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Mercury Zeus Manual

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Identification Information
Drive serial number and model number—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.
The serial number, model number, and other information needed for the identification record is located as shown.
a
Drive identification
a -
Transmission identification plate
b -
Drive identification decal
c -
Pod location stamping
c
b
a
Control system identification (if applicable)—SmartCraft 3.0 versions of the Zeus electronic control system (refer to
Section 2—General Information) have an Electronics Serial Number (ESN) data tag located on the inside of the Vessel
Interface Panel (VIP) door. The number is needed for the identification record.
www.cmdmarine.com
ELECTRONICS SERIAL NO:
Engine serial number and model number—Refer to the engine operation and maintenance manual available from the
engine manufacturer for the location of the engine data tag that contains the engine serial number and model number
needed in the identification record.
Drive identification decal
d
a -
Decal
b -
Gear ratio
e
c -
Serial number
d -
Model number
f
e -
Location of drive in vessel
f -
CMD part number
44121
MADE IN USA
88 500 000
Typical ESN data tag and VIP
b
c
44122
44343

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Summary of Contents for Mercury Zeus

  • Page 1 CMD part number 44121 Control system identification (if applicable)—SmartCraft 3.0 versions of the Zeus electronic control system (refer to Section 2—General Information) have an Electronics Serial Number (ESN) data tag located on the inside of the Vessel Interface Panel (VIP) door. The number is needed for the identification record.
  • Page 2 Mariner, Quicksilver, Alpha, Axius, Bravo One, Bravo Two, Bravo Three, K‑Planes, MerCathode, OptiMax, Precision Pilot, Pro Max, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Total Command, Verado, VesselView, Zero Effort, Zeus, #1 On The Water, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
  • Page 3 Read this Manual Thoroughly IMPORTANT: If you do not understand any portion of this manual, contact your dealer for a demonstration of the actual starting and operating procedures. Notice Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the International Hazard Symbol , may be used to alert the installer and user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.

  • Page 5: Table Of Contents

    Wave and Wake Jumping..........27 Auxiliary Joystick Station—Special Features....41 Impact with Underwater Hazards........27 General Information............41 Zeus Drive Impact Protection........... 28 Auxiliary Joystick Station and Throttle Only Feature..42 Zeus Drive Alignment............28 Stopping the Engines from an Auxiliary Joystick Station 42 Conditions Affecting Boat Operation........28 Trim Tabs, If Equipped.............
  • Page 6 Special Digital Throttle and Shift (DTS) Features... 44 Track Waypoint............... 54 Troll and Throttle Response........44 Engaging Track Waypoint Mode......... 55 Dock................45 Disengaging Track Waypoint Mode......56 Throttle Only..............46 Turn Buttons in Track Waypoint Mode......57 Single Lever (1 Lever) Operation........ 46 Auto Heading Button in Track Waypoint Mode ..
  • Page 7 Andre sprog..............135 Outside the United States and Canada......136 Section 9 - Pre-Delivery Information Pre‑Delivery Information............140 Before Starting—Key On..........141 Dealer Pre‑Delivery Checklist for Zeus Products (Before Delivery Engines Running at the Dock...........141 to the Customer)..............140 Sea Trial................141 Skyhook (If Equipped)............140 After On Water Test............
  • Page 8 Page iv 90-879172181 FEBRUARY 2011...
  • Page 9 Section 1 - Limited Warranty Section 1 - Limited Warranty Table of Contents Warranty Information.............. 2 World‑Wide Limited Warranty.......... 2 Warranty Registration—United States and Canada..2 Emission Warranty............8 Warranty Registration—Outside the United States and Transfer Of Warranty............8 Canada................2 90-879172181 FEBRUARY 2011 Page 1...

  • Page 10: Warranty Information

    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. 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 Section 1 - Limited Warranty Zeus 2000 and Zeus 3000 pod drives, Alpha, Bravo One, Bravo Two, Bravo Three, and NXT sterndrives sold with CMD engines Products Warranted Cummins MerCruiser Diesel (herein CMD) warrants to the owner that the purchased product is free from any material or workmanship defects.
  • Page 12 Base Warranty and continues beyond the expiration of the Base Warranty for an additional four years or 2000 hours, whichever occurs first. Only the Zeus 2000/3000 HO applications have this warranty provision. The Extended Major Components Warranty covers the Warrantable Failures of the following drive parts...
  • Page 13 Section 1 - Limited Warranty Steering and Trim Oil Tank Skeg—(Underwater Impact Damage Excluded) Zeus 2000: Marine Gear Housing Marine Gear Drop Box Housing Steering Housing Midsection Casting Lower Gear Housing Casting—(Underwater Impact Damage Excluded) Bearing Carrier Casting—(Underwater Impact Damage Excluded) Intermediate Shaft—(Underwater Impact Damage Excluded)
  • Page 14 Section 1 - Limited Warranty • Operation without adequate coolants or lubricants • Improper propping that does not allow the engine to run at its maximum rated speed • Unapproved installation • Lack of maintenance • Improper storage set up and maintenance •...
  • Page 15 Drive Limited Warranty Against Corrosion (Worldwide) What Is Covered CMD warrants the Zeus 2000 and Zeus 3000 pod drives, Alpha, Bravo One, Bravo Two,Bravo Three, and NXT sterndrives are covered. Product will not be rendered inoperative as a direct result of corrosion for the period of time described below.

  • Page 16: 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 17: Section 2 - Getting To Know Your Power Package

    Gauges (If Equipped) ..........13 Overload Protection for the DC‑to‑DC Voltage System (If System Link Digital Gauges (If Equipped) ..... 14 Equipped)..............20 Mercury Gateway Electronic Accessory......14 Overload Protection for Other Circuits......21 Electronic Helm Steering..........14 Dual‑Handle Electronic Remote Control (ERC)—Features and Operation..............15...

  • Page 18: General Information

    Electronic Control System Architecture There are two different control system architecture options for use with the Zeus 3000 Series pod drives: • SmartCraft 2.2—First generation architecture; initial release of Zeus electronic control system architecture.

  • Page 19: Smartcraft 2.2 Control System

    Section 2 - Getting to Know Your Power Package SmartCraft 2.2 Control System The control system option used on your vessel can be identified by the following: • Two separate Vessel Interface Panels (VIP), one for each engine system. 43914 Typical SmartCraft 2.2 VIP SmartCraft 3.0 Control System The control system option used on your vessel can be identified by the following:...
  • Page 20 Section 2 - Getting to Know Your Power Package IMPORTANT: Some E‑stop switches are equipped with a lock to prevent unintentional activation. The switch must be first unlocked to depress the rocker switch and activate the emergency stop. To activate the switch: Push and slide the lock up.

  • Page 21: Instrumentation

    Section 2 - Getting to Know Your Power Package The E‑stop switches must be maintained and tested at a specified interval. Refer to Maintenance Schedules—Routine Maintenance. Instrumentation VesselView VesselView is the primary source of information for the Zeus drive. • Engine information • Fault codes •...

  • Page 22: System Link Digital Gauges (If Equipped)

    OEM supplied display devices or CAN bus components. In SmartCraft 3.0 engine control system applications, a single Mercury Gateway can support all of the engines. The Mercury Gateway is typically mounted behind the dash away from view since it is only used as a gateway device and not an actual gauge.

  • Page 23: Dual-Handle Electronic Remote Control (Erc)-Features And Operation

    Section 2 - Getting to Know Your Power Package Dual‑Handle Electronic Remote Control (ERC)—Features and Operation Operation The electronic remote control (ERC) handle controls the operation of shift and throttle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from the forward position to the neutral position to decrease speed and eventually stop.

  • Page 24: Adjustment

    Section 2 - Getting to Know Your Power Package NOTE: In certain modes, gear position is determined by the position of the shift valves on the transmission, not the position of the ERC levers. When using the joystick or while in Skyhook, the computer moves the transmission in and out of gear even though the handles are in neutral.
  • Page 25 Section 2 - Getting to Know Your Power Package Remove the three M5 screws securing the side cover. 41347 Location of side cover screws Remove the side cover. For adjustment, temporarily install the handle, washer and screw. Finger‑tighten the screw. To adjust the ERC handle detent tension: Turn the adjustment screw clockwise to increase tension on the control handle and counter‑clockwise to decrease tension.

  • Page 26: Joystick-Basic Operation

    Section 2 - Getting to Know Your Power Package 12. Install the washer and the M8 x 45 mm long screw. Tighten the screw to specification. 41350 Location of handle screw and washer Description lb‑in. lb‑ft Handle screw 28.2 – 13.

  • Page 27: Electrical System Overload Protection

    After finding and correcting the cause of the overload, reset the circuit breaker by pressing the reset button. Vessel Interface Panel (VIP) Overload Protection—SmartCraft 2.2 For additional information refer to Identifying Your Zeus Control System. The Vessel Interface Panel (VIP) contains circuit breakers that help protect the harnesses for the transmission, engine, vessel sensors, and helm.

  • Page 28: Overload Protection For The Dc-To-Dc Voltage System (If Equipped)

    Section 2 - Getting to Know Your Power Package NOTE: One double‑door VIP is provided for all engines when using SmartCraft 3.0 control systems. 45129 Dual‑display (both sides of VIP with quads) Engine location Single‑display (one side of VIP with triples) 43474 Typical circuit breaker locations inside the VIP—dual-display shown Item...

  • Page 29: Overload Protection For Other Circuits

    Section 2 - Getting to Know Your Power Package The boat manufacturer may replace the fuse and holder with a circuit breaker. Have your boat manufacturer or dealer show you the location and identify the fuse or circuit breaker for your reference. 37994 DC-to-DC voltage regulator—SmartCraft 2.2 Regulator...
  • Page 30 Section 2 - Getting to Know Your Power Package For example, the MerCathode system has an in‑line fuse in the wire that connects from the positive (+) battery terminal to the positive (+) terminal on the controller. If the fuse is defective (open), the system will not operate, resulting in a loss of corrosion protection.
  • Page 31 Wave and Wake Jumping..........27 Helm Transfer and Precision Pilot......... 49 Impact with Underwater Hazards........27 Helm Transfer—Auxiliary Joystick Stations......50 Zeus Drive Impact Protection........28 Auxiliary Joystick Station Transfer......... 50 Zeus Drive Alignment............ 28 Requesting Transfer to an Auxiliary Joystick Station..50 Conditions Affecting Boat Operation........

  • Page 32: 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 33: Be Alert To Carbon Monoxide Poisoning

    Section 3 - On the Water • Report accidents. Boat operators are required by law to file a 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) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds US $500.00 or 4) there is complete loss of the boat.

  • Page 34: Drain Plug And Bilge Pump

    Section 3 - On the Water NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.

  • Page 35: Wave And Wake Jumping

    Section 3 - On the Water Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. mc79680-1 Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with enough speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the water.

  • Page 36: Zeus Drive Impact Protection

    The Zeus drive has some impact protection by design, since the drive is mounted in a tunnel above the bottom of the hull. If the drive strikes a floating or submerged object while the boat is moving, the skeg is designed to break away, absorbing some of the impact and possibly reducing damage to the propellers and the exposed lower part of the drive.

  • Page 37: Ventilation

    Rated Speed (RPM), contact your boat builder, boat dealer, or an Authorized Cummins MerCruiser Diesel Repair Facility for assistance in propeller selection. A list of propellers for the Zeus drive can be located in the Zeus drive parts manual.

  • Page 38: Starting And Stopping The Engines

    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 on the appropriate SmartCraft 2.2 or SmartCraft 3.0 VIP. The VIP is usually located in the engine room. Refer to Section 2—Identifying Your Zeus Control System for additional information.

  • Page 39: Normal Stopping

    Section 3 - On the Water Corresponding to the engine you want to start, do one of the following: • Turn the key switch to the start position. • Press and release the "START/STOP" switch, if equipped with the optional SmartStart switch panel (dual or triple engines) or panels (quad engines).

  • Page 40: Starting An Engine Using The Vip Smartstart Switch

    Section 3 - On the Water Close the seacock for the seawater inlet. Rotate the handle in the direction indicated by the arrow. Typical inlet seacock—port orientation (starboard similar) Seacock for seawater inlet Former position (open) Handle in closed position 41196 Starting an Engine Using the VIP SmartStart Switch You may desire to start an engine from the engine room or under certain circumstances the engine control systems may not be...
  • Page 41 Section 3 - On the Water NOTE: Ask your dealer for the location of the key switches if the key switches are not located at the helm. Turn the key switch to the on position for each engine to be started. Verify it is safe to start the engines.

  • Page 42: Stopping The Engine Using The Vip Smartstart Switch

    Section 3 - On the Water IMPORTANT: To avoid excessive exhaust aeration of the seawater, do not operate the engines over 1500 RPM when the vessel is at rest. 12. If you must operate the engines above 1500 RPM, put the vessel underway with a light throttle load until the engines reach normal operating temperature.

  • Page 43: Traditional Maneuvering With Steering And Thrust

    Traditional Maneuvering with Steering and Thrust You can maneuver your Zeus‑equipped vessel much like a traditional inboard boat. However, the Zeus drive system expands the maneuvering capability of your vessel at both slow and planing speeds. At slow speeds, the drive system is capable of directing the thrust to produce more responsive turning of the vessel.

  • Page 44: To Steer The Boat In Tight Turns At Low Speeds

    For example, if you move the joystick sideways, the control system commands the vessel in the sideways direction. IMPORTANT: When at least one engine system is running and operational on triple and quad Zeus installations, the joystick at the helm station or the auxiliary joystick station will have electronic control of the vessel by using that one engine system or all of the engine systems that remain operational.
  • Page 45 Section 3 - On the Water Joystick Input and Boat Response Table Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat at rest 25911 24704 Boat moves forward 25928 24705 Boat moves aft 24706 25927 Boat moves to starboard without rotating 25929 24707 90-879172181...
  • Page 46 Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves to port without rotating 25931 24708 Boat moves diagonally forward and to the starboard without rotating 25926 24709 NOTE: In this maneuver move and twist the joystick for yaw correction, if required.
  • Page 47 Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves diagonally aft and to the port without rotating 25923 24711 Boat moves diagonally forward and to the port without rotating 25925 24712 Boat rotates clockwise...
  • Page 48 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 clockwise 25916 24715 Boat moves diagonally forward and to the starboard while rotating counterclockwise 25918 24718 Boat moves diagonally forward and to the...

  • Page 49: Auxiliary Joystick Station-Special Features

    Section 3 - On the Water Auxiliary Joystick Station—Special Features General Information Each auxiliary joystick station is equipped with an E‑stop switch, auxiliary joystick, and a trackpad. Typical auxiliary joystick station components for dual drives E‑stop switch PORT STBD Auxiliary joystick Joystick trackpad for triple installations Port drive status indicator light...

  • Page 50: Auxiliary Joystick Station And Throttle Only Feature

    Unless otherwise, the Zeus drive comes equipped with an automatic trim tab control feature that operates through the vessel control system to deploy the tabs based on vessel speed over ground. NOTE: Some vessels will not use the factory Zeus trim tabs. Refer to the vessel manufacturer (OEM) for instructions on the use of their trim tab system.

  • Page 51: Manual Control

    Section 3 - On the Water The automatic trim tab control feature can be engaged (turned on) or disengaged (turned off). To engage the feature, press the "AUTO" trim tab button. The trim tabs will automatically adjust as the speed of the boat is changed. Pressing it again will disengage the feature.

  • Page 52: 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 Low Speed Trim visibility. In automatic control or manual control, lowered trim tabs keep the boat on plane longer at lower speeds while maintaining a level boat attitude.

  • Page 53: Dock

    Section 3 - On the Water Dock mode can be engaged along with troll mode to double the region of troll to 60% of lever travel and limit the maximum throttle to 50% beyond that amount of lever travel. Refer to Dock for dock mode information. 31463 "TROLL"...

  • Page 54: Throttle Only

    Notice that the neutral lights remain on. Single Lever (1 Lever) Operation The Zeus single lever (1 Lever) feature simplifies engine management during rough sea conditions by allowing you to grasp a single lever to command all engines simultaneously. To engage the single lever (1 Lever) mode: Place both ERC levers in neutral.

  • Page 55: Synchronizing The Engines

    Section 3 - On the Water Press the "1 LEVER" button located on the DTS trackpad attached to the ERC levers. 31466 "1 LEVER" button The "1 LEVER" button light turns on. Place the starboard ERC lever into gear. The engine RPM raises and lowers simultaneously while the transmissions remain in the same gear. To disengage the single lever (1 Lever) mode: Place both ERC levers in neutral.

  • Page 56: Dts Shadow Mode-Triple Engines

    Section 3 - On the Water DTS Shadow Mode—Triple Engines When both ERC throttle levers are in the same position (same direction), the center engine will duplicate the RPM of the outer engine with the lowest RPM. When the throttle levers are in opposing positions (opposite directions), the center engine will be in neutral at idle speed.

  • Page 57: Requesting Helm Transfer

    Section 3 - On the Water SportFish handle ERC and separate DTS trackpad DTS trackpad ERC handle Transfer button 44090 NOTICE The ERC levers must be in neutral to perform a helm transfer. While in neutral your vessel could drift and collide with objects nearby resulting in damage.

  • Page 58: Helm Transfer-Auxiliary Joystick Stations

    Section 3 - On the Water • In Track Waypoint mode the control of the route and display of route data on your chart plotter does not automatically transfer to the chart plotter at the requested helm. You must turn on the chart plotter at the newly active helm, input the waypoint or waypoint route to be tracked, and re‑engage Track Waypoint.

  • Page 59: Autopilot Screen

    Section 3 - On the Water • Course correction to the port or starboard with the press of a button. • Automatic course and heading modes. • Station keeping • A VesselView screen called "AUTOPILOT" (located under the Environment chapter) to display certain Precision Pilot functions.

  • Page 60: Trackpad Buttons With The Power Icon

    Section 3 - On the Water When the "ACTIVE" light is illuminated one mode of Precision Pilot is engaged. "STANDBY" light "ACTIVE" light 27695 Trackpad Buttons with the 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.
  • Page 61 Section 3 - On the Water Under typical operating conditions Skyhook is capable of holding the vessel within a radius of 10 meters (30 feet). However this distance may sometimes increase to a radius of 30 meters (100 feet). Do not engage Skyhook when the vessel is within 30 meters (100 foot) of any obstacle, obstruction, dock, bridge, vessel, swimmer, etc.

  • Page 62: Track Waypoint

    Section 3 - On the Water 33824 Label in the vicinity of the transom boarding area NOTE: If the labels cannot be located or are not legible, they must be replaced before engaging Skyhook. For replacement labels, contact the manufacturer of your boat, your Cummins distributor, or an Authorized Cummins MerCruiser Diesel Repair Facility. Track Waypoint WARNING In some Precision Pilot modes—"Auto Heading,"...

  • Page 63: Engaging Track Waypoint Mode

    Section 3 - On the Water • If the boat is on plane, and in Waypoint Sequence, the boat will make an automatic high‑speed, sharp turn upon arrival at waypoint 2. 45127 When the Track Waypoint feature is activated and the boat is put in operation: •...

  • Page 64: Disengaging Track Waypoint Mode

    Section 3 - On the Water Press the "TRACK WAYPOINT" button on the Precision Pilot keypad. The "TRACK WAYPOINT" button light turns on and a single horn beep sounds, indicating Track Waypoint engaged. Pilot tracks to the first waypoint on the chart plotter course. Two horn beeps sound if Track Waypoint does not engage.

  • Page 65: Turn Buttons In Track Waypoint Mode

    Section 3 - On the Water Turn Buttons in Track Waypoint Mode While in "TRACK WAYPOINT" mode, using the left or right "TURN" buttons on the keypad changes the mode to "AUTO HEADING." Auto Heading Button in Track Waypoint Mode While in "TRACK WAYPOINT"...

  • Page 66: Waypoint Sequence

    Section 3 - On the Water 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.
  • Page 67 Section 3 - On the Water A horn beep sounds on VesselView and the green circle icon on the Pilot screen will display "TRACK" with the words "WAYPOINT SEQUENCE" wrapped around the green circle icon. 31411 Waypoint Sequence TRACK icon 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 68: Response Button

    Section 3 - On the Water Press the enter button to acknowledge the you understand it is OK to turn. The enter button is in the upper right corner of VesselView and has a check mark symbol. 31414 Waypoint acknowledge screen Stay alert;...

  • Page 69: Auto Heading

    Section 3 - On the Water NOTE: Each time you press the "RESPONSE" button, the button light blinks to indicate you changed the response setting for that mode. 27704 Response button Press the "RESPONSE" button again to increase how aggressively the vessel reacts to programmed changes. The initial button press shows the current response setting.

  • Page 70: Course Adjustment Using The Turn Buttons Or Joystick

    Section 3 - On the Water Press the "AUTO HEADING" button to engage the Auto Heading mode. The button illuminates and a single horn beep sounds acknowledging engagement. A double horn beep sounds if Auto Heading does not engage. "TURN" (course adjust) buttons "RESUME"...

  • Page 71: Course Adjustment Using The Turn Buttons Or Joystick 62 To Resume A Heading

    Section 3 - On the Water Press the "TURN" button in the direction of the desired heading change. Each press of the button changes the desired heading by 10°. Port "TURN" button Starboard "TURN" button 27699 Move (press) the joystick in the desired direction to make small adjustments in the chosen heading. Each recognized movement adjusts the chosen heading by 1°.

  • Page 72: Disengaging Auto Heading

    Section 3 - On the Water • Pressed one of the "TURN" (course adjust) buttons with Auto Heading engaged. "TURN" button "RESUME" button "AUTO HEADING" button 27700 Disengaging Auto Heading Disengage the Auto Heading mode with any of the following actions: •...

  • Page 73: Contingent Operations

    Operating on Less than all Available Engines Dual, triple, and quad Zeus applications are capable of operating on less than all available engines, however such operation should only be done in the event of a system failure. Do not intentionally operate with less than all engines running.

  • Page 74: Gear Engagement-Emergency Procedure

    Section 3 - On the Water Gear Engagement—Emergency Procedure If a transmission or electrical system is damaged or has experienced a condition resulting in a fault such that a transmission does not respond to the helm controls, it is possible to manually engage a gear. In an emergency you can manually place a transmission into gear by using a suitable wrench to actuate the appropriate gear shifting solenoid.

  • Page 75: Steering And Trim-Manual Override

    Section 3 - On the Water Steering and Trim—Manual Override The steering and trim system operate using a hydraulic manifold fitted with control valves. If a malfunction occurs in the manifold for the steering and trim system, VesselView should display a fault code. The steering actuator, trim cylinder, or both may not respond to helm control resulting in the loss of normal steering or trim control.

  • Page 76: 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 77: End Of First Season Checkup

    Section 3 - On the Water If the trim tab fault does not clear using the above procedure, then shift the transmission into neutral, shut down the engine, turn the key switch off, and alternately push the trim‑up and trim‑down manual‑override buttons to release the spool. Refer to the decal on the manifold bracket or on the port‑side of the drive cover, if equipped, for additional information.
  • Page 78 Section 3 - On the Water Notes: Page 70 90-879172181 FEBRUARY 2011...
  • Page 79 Section 4 - Specifications Section 4 - Specifications Table of Contents Drive Gear Lubricant............72 Approved Paints..............72 Transmission................ 72 Approved Lubricants............. 72 Steering Actuator and Trim Oil..........72 90-879172181 FEBRUARY 2011 Page 71...

  • Page 80: Drive Gear Lubricant

    Drive Gear Lubricant Fluid Capacity Model (includes the drive and the Fluid Type Fluid Part Number gear lube monitor) Zeus (during break‑in) 5‑1/4 L (5‑1/2 US qt) Premium Gear Lubricant 92‑858058K01 High Performance Gear Zeus (after break‑in) 5‑1/4 L (5‑1/2 US qt) 92‑858064K01...
  • Page 81 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Product Responsibilities............74 Boat In the Water ..........101 Owner and Operator Responsibilities......74 Checking the Seawater Pickup on the Drive....104 Dealer Responsibilities..........74 Seawater Strainer............105 Do‑It‑Yourself Maintenance Suggestions...... 74 Flushing (Cleaning) the Seawater System....

  • Page 82: 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.

  • Page 83: Drive Service Point Locations

    Decal placed where no step is allowed The Zeus drive cover, if equipped, protects and separates some components after the drive is installed. The drive cover provides added protection against damage to the hoses and other components as a result of mechanical hose abrasion during operation or damage to the hoses, such as being stepped on during service or maintenance.

  • Page 84: Port

    Section 5 - Maintenance Port Seawater inlet seacock (if drive mounted) Driveshaft (under shield, if equipped) Driveshaft shield Gear lube monitor fill Hydraulic fluid filter Trim tab and anode plates Propeller shaft 41381 Transmission dipstick Gear lube monitor fill cap Exhaust elbow Driveshaft shield screws Upper exhaust clamps...

  • Page 85: Maintenance Schedules

    Maintenance Schedules Application The following schedules apply to the Zeus drive and driveshaft connection, not to the Cummins engine. For the engine maintenance schedule and procedures, refer to the Marine Recreational High Output Propulsion Units QSB, QSC, or QSM Operation and Maintenance Manual available from the manufacturer of the engine.

  • Page 86: Maintenance Log

    Section 5 - Maintenance Task Interval Maintenance to be Performed • Change the transmission oil (fluid) and filter, including the transmission oil in the drop box, After the first 25 hours of if equipped. operation and not to exceed • Change the gear lube in the drive gearcase and gear lube monitor.
  • Page 87 Section 5 - Maintenance Date Maintenance Performed Engine Hours 90-879172181 FEBRUARY 2011 Page 79...

  • Page 88: 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. Remove the three upper screws (port and starboard) holding the side cover to the top cover.
  • Page 89 Section 5 - Maintenance Install the two screws. Tighten the screws to specification. Top cover screw Washer Torque wrench 39498 Description lb‑in. lb‑ft Top cover screw – Install the starboard side cover using four screws. Starboard cover Screw (4) 39590 Align and insert the starboard cover into the groove of the H‑trim section on the port cover.

  • Page 90: Drive Gear Lubrication

    Section 5 - Maintenance Tighten the three lower and six upper cover screws to specification. Description lb‑in. lb‑ft Cover upper screws – Cover lower screws – Install the hatch cover. Insert the molded clip on the aft end of the hatch cover under the indented‑edge of the cover top. Hatch cover Molded clip Indented‑edge...

  • Page 91: Checking

    Section 5 - Maintenance Event Summary Table Event Task Low without an alarm Fill the gear lube monitor to the specified level. Refer to Filling. Low with an alarm, lubricant low but visible in monitor Remove the drive side cover, if equipped. Pressure fill the drive unit through the steering actuator until the gear lube appears in the gear lube monitor at the "COLD FILL LEVEL"...
  • Page 92 Section 5 - Maintenance 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 93: Filling

    Section 5 - Maintenance Insert the molded clip on the aft end of the hatch cover under the indented‑edge of the cover. Hatch cover Molded clip Indented‑edge 39506 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 94: Changing

    Section 5 - Maintenance 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 95 Section 5 - Maintenance Quickly install the special gear lube adapter with washer into the threaded hole for the drain and fill screw. Coupling nut and washer Adapter Threads into steering actuator (3/8 in.‑16 UNC) 38298 Description Part Number Gear lube adapter 91‑24789A1 Install a suitable double‑ended male adapter to the gear lube adapter.
  • Page 96 Part Number Spacer 23‑806445 Sealing washer 26‑830749 Install and hand‑tighten the adapter assembly into the fill and drain hole of the steering actuator. IMPORTANT: Use Mercury or Quicksilver High Performance Gear Lube in the drive. Page 88 90-879172181 FEBRUARY 2011...

  • Page 97: With The Boat Out Of The Water

    Fluid Type Fluid Part Number monitor) High Performance Gear 92‑858064K01 1 L (1 US qt) Zeus 5‑1/4 L (5‑1/2 US qt) Lube 92‑858065Q01 9.5 L (2.5 US gal) 10. Operate the gear lube pump and begin to fill the drive.
  • Page 98 Allow the gear lube to drain completely. Properly dispose of the gear lube. IMPORTANT: Use Mercury or Quicksilver High Performance Gear Lube in the drive. Install a suitable gear lube pump into the gearcase fill and drain hole. Fill the drive with the specified gear lube.

  • Page 99: Steering Actuator And Trim-Hydraulic Oil

    Fluid Part Number monitor) High Performance Gear 92‑858064K01 1 L (1 US qt) Zeus 5‑1/4 L (5‑1/2 US qt) Lube 92‑858065Q01 9.5 L (2.5 US gal) Remove the gear lube pump and quickly reinstall the gear case fill and drain screw and washer.

  • Page 100: Checking

    Section 5 - Maintenance Checking Using a clean, lint‑free cloth, wipe the dirt and debris away from the cap and exterior of the steering actuator and trim fluid reservoir. Typical Reservoir 45966 NOTE: The direction to rotate the cap to open or close is imprinted on the top of the cap. Push down and turn the reservoir cap and dipstick about 1/3 turn in the open direction.

  • Page 101: Filling

    Section 5 - Maintenance 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. Cap and dipstick Open direction Close direction 40235 Filling Using a clean, lint‑free cloth, wipe the dirt and debris away from the cap and exterior of the steering actuator and trim fluid reservoir.

  • Page 102: Changing

    Section 5 - Maintenance Changing You do not need to change the steering actuator and trim system oil and filter unless they become contaminated with water or debris. A switch in the high‑pressure filter system will set a VesselView fault code to alert the operator when the hydraulic oil and filter require changing.
  • Page 103 NOTICE The seawater pumps on vessels equipped with Zeus pod drives can be damaged by excessive exhaust aeration due to inadequate water flow. To ensure adequate water flow across the seawater inlets, make sure that the vessel is underway before exceeding 1500 RPM.

  • Page 104: Filling

    Section 5 - Maintenance Insert the molded clip on the aft end of the hatch cover under the indented‑edge of the cover. Access cover Molded clip Indented edge 39506 Align the access cover with the opening in the top cover. Press down evenly on the front of the access cover.
  • Page 105 NOTICE The seawater pumps on vessels equipped with Zeus pod drives can be damaged by excessive exhaust aeration due to inadequate water flow. To ensure adequate water flow across the seawater inlets, make sure that the vessel is underway before exceeding 1500 RPM.

  • Page 106: Changing

    Section 5 - Maintenance Changing NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.
  • Page 107 Section 5 - Maintenance NOTE: Except in the cases of extreme contamination or mechanical failure, it is not necessary to drain the oil from the engine‑mounted transmission oil cooler, if equipped. Typical From transmission To primary cooler Engine‑mounted transmission oil cooler 45933 Dispose of the transmission oil properly.
  • Page 108 Section 5 - Maintenance 13. Using a 6M Allen wrench, tighten the filter assembly screw to specification. Assembly screw Fluid filter assembly 28239 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. Drop box Drain cap 41195...

  • Page 109: Seawater System

    Section 5 - Maintenance 18. Install the drive cover, if equipped. Refer to Installing the Drive Cover. Seawater System Draining the Seawater System IMPORTANT: The vessel must be as level as possible to ensure complete draining of the cooling system. Drain the seawater system of the power package before flushing or before cold weather (freezing temperature), seasonal storage, or extended storage.
  • Page 110 Section 5 - Maintenance On models using a through‑hull seawater inlet, refer to your boat manufacturer for instructions and close the seawater inlet seacock. On models using the through‑drive seawater inlet, close the seawater inlet seacock. Rotate the handle in the direction indicated by the arrow.
  • Page 111 Section 5 - Maintenance Remove the drain screw on the discharge seacock. Drain the seawater. Dual hose clamps Primary cooler Seawater hose Drain screw 41264 On models with a drop box and engine‑mounted transmission oil cooler, remove the drain plug and drain the seawater. Typical Drain plug Engine‑mounted oil cooler...

  • Page 112: Checking The Seawater Pickup On The Drive

    Section 5 - Maintenance 15. Install the drain screw on the discharge seacock. Tighten the screw securely. Dual hose clamps Primary cooler Seawater hose Drain screw 41264 NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures.

  • Page 113: Seawater Strainer

    Section 5 - Maintenance Seawater Strainer Refer to the appropriate Cummins Operation and Maintenance Manual Marine Engine for seawater strainer maintenance instructions. Flushing (Cleaning) the Seawater System Before seasonal or extended storage, we recommend flushing or cleaning the seawater cooling system to avoid salt or silt build‑up. Contact your Cummins MerCruiser Diesel Authorized Repair Facility for additional information.

  • Page 114: Cooling System And Exhaust System

    Section 5 - Maintenance WARNING An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries. WARNING Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion.

  • Page 115: Driveshaft U-Joints

    Section 5 - Maintenance Pump grease into the grease fitting for the slip‑joint until grease is expelled from the pressure relief hole in the cap plug. Grease fitting Cap plug Expelled grease 34012 Apply adhesive to the threads of the flange‑head screws for the driveshaft shield on the engine end. Tube Ref No.
  • Page 116 Section 5 - Maintenance Remove the top and bottom driveshaft shields on the transmission end as shown. Bottom shield Driveshaft shield upper‑to‑lower retaining hardware (2) Top shield Driveshaft shield retaining screw (4) 36689 Visually inspect each U‑joint bearing for: Seal deterioration or damage. The appearance of rust or fretting around the yokes.

  • Page 117: Propeller Shaft

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

  • Page 118: Driveshaft Connection Torque

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shafts 92-802867Q 1 Special Lubricant 101 Propeller shaft 92-802865Q02 2-4-C Marine Lubricant Propeller shaft 92-802859A 1 with Teflon Install the propellers. Refer to Propellers. Driveshaft Connection Torque Remove the engine and transmission end driveshaft shields, if not already.

  • Page 119: Corrosion And Corrosion Protection

    (shock) currents. Refer to the Diesel Parts and Accessories Guide (90‑892645008) or the Mercury Accessories Guide (90‑420000009) for part numbers. IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and anodes may be unable to handle the increased galvanic corrosion potential.

  • Page 120: Reference Electrode Wire Of The Mercathode System

    Section 5 - Maintenance Anodes and MerCathode System Locations Description Location Figure The MerCathode reference electrode and anode are mounted to the composite cover on MerCathode the underside of the drive. The MerCathode System controller is mounted on the transmission. The controller harness connects the components.

  • Page 121: Mercathode Anode

    Section 5 - Maintenance MerCathode Anode Checking Inspect the MerCathode anode and replace the anode if damaged. Anode Reference electrode (not visible in this view) 41163 Replacing Contact your Cummins MerCruiser Diesel Authorized Repair Facility. MerCathode System Testing If the boat is equipped with a Quicksilver MerCathode system, test the system to ensure that it is providing adequate output to protect the underwater metal parts on the boat.

  • Page 122: Continuity Circuits

    Section 5 - Maintenance Remove the five trim tab anode attaching screws on each anode from the bottom of the trim tab. Removing the starboard anode Screw (5) Anode 39660 Remove and discard the trim tab anode. Inspect and replace any trim tab anode mounting screws damaged by corrosion. Clean the trim tab anode mounting surfaces to bare metal.

  • Page 123: Inhibiting Corrosion

    Section 5 - Maintenance Inspect the MerCathode controller and wires for loose connections, broken connectors, or frayed wiring. Anode wire Battery positive (+) terminal wire MerCathode controller Reference electrode wire Black/green continuity wire (–) to bonding stud Battery negative (–) terminal wire 41253 Inspect the bonding stud, nut, and continuity wire (–) on the center section for corrosion, loose connections, broken connectors, or frayed wiring.

  • Page 124: Propellers

    Section 5 - Maintenance • Follow the paint manufacturer’s recommendations regarding preparation and application. • Use high‑quality, anti‑fouling paint designed for marine use. • If using copper‑based or tin‑based paints is necessary, ensure that you comply with all local and federal laws prohibiting their use.

  • Page 125: Propeller Repair

    Section 5 - Maintenance Using the propeller nut tool, turn the front propeller nut counter‑clockwise and remove the nut. Block of wood Trim tab Propeller nut tool 24035 Propeller Nut Tool 91‑805457T 1 Aids in the removal and installation of the front propeller nut. 10677 Slide the front propeller and the front thrust hub off the propeller shaft.
  • Page 126 Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shaft splines 92-802867Q 1 24029 Lubricating the propeller shaft splines Slide the front thrust hub onto the propeller shaft with the tapered side toward the propeller hub. Align the splines and place the front propeller on the propeller shaft.
  • Page 127 11. Place a block of wood between the trim tab and the propeller. 12. Tighten the rear propeller nut to specification. Block of wood Trim tab 24037 Zeus drive propeller assembly Front thrust hub Front propeller Front propeller nut Rear thrust hub...
  • Page 128 Section 5 - Maintenance Notes: Page 120 90-879172181 FEBRUARY 2011...
  • Page 129 Section 6 - Storage Section 6 - Storage Table of Contents Storage Descriptions............122 Battery Storage..............123 Drive Storage..............122 Recommissioning............... 124 Cold Weather (Freezing Temperature) Storage..122 Engine................124 Seasonal and Extended Storage Instructions....122 Drive................124 Engine Storage............123 Power Package............

  • Page 130: 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. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures.

  • Page 131: Engine Storage

    Outside of engine Marine Cloud White paint Obtain locally (CMD part number: 4918660) Mercury Phantom Black Shift plate and air filter housing 92‑802878Q1 12. Your Cummins MerCruiser Diesel Authorized Repair Facility should now perform all checks, inspections, lubrications, and fluid changes outlined in Maintenance Schedules under the interval of Every 500 hours of operation or once a year (whichever occurs first).

  • Page 132: Recommissioning

    Section 6 - Storage Recommissioning Engine NOTE: Discharge of propylene glycol into the environment may be restricted by law. Contain and dispose of propylene glycol in accordance with federal, state, and local laws and guidelines. On engines that were prepared for cold weather (freezing temperature) or seasonal storage, drain the propylene glycol into a suitable container.
  • Page 133 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing Electronically Controlled Fuel System Problems Standard Helm Joystick..........128 .................... 126 Auxiliary Joystick Station..........128 Electrical Connections............126 Electronic Remote Controls......... 129 Troubleshooting Engine Related Problems......126 Steering System............130 Check VesselView First............

  • Page 134: 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 135: Troubleshooting Charts

    Section 7 - Troubleshooting Fault Code Fault Code (continued) • Battery Voltage High • Intake Manifold Temp High • Battery Voltage Low • Joystick Operation Disabled • Check Engine • Joystick Operation Minimal • Compass Sensor Fault • Joystick Operation Reduced •...

  • Page 136: Standard Helm Joystick

    Section 7 - Troubleshooting Symptom Remedy Boat overloaded or load improperly Reduce the load or redistribute the load more evenly. distributed. Boat bottom fouled or damaged. Clean or repair as necessary. Tabs locked in the down position. Unlock the automatic tab override switch. Use a cetane booster as recommended by your Authorized Cummins MerCruiser Diesel Poor quality of fuel.

  • Page 137: Electronic Remote Controls

    Section 7 - Troubleshooting Electronic Remote Controls Symptom Remedy Adjust detent tension. Refer to Section 2: Dual-Handle Electronic ERC (electronic remote control) lever is too hard or too Remote Control (ERC)—Features and Operationor Optional easy to get out of neutral detent. SportFish Electronic Remote Control (ERC)—Features and Operation.

  • Page 138: Steering System

    Section 7 - Troubleshooting Steering System Symptom Remedy Starboard key switch turned off. Turn starboard key switch on. Steering wheel operates without resistance, but steers boat. The circuit breaker for the helm circuit is tripped. Reset the circuit breaker. Station is not active; transfer helm to the station required. For contingent operation, change to joystick for directional control if limited RPMs are sufficient.

  • Page 139: Battery Will Not Charge

    Section 7 - Troubleshooting Battery Will Not Charge Possible Cause Remedy Turn off non‑essential accessories, like the air conditioning and hot water Excessive current draw from battery. heater. Check all associated electrical connections and wires (especially battery cables). Clean and tighten faulty connections. Repair or replace damaged Loose or dirty electrical connections or damaged wiring.
  • Page 140 Section 7 - Troubleshooting Notes: Page 132 90-879172181 FEBRUARY 2011...

  • Page 141: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance..........134 Andere talen ............... 135 Marine Repair Logistics..........134 Muut kielet ..............135 Local Repair Service............ 134 Autres langues ............135 Service Away From Home........... 134 Andere Sprachen ............

  • Page 142: Owner Service Assistance

    Cummins MerCruiser Diesel offers Marine Repair Logistics (MeRL) as a concierge service during the warranty period for your new Zeus and Axius equipped vessel. MeRL is a proactive 24 x 7 x 365 team offering premium global service focused on reducing vessel repair cycle time.

  • Page 143: Resolving A Problem

    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 144: Andere Sprachen

    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 145 Section 8 - Customer Assistance Information Mercury Marine Please submit the Attn: Publications Department following order form with W6250 West Pioneer Road payment to: P.O. Box 1939 Fond du Lac, WI 54936-1939 Ship To: (Please copy this form and print or type–This is your shipping label)
  • Page 146 Section 8 - Customer Assistance Information Notes: Page 138 90-879172181 FEBRUARY 2011...

  • Page 147: Section 9 - Pre-Delivery Information

    Section 9 - Pre-Delivery Information Table of Contents Pre‑Delivery Information............. 140 Before Starting—Key On ..........141 Dealer Pre‑Delivery Checklist for Zeus Products (Before Engines Running at the Dock ........141 Delivery to the Customer)........... 140 Sea Trial ..............141 Skyhook (If Equipped) ..........140 After On Water Test ............

  • Page 148: 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 149: Before Starting-Key On

    Section 9 - Pre-Delivery Information Before Starting—Key On Dealer Check Checklist Item Manual Code or Task ☐ Audio warning horn chirp at key on VVM Section 8 ☐ Check the VesselView for fault codes VVM Section 8 ☐ Neutral lights on the ERC lever assembly ZOM Section 3 Engines Running at the Dock Dealer Check...

  • Page 150: After On Water Test

    Drive interface ring seal (sealing grommet)—visual check for leaks Visual Inspection ☐ Supply the customer with the Engine Owners Manual – ☐ Supply the customer with the Zeus Operation, Maintenance, and Warranty Manual – ☐ Supply the customer with the VesselView Operations manual – ☐...

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