cap and dipstick Open direction Close direction IMPORTANT: Always use the dipstick to determine the exact quantity of oil required. 3.

  • Page 110: Changing

    Section 5 - Maintenance Changing Refer to the Maintenance Schedules. Change the steering actuator and trim system oil whenever the VesselView fault code is displayed. Contact your local Authorized Cummins MerCruiser Diesel Repair Facility for additional information. 37306 High‑pressure filter system Filter head Filter housing with filter element Transmission Oil (Fluid) and Filter...
  • Page 111 Section 5 - Maintenance 2. Remove the dipstick. Wipe the dipstick with a clean, lint‑free cloth. 37829 Transmission dipstick, with cover removed for clarity 3. Insert the dipstick, resting it on the top of the threaded hole. 4. Remove the dipstick and check the oil level indicated. The oil level should be between the maximum and minimum marks on the dipstick.

  • Page 112: Filling

    Section 5 - Maintenance 11. Install the drive cover if it was removed. Refer to Installing the Drive Cover. 12. If your model is equipped with a drive cover, install the access cover. Insert the molded clip on the aft end of the hatch cover under the indented‑edge of the cover.
  • Page 113 Section 5 - Maintenance 1. To access the transmission dipstick, you must remove the access cover or remove the drive cover, if equipped. Refer to Removing the Drive Cover. 25914 Access cover Transmission Transmission dipstick 2. Remove the dipstick. Wipe the dipstick with a clean, lint‑free cloth. Check the oil level as outlined in Checking.

  • Page 114: Changing

    Section 5 - Maintenance 5. Stop the engine. Quickly unscrew and remove the dipstick. 6. Check the oil level. Refer to Checking. 28080 Maximum mark Top of threaded hole Minimum mark Dipstick 7. If the oil level is low, add the specified transmission oil to bring the level up to the maximum mark on the dipstick.
  • Page 115 Section 5 - Maintenance 3. Remove the M30 drain plug and sealing washer from the aft, starboard end of the transmission and drain the transmission oil (fluid) into a suitable container. 41194 Transmission Drain plug and sealing washer 4. On models with a drop box, remove the drain cap from the lower, port side of the drop box.
  • Page 116 Section 5 - Maintenance 7. Use a 6M Allen wrench and remove the oil filter assembly screw. 28239 Fluid filter assembly Assembly screw 8. Remove the filter cover assembly. 9. Remove and discard the filter element and the O‑rings. 28242 Assembly screw O‑ring Washer...
  • Page 117 Section 5 - Maintenance 13. Using a 6M Allen wrench, tighten the filter assembly screw to specification. 28239 Assembly screw Fluid filter assembly Description lb‑in. lb‑ft Filter assembly screw – IMPORTANT: Use new sealing washers to avoid leaks. 14. On models with a drop box, install the drain cap. Tighten the drain cap to specification.

  • Page 118: Seawater System

    Section 5 - Maintenance 15. Install the transmission drain plug with a new sealing washer. Tighten the drain plug to specification. 41194 Drain plug and sealing washer Transmission Description lb‑in. lb‑ft Transmission drain plug – NOTE: The drop box fills with oil when the transmission is filled. The transmission may have to be operated to fill the engine‑mounted cooler.
  • Page 119 Section 5 - Maintenance 4. On models with a drop box and engine mounted transmission oil cooler, remove the two anode plugs and drain the seawater. 37838 Transmission oil cooler Anode (drain) plugs 5. On models with a drop box and drive mounted transmission oil cooler, as shown, remove the drain plug.

  • Page 120: Boat In The Water

    Section 5 - Maintenance BOAT IN THE WATER CAUTION Water can enter 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 bilge pump when draining.
  • Page 121 Section 5 - Maintenance 5. Remove the hose from the seawater inlet seacock. Drain the seawater. 41200 Typical connection Inlet seacock Dual hose clamps Hose 6. Remove the seawater hose from the outlet end of the primary cooler for the hydraulic oil.
  • Page 122 Section 5 - Maintenance 9. On models with a drop box and drive mounted transmission oil cooler, as shown, remove the drain plug and drain the seawater. 41401 Drain plug Transmission oil cooler 10. On models equipped with a seawater strainer, refer to Seawater Strainer. 11.

  • Page 123: Checking The Seawater Pickup On The Drive

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Threads of the drain screw for Perfect Seal 92-34227 1 the return seacock 15. Install the drain screw on the return seacock. Tighten the screw securely. 41264 Dual hose clamps Primary cooler Seawater hose Drain screw...

  • Page 124: Seawater Strainer

    Section 5 - Maintenance 2. Looking through the inlet openings, visually inspect the cavity between the inlet cover and the center section plate for marine growth (shells, crustaceans, etc.). If marine growth is found in the cavity, contact your Authorized CMD Repair Facility. 41411 Shown with cover removed for clarity Seawater inlet to seacock...

  • Page 125: Cleaning Gauges

    Section 5 - Maintenance 2. Check that any viewing systems such as VesselView, if equipped, are securely mounted. 3. Check for loose, damaged, or corroded wiring and connectors. 4. Contact your Cummins MerCruiser Diesel Authorized Repair Facility for correction or repair if necessary.
  • Page 126 Section 5 - Maintenance 2. Lubricate the driveshaft slip‑joint through the grease fitting. 34051 Driveshaft Grease fitting Tube Ref No. Description Where Used Part No. U-joint and Gimbal Bearing Driveshaft slip-joint 92-802870A1 Grease NOTE: A cup plug is installed in the center of the nearest universal joint on the driveshaft slip‑joint.

  • Page 127: Driveshaft U-Joints

    Section 5 - Maintenance 5. Install the driveshaft shield on the engine end using the flange‑head screws as shown. Tighten the screws to specification. 34052 Top shield Driveshaft shield to engine screw Engine end Description lb. in. lb. ft. Driveshaft shield screw—engine end –...
  • Page 128 Section 5 - Maintenance 2. Remove the top and bottom driveshaft shields on the transmission end as shown. 36689 Bottom shield Driveshaft shield upper‑to‑lower retaining hardware (2) Top shield Driveshaft shield retaining screw (4) 3. Visually inspect each U‑joint bearing for: Seal deterioration or damage.

  • Page 129: Propeller Shaft

    Section 5 - Maintenance 6. Install the top and bottom driveshaft shields on the transmission end as shown. Tighten the driveshaft shield retaining screws and nuts to specifications. 36689 Typical Bottom shield Driveshaft shield upper‑to‑lower retaining screw, nut, and washer (2) Top shield Driveshaft shield retaining screw and washer (4) Description...

  • Page 130: Corrosion And Corrosion Protection

    A Quicksilver Galvanic Isolator can be installed to block the passage of these currents while providing a path to ground for dangerous fault (shock) currents. Refer to the Diesel Parts and Accessories Guide (90‑892645008) or the Mercury Accessories Guide (90‑420000009) for part numbers.

  • Page 131: Anodes And Mercathode System

    Section 5 - Maintenance Anodes and MerCathode System Anodes help protect against galvanic corrosion by sacrificing their metal to be slowly eroded instead of the metal components on the drive or vessel. Corrosion protection for the drive is provided by sacrificial anodes installed on the trim tabs.

  • Page 132: Reference Electrode Wire Of The Mercathode System

    Section 5 - Maintenance Reference Electrode Wire of the MerCathode System NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or high‑pressure washers to clean the MerCathode assembly. Do not pressure‑wash the reference electrode of the MerCathode assembly.

  • Page 133: Trim Tab Anode

    Section 5 - Maintenance Reference Electrode 91‑76675T 1 Senses the electrical current in the water when testing the MerCathode system. Use to check hull potential. 9188 Contact a Cummins MerCruiser Diesel Authorized Repair Facility for testing or refer to the appropriate Cummins MerCruiser Diesel Drive Service Manual for testing procedures.

  • Page 134: Continuity Circuits

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Loctite 271 Threadlocker Trim tab anode screw 92-809819 7. Install the anodes on the trim tab. Tighten the screws to specification. 41252 Port anode Starboard anode Screws (5) Description lb‑in.

  • Page 135: Inhibiting Corrosion

    Section 5 - Maintenance 3. Inspect the bonding stud, nut, and continuity wire (–) on the center section for corrosion, loose connections, broken connectors, or frayed wiring. 41261 Black/green continuity wire Bonding stud 4. At the specified interval, with the boat out of the water, lower the trim tabs and inspect the continuity wire (–) located between the trim tab and the hinge block.

  • Page 136: Propellers

    Section 5 - Maintenance • Avoid using anti‑fouling paint that contains copper material, which could conduct electrical current. • If using copper‑based or tin‑based paints is necessary, comply with all local and federal laws prohibiting their use. • Do not paint drain holes or items as specified by the boat manufacturer. •...

  • Page 137: Propeller Repair

    Section 5 - Maintenance 4. Using the propeller nut tool, turn the front propeller nut counter‑clockwise and remove the nut. 24035 Block of wood Trim tab Propeller nut tool Propeller Nut Tool 91‑805457T 1 Aids in the removal and installation of the front propeller nut. 10677 5.

  • Page 138: Propeller Installation

    Section 5 - Maintenance Propeller Installation WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
  • Page 139 Section 5 - Maintenance 4. Install the front propeller nut. 24031 Front propeller 5. Place a block of wood between the trim tab and the propeller. 6. Tighten the front propeller nut to specification using the propeller nut tool. 24035 Block of wood Trim tab Propeller nut tool...
  • Page 140 Section 5 - Maintenance 10. Install the rear propeller nut. 11. Place a block of wood between the trim tab and the propeller. 12. Tighten the rear propeller nut to specification. 24037 Block of wood Trim tab 25876 Zeus drive propeller assembly Front thrust hub Rear thrust hub Front propeller...

  • Page 141: Section 6 - Storage

    Section 6 - Storage Section 6 - Storage Table of Contents Storage Descriptions........134 Engine Storage...........135 Drive Storage............ 134 Battery Storage..........135 Cold Weather (Freezing Temperature) Storage Recommissioning..........135 ..............134 Engine............135 Seasonal and Extended Storage Instructions Drive............136 ..............135 Power Package...........136 90-866938081 MAY 2009 Page 133...

  • Page 142: Storage Descriptions

    Section 6 - Storage Storage Descriptions IMPORTANT: We strongly recommend that this service be performed by a Cummins MerCruiser Diesel Authorized Repair Facility. Damage caused by freezing is not covered by the Cummins MerCruiser Diesel Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage.

  • Page 143: Seasonal And Extended Storage Instructions

    Description Where Used Part Number Light gray primer Outside of engine and drive 92‑802878‑52 Outside of drive components when painted Mercury Phantom Black 92‑802878Q1 black Marine Cloud White paint Outside of engine Obtain locally (CMD part number: 4918660) Corrosion Guard Outside of engine and drive 92‑802878‑55...

  • Page 144: Drive

    Section 6 - Storage Drive 1. Perform all maintenance specified for completion under the interval of Every 500 Hours or Once a Year (Whichever Occurs First) in Section 5—Maintenance except items that were performed at the time of drive layup. 2.

  • Page 145: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing Electronically Controlled Fuel System Joystick............139 Problems............138 Electronic Remote Controls......139 Electrical Connections........138 Steering System..........140 Troubleshooting Charts........138 Trim Tabs............141 Troubleshooting Engine Related Problems Boat Response Changes......141 ..............138 Battery Will Not Charge.......141 Check VesselView First......138 Gauges and Instrumentation.......142...

  • Page 146: Diagnosing Electronically Controlled Fuel System Problems

    Section 7 - Troubleshooting Diagnosing Electronically Controlled Fuel System Problems Your Cummins MerCruiser Diesel Authorized Repair Facility has the proper service tools for diagnosing problems on electronically controlled fuel systems. The Engine Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a trouble code in the ECM's memory.

  • Page 147: Poor Performance

    Section 7 - Troubleshooting Poor Performance Symptom Remedy Check that the Cruise Control is disengaged. Throttle not operating properly. Turn off Troll or Dock functions on DTS control pad. Refer to Special DTS Functionality. Replace the propeller. See an Authorized Cummins MerCruiser Diesel Damaged or improper propeller.

  • Page 148: Steering System

    Section 7 - Troubleshooting Symptom Remedy Key off and key on. Check "Throttle Only" button on DTS track pad. Put ERC levers in neutral and push the button to disengage, if the light is on. Check transmission fluid level and fill if necessary. See ERC lever increases engine RPM, but does not engage gears and boat does not move.

  • Page 149: Trim Tabs

    Section 7 - Troubleshooting Symptom Remedy Key off and key on. Check and start port engine. Check trim tab function. Steering works, but boat is not as Check steering actuator fluid level and fill if necessary. See responsive. Section 5, Maintenance. Contact your Authorized Cummins MerCruiser Diesel Repair Facility.

  • Page 150: Gauges And Instrumentation

    Section 7 - Troubleshooting Possible Cause Remedy Alternator drive belt loose or in poor Replace or adjust belt. condition. Unacceptable battery condition. Test battery. Battery charge switch off Turn the battery charge switch on. Check the condition of the connections, cables, and shore power Shore power not on supply.

  • Page 151: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 144 Andere talen ..........146 Marine Repair Logistics.......144 Muut kielet ..........146 Local Repair Service........144 Autres langues ........... 146 Service Away From Home......144 Andere Sprachen ........

  • Page 152: Owner Service Assistance

    Only the dealer/distributor has the factory‑trained mechanics, knowledge, special tools and equipment, and the genuine Cummins/Mercury Marine parts and accessories to properly service your engine and drive should the need occur. They know your engine and drive best. Contact 1‑800‑DIESELS to locate your closest distributor.

  • Page 153: Parts And Accessories Inquiries

    Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: •...

  • Page 154: Andere Talen

    Autres langues Pour obtenir un Manuel d'utilisation et d'entretien dans une autre langue, contactez le centre de service après‑vente international Mercury Marine ou Marine Power le plus proche pour toute information. Une liste des numéros de pièces en d'autres langues accompagne votre bloc‑moteur.

  • Page 155: Outros Idiomas

    Para obtener un Manual de operación y mantenimiento en otro idioma, póngase en contacto con el centro de servicio más cercano de Mercury Marine o Marine Power International para recibir información. Con su conjunto motriz se entrega una lista de los números de pieza para los otros idiomas.
  • Page 156 Section 8 - Customer Assistance Information Name Address City, State, Province ZIP or postal code Country Quantity Item Stock Number Price Total Total Due Page 148 90-866938081 MAY 2009...

  • Page 157: Section 9 - Pre-Delivery Information

    Section 9 - Pre-Delivery Information Section 9 - Pre-Delivery Information Table of Contents Pre‑Delivery Information........150 Before Starting—Key On ......151 Dealer Pre‑Delivery Checklist for Zeus Products Engines Running at the Dock ..... 151 (Before Delivery to the Customer)....150 Sea Trial .............

  • Page 158: Pre-Delivery Information

    Section 9 - Pre-Delivery Information Pre‑Delivery Information IMPORTANT: This section of the Operation, Maintenance, and Warranty Manual guides our boat dealers and boat company service personnel in the proper initial (pre‑delivery) service of the Cummins MerCruiser Diesel Zeus products. The Dealer Pre‑Delivery Checklist must be completed prior to delivery of the product to the customer and is not a substitute for the maintenance schedules listed in this manual.

  • Page 159: Before Starting-Key Off

    Section 9 - Pre-Delivery Information Before Starting—Key Off Dealer Check Checklist Item Manual Code or Task ☐ Identification Record table listed on front page is filled out. ☐ Copy of all required support publications present Visual Inspection ☐ Drive skegs and propellers are installed Visual Inspection ☐...

  • Page 160: Sea Trial

    Section 9 - Pre-Delivery Information Sea Trial Dealer Check Checklist Item Manual Code or Task ☐ VesselView—functional check all operational modes VVM Section 3 ☐ Instrumentation—check ZOM Section 2 ☐ Joystick—functional check ZOM Section 3 ☐ Single lever—functional check ZOM Section 3 ☐...

Table of Contents

Save PDF