Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the

Transcription

1 Welcome You hve selected one of the finest mrine power pckges ville. It incorportes numerous design fetures to ensure operting ese nd durility. With proper cre nd mintennce, you will thoroughly enjoy using this product for mny oting sesons. This mnul is supplement to the Opertion, Mintennce, nd Wrrnty Mnul included with your engine pckge nd provides informtion out the Zeus propulsion system. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul, which contins specific instructions for using nd mintining your product. We suggest tht this mnul remin with the product for reference whenever you re on the wter. Thnk you for purchsing one of our Mercury Diesel products. We sincerely hope your oting will e plesnt. Mercury Diesel Wrrnty Messge The product you hve purchsed comes with limited wrrnty from Mercury Diesel; the terms of the wrrnty re set forth in the Wrrnty Sections of this mnul. The wrrnty sttement contins description of wht is covered, wht is not covered, the durtion of coverge, how to est otin wrrnty coverge, importnt disclimers nd limittions of dmges nd other relted informtion. Plese review this importnt informtion. Mercury Diesel products re designed nd mnufctured to comply with our own high qulity stndrds, pplicle industry stndrds nd regultions, s well s certin emissions regultions. At Mercury Mrine every engine is operted nd tested efore it is oxed for shipment to mke sure tht the product is redy for use. In ddition, certin Mercury Mrine products re tested in controlled nd monitored environment, for up to 10 hours of engine run time, in order to verify nd mke record of complince with pplicle stndrds nd regultions. All Mercury Mrine product, sold s new, receives the pplicle limited wrrnty coverge, whether the engine prticipted in one of the test progrms descried ove or not. Red this Mnul Thoroughly IMPORTANT: If you do not understnd ny portion of this mnul, contct your deler for demonstrtion of the ctul strting nd operting procedures. Notice Throughout this puliction, nd on your power pckge, dngers, wrnings, cutions, nd notices, ccompnied y the Interntionl Hzrd Symol!, my e used to lert the instller nd user to specil instructions concerning prticulr service or opertion tht my e hzrdous if performed incorrectly or crelessly. Oserve them crefully. These sfety lerts lone cnnot eliminte the hzrds tht they signl. Instllers must comply strictly with these specil instructions nd should exercise common sense during opertion to prevent ccidents.! DANGER Indictes hzrdous sitution which, if not voided, will result in deth or serious injury.! WARNING Indictes hzrdous sitution which, if not voided, could result in deth or serious injury.! CAUTION Indictes hzrdous sitution which, if not voided, could result in minor or moderte injury. NOTICE Indictes sitution which, if not voided, could result in engine or mjor component filure. IMPORTANT: Identifies informtion essentil to the successful completion of the tsk. NOTE: Indictes informtion tht helps in the understnding of prticulr step or ction. Identifiction Informtion Seril numers nd model numers The seril numers re the mnufcturer s keys to numerous engineering detils tht pply to your Mercury Diesel product. When contcting Mercury Diesel out service, lwys specify model nd seril numers. Engine seril numer nd model numer Refer to the engine opertion nd mintennce mnul ville from the engine mnufcturer for the loction of the engine dt tg tht contins the engine seril numer nd model numer needed in the identifiction record Mercury Mrine Zeus 3000 Series Pod Drive Models *8M * 90-8M

2 Identifiction Record Plese record the following informtion: Drive Loction Zeus Drive Seril Numer Zeus Drive Model Numer Trnsmission Seril Numer Strord Center Port Strord Center Port Center Engine Seril Numer Strord Strord Center Center Port Center Port Engine Model nd Horsepower Propeller Informtion Propeller Prt Numer Pitch / Front Rer Bot Hull Identifiction Numer (HIN) Purchse Dte / Bot Mnufcturer Bot Model Bot Length Exhust Gs Emissions Certificte Numer (Europe Only) / Electronic Control Seril Numer Trdemrk nd Copyright Informtion The description nd specifictions contined herein were in effect t the time this guide ws pproved for printing. Mercury Mrine, whose policy is one of continuous improvement, reserves the right to discontinue models t ny time, or to chnge specifictions or designs, without notice nd without incurring oligtion. Mercury Mrine, Fond du Lc, Wisconsin, USA. Alph, Axius, Brvo One, Brvo Two, Brvo Three, Circle M with Wves Logo, K plnes, Mriner, MerCthode, MerCruiser, Mercury, Mercury with Wves Logo, Mercury Mrine, Mercury Precision Prts, Mercury Propellers, Mercury Rcing, MotorGuide, OptiMx, Quicksilver, SeCore, Skyhook, SmrtCrft, Sport Jet, Verdo, VesselView, Zero Effort, Zeus, nd #1 On the Wter re registered trdemrks of Brunswick Corportion. Mercury Product Protection is registered service mrk of Brunswick Corportion.! WARNING The opertor (driver) is responsile for the correct nd sfe opertion of the ot, the equipment ord nd the sfety of ll occupnts ord. We strongly recommend tht the opertor red this Opertion, Mintennce nd Wrrnty Mnul nd thoroughly understnd the opertionl instructions for the power pckge nd ll relted ccessories efore the ot is used.! WARNING The engine exhust from this product contins chemicls known to the stte of Cliforni to cuse cncer, irth defects or other reproductive hrm.

3 TABLE OF CONTENTS Section 1 - Wrrnty Informtion Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd... 2 Wrrnty Registrtion Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty... 2 Wrrnty Policy Zeus Models... 3 Zeus Drive High Output Recretionl Use Limited Wrrnty... 3 Zeus Drive Intermittent Commercil Use Limited Wrrnty... 5 Zeus Drive Limited Wrrnty Aginst Corrosion... 6 Trnsfer of Wrrnty... 7 Wrrnty Policy Austrli nd New Zelnd... 8 MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy... 8 Trnsfer of Wrrnty Austrli nd New Zelnd Policy Glol Wrrnty Chrts United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel Outside United Sttes...10 Cnd Wrrnty Chrt MerCruiser Gs nd Diesel Outside Cnd...11 Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel Outside Austrli nd New Zelnd South Pcific Wrrnty Chrt MerCruiser Gs nd Diesel Outside of the South Pcific Asi Wrrnty Chrt MerCruiser Gs nd Diesel Outside of Asi Europe nd the Confedertion of Independent Sttes (CIS) Wrrnty Chrts MerCruiser Gs nd Diesel Outside Europe nd CIS...12 Middle Est nd Afric (excluding South Afric) Wrrnty Chrts MerCruiser Gs nd Diesel Outside Middle Est nd Afric South Afric Wrrnty Chrts MerCruiser Gs nd Diesel Outside South Afric...13 Section 2 - Getting to Know Your Power Pckge Generl Informtion Models Covered Drive Seril Numer nd Decl Plcement Fetures nd Controls Audio Wrning System Instrumenttion VesselView SmrtCrft Speedometer, Tchometer, nd Digitl Guges System Link Digitl Guges Key Switch Emergency Stop Switch Lnyrd Stop Switch Vessel Interfce Pnel (VIP) Overlod Strting nd Stopping the Engines Strting n Engine Using the VIP SmrtStrt Switch Stopping the Engine Using the VIP SmrtStrt Switch Electronic Helm Steering Trim T Pnel Dul Hndle Electronic Remote Control (ERC) Opertion nd Adjustment Opertion Adjustment...24 Dul Hndle Ycht Console Control Opertion nd Adjustment Opertion Adjustment...25 Bsic Joystick Opertion Auxiliry Joystick Sttion Fetures Generl Informtion Electricl System Overlod Protection Vessel Interfce Pnel (VIP) Overlod Protection Overlod Protection for the DC Voltge Regultor System, If Equipped Overlod Protection for Other Circuits...27 Shdow Mode Control Opertion nd Fetures Triple Engine Throttle nd Shift Opertion Qud Engine Throttle nd Shift Opertion Corrosion Protection Glvnic Isoltor nd Monitor Theory of Opertion Fult Codes Anodes nd MerCthode System Reference Electrode Wire MerCthode Assemly Pinting the Bot Section 3 - On the Wter Sfe Boting Suggestions Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Sfe Boting Recommendtions Bsic Bot Opertion M eng OCTOBER 2013 Pge i

4 Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge Drin Plug nd Bilge Pump Protecting People in the Wter While the Bot is Moving...39 While the Bot is Sttionry Wve nd Wke Jumping Impct with Underwter Hzrds Zeus Drive Impct Protection Zeus Drive Alignment Conditions Affecting Bot Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Bottom Of Bot Cvittion Ventiltion Propeller Selection Getting Strted Brek In Period (New or With Replcement Gers) DC Voltge Regultor Switch, If Equipped Strting nd Stopping the Engines Strting n Engine Using the VIP SmrtStrt Switch...42 Stopping the Engine Using the VIP SmrtStrt Switch...44 Trditionl Mneuvering with Steering nd Thrust To Mneuver the Bot in Forwrd...45 To Steer the Bot in Tight Turns t Low Speeds To Spin the Bot on its Axis t Low Speeds Mneuvering with the Joystick Trim Ts Automtic Control...49 Mnul Control Using Trim T Offset Specil Digitl Throttle nd Shift (DTS) Fetures Troll nd Throttle Response Dock Throttle Only...53 Single Lever (1 Lever) Opertion Synchronizing the Engines...54 Cruise Control Helm Trnsfer Requesting Helm Trnsfer Helm Trnsfer nd Precision Pilot Autopilot Trckpd Fetures Chrtplotter Requirements Response Settings VesselView Autopilot Screen Autopilot Trckpd Lights Autopilot Modes Skyhook Sttion Keeping Importnt Sfety Considertions Engging Skyhook Disengging Skyhook Using Skyhook Auto Heding Engging Auto Heding Course Adjustment Using the Turn Buttons or Joystick To Resume Heding Disengging Auto Heding Trck Wypoint Engging Trck Wypoint Mode Disengging Trck Wypoint Mode Turn Buttons in Trck Wypoint Mode Auto Heding Button in Trck Wypoint Mode Acknowledging Turn During Wypoint Arrivl Wypoint Sequence Cruise Control Contingent Opertions Steering Emergency Alterntive Method Port Engine Only Opertion Ger Enggement Emergency Procedure Steering nd Trim Mnul Override Procedure for Stuck Steering Control Vlve Procedure for Stuck Trim T Control Vlve End of First Seson Checkup Section 4 - Specifictions Drive Ger Luricnt Trnsmission Steering Actutor nd Trim Oil Approved Pints Approved Luricnts Section 5 - Mintennce Product Responsiilities Owner nd Opertor Responsiilities Deler Responsiilities Do It Yourself Mintennce Suggestions Generl Inspection of Power Pckge Drive Service Point Loctions Strord Port Top Drop Box Mintennce Schedules Appliction Routine Mintennce Scheduled Mintennce Zeus Pod Scrificil Anode Inspection Drive Cover, If Equipped Removing the Drive Cover Clening nd Inspecting the Drive Cover Instlling the Drive Cover Drive Ger Lue Drive Ger Luriction Checking Filling Chnging Drive Ger Luricnt With the Bot in the Wter With the Bot Out of the Wter Pge ii 90-8M eng OCTOBER 2013

5 Steering Actutor nd Trim Hydrulic Fluid Steering Actutor nd Trim Hydrulic Fluid Reservoir Checking Filling Trnsmission Oil (Fluid) nd Filter Checking the Trnsmission Oil Level Filling Chnging Sewter System Drining the Sewter System Bot out of the Wter Bot in the wter Checking the Sewter Pickup on the Drive Flushing the Sewter System Bttery Electricl System Cooling System nd Exhust System Luriction Driveshft Slip Joint Driveshft U Joints Propeller Shft Corrosion nd Corrosion Protection The Cuses of Corrosion Corrosion Protection Theory of Opertion Fult Codes Anodes nd MerCthode System Reference Electrode Wire MerCthode Assemly MerCthode Anode Checking Replcing MerCthode System Testing Trim T Anode Checking Replcing Continuity Circuits Inhiiting Corrosion Pinting the Bot Propellers Propeller Removl Propeller Repir Propeller Instlltion Section 6 - Storge Storge Descriptions Drive Storge Cold Wether (Freezing Temperture) Storge Sesonl nd Extended Storge Instructions Bttery Storge Recommissioning Engine Drive Power Pckge Section 7 - Trouleshooting Dignosing Electroniclly Controlled Fuel System Prolems Electricl Connections Trouleshooting Chrts Trouleshooting Engine Relted Prolems Check VesselView First Poor Performnce Joystick Electronic Remote Controls Steering System Trim Ts Bot Response Chnges Bttery Will Not Chrge Guges nd Instrumenttion Glvnic Isoltor Section 8 - Customer Assistnce Informtion Owner Service Assistnce Locl Repir Service Service Awy From Home Stolen Power Pckge Attention Required After Sumersion Replcement Service Prts Prts nd Accessories Inquiries Resolving Prolem Contct Informtion for Mercury Mrine Customer Service Customer Service Literture English Lnguge Other Lnguges Ordering Literture United Sttes nd Cnd Outside the United Sttes nd Cnd Section 9 - Mintennce Log Mintennce Log M eng OCTOBER 2013 Pge iii

6 Section 10 - Predelivery Informtion Predelivery Informtion Deler Predelivery Checklist for Zeus Products (Before Delivery to the Customer) Before Strting Key Off Before Strting Key On Engines Running t the Dock Se Tril After On Wter Test Skyhook (if Equipped) Pge iv 90-8M eng OCTOBER 2013

7 Tle of Contents Section 1 - Wrrnty Informtion Section 1 - Wrrnty Informtion 1 Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd... 2 Wrrnty Registrtion Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty... 2 Wrrnty Policy Zeus Models... 3 Zeus Drive High Output Recretionl Use Limited Wrrnty... 3 Zeus Drive Intermittent Commercil Use Limited Wrrnty... 5 Zeus Drive Limited Wrrnty Aginst Corrosion...6 Trnsfer of Wrrnty... 7 Wrrnty Policy Austrli nd New Zelnd... 8 MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy... 8 Trnsfer of Wrrnty Austrli nd New Zelnd Policy Glol Wrrnty Chrts United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel Outside United Sttes Cnd Wrrnty Chrt MerCruiser Gs nd Diesel Outside Cnd Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel Outside Austrli nd New Zelnd South Pcific Wrrnty Chrt MerCruiser Gs nd Diesel Outside of the South Pcific Asi Wrrnty Chrt MerCruiser Gs nd Diesel Outside of Asi Europe nd the Confedertion of Independent Sttes (CIS) Wrrnty Chrts MerCruiser Gs nd Diesel Outside Europe nd CIS Middle Est nd Afric (excluding South Afric) Wrrnty Chrts MerCruiser Gs nd Diesel Outside Middle Est nd Afric South Afric Wrrnty Chrts MerCruiser Gs nd Diesel Outside South Afric M eng OCTOBER 2013 Pge 1

8 Section 1 - Wrrnty Informtion Wrrnty Informtion Wrrnty Registrtion United Sttes nd Cnd Outside United Sttes nd Cnd Check with your locl distriutor. 1. You my chnge your ddress on file with Mercury Mrine t ny time, including t time of wrrnty clim, y clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd engine seril numer to Mercury Mrine s wrrnty registrtion deprtment. Your deler cn lso process this chnge of informtion. Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx NOTE: Registrtion lists must e mintined y Mercury Mrine nd ny deler on mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Sfety Act e required. 2. To e eligile for wrrnty coverge, the product must e registered with Mercury Mrine. At the time of sle, the deler should complete the wrrnty registrtion nd immeditely sumit it to Mercury Mrine vi MercNET, E mil, or mil. Upon receipt of this wrrnty registrtion, Mercury Mrine will record the registrtion. 3. Upon processing the wrrnty registrtion, Mercury Mrine will send registrtion verifiction y mil to the purchser of the product. If this registrtion verifiction is not received within 30 dys, plese contct your selling deler immeditely. Wrrnty coverge is not effective until your product is registered with Mercury Mrine. Wrrnty Registrtion Outside the United Sttes nd Cnd 1. It is importnt tht your selling deler fills out the wrrnty registrtion crd completely nd mils it to the distriutor or Mrine Power Service Center responsile for dministering the wrrnty registrtion nd clim progrm for your re. 2. The wrrnty registrtion crd identifies your nme nd ddress, product model nd seril numers, dte of sle, type of use nd the selling distriutor's nd deler's code numer, nme nd ddress. The distriutor or deler lso certifies tht you re the originl purchser nd user of the product. 3. A copy of the wrrnty registrtion crd, designted s the purchser's copy, must e given to you immeditely fter the crd hs een completely filled out y the selling distriutor or deler. This crd represents your fctory registrtion identifiction, nd should e retined y you for future use when required. Should you ever require wrrnty service on this product, your deler my sk you for the wrrnty registrtion crd to verify dte of purchse nd to use the informtion on the crd to prepre the wrrnty clim forms. 4. In some countries, the Mrine Power Service Center will issue you permnent (plstic) wrrnty registrtion crd within 30 dys fter receiving the fctory copy of the wrrnty registrtion crd from your distriutor or deler. If you receive plstic wrrnty registrtion crd, you my discrd the purchser's copy tht you received from the distriutor or deler when you purchsed the product. Ask your distriutor or deler if this plstic crd progrm pplies to you. 5. For further informtion concerning the wrrnty registrtion crd nd its reltionship to Wrrnty Clim processing, refer to the Interntionl Wrrnty. See Tle of Contents. IMPORTANT: Registrtion lists must e mintined y the fctory nd deler in some countries y lw. It is our desire to hve ALL products registered t the fctory should it ever e necessry to contct you. Mke sure your Mercury Mrine distriutor or Mercury Mrine uthorized deler fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re. Trnsfer of Wrrnty The limited wrrnty is trnsferle to susequent purchser, ut only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the susequent owner, send or fx copy of the Bill of Sle or Purchse Agreement, new owner s nme, ddress, nd engine seril numer to Mercury Mrine s Wrrnty Registrtion Deprtment. In the United Sttes nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product y mil. Pge M eng OCTOBER 2013

9 There is no chrge for this service. Section 1 - Wrrnty Informtion For products purchsed outside the United Sttes nd Cnd, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Wrrnty Policy Zeus Models Zeus Drive High Output Recretionl Use Limited Wrrnty WHAT IS COVERED: Mercury Mrine wrrnts ech new Zeus drive system (Product) to e free of defects in mteril nd workmnship during the period descried following. DURATION OF COVERAGE: The wrrnty period egins on the dte the product is first sold to recretionl use retil purchser or the dte on which the product is first put into service, whichever occurs first. This Limited Wrrnty provides coverge for 24 months or 1000 hours of use, whichever occurs first. Commercil use of the product voids the wrrnty. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income during ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. The repir or replcement of prts, or the performnce of service under this wrrnty does not extend the term of this wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred from one recretionl use customer to susequent recretionl use customer upon proper registrtion of the product. TWO YEAR LIMITED WARRANTY LIMITED WARRANTY COVERAGE: This limited wrrnty provides coverge for 24 months or 1000 hours of use, whichever occurs first for the se drive wrrnty. Coverge Ctegory Months Hours Prts nd Lor Trvel Bse drive Yes Yes Extended mjor components Yes Yes EXTENDED MAJOR COMPONENTS LIMITED WARRANTY: The Extended Mjor Components Limited Wrrnty tkes effect when the Bse Drive Limited Wrrnty expires. The Bse Drive Limited Wrrnty expires fter 24 months or 1000 hours in service, whichever occurs first. The Extended Mjor Components Limited Wrrnty covers wrrntle filures of the following drive prts or cstings for 48 months or 2000 hours in service, whichever occurs first: Extended Mjor Components Limited Wrrnty Coverge Mrine ger housing csting Mrine ger drop ox housing csting Steering ctutor housing csting Drive midsection csting Lower ger housing csting (underwter impct dmge excluded) Trim t csting (underwter impct dmge excluded) Bering crrier csting (underwter impct dmge excluded) Driveshft (U joints excluded) Intermedite shft (underwter impct dmge excluded) Clmp rings Skeg (underwter impct dmge excluded) HIGH OUTPUT RATING: A high output rting pplies to vrile lod pplictions nd requires full power to e limited to one (1) hour out of every eight (8) hours of opertion. Reduced power opertion (the 7 hours out of 8 hours in which the engine is not operted t full power) must e t or elow cruise speed. Cruise speed is dependnt on the engine's mximum engine rted speed (RPM): Full Power Engine Rted Speed (RPM) (Full Power is defined s n RPM tht exceeds cruise speed) Cruise Speed Reduction from Engine Rted Speed (RPM) RPM 200 RPM RPM 300 RPM RPM 400 RPM 90-8M eng OCTOBER 2013 Pge 3

10 Section 1 - Wrrnty Informtion CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is ville only to retil customers tht purchse from deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified predelivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or susequent chnge of use from recretionl to commercil (unless properly registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce outlined in the Opertion, Mintennce, nd Wrrnty Mnul must e timely performed in order to otin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. NOTE: The product ppliction must e reviewed nd pproved y Mercury Mrine. WHAT MERCURY WILL DO: Mercury Mrine s sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: Wrrnty clims must e mde through Mercury Mrine uthorized repir fcility. The customer must provide Mercury Mrine with resonle opportunity to repir nd resonle ccess to the product for wrrnty service. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. TERMINATION OF COVERAGE: Wrrnty coverge my e terminted for used product otined in ny of the following wys: Repossession from retil customer Purchsed t n uction Purchsed from slvge yrd Purchsed from n insurnce compny tht otined the product s result of n insurnce clim Inccurte wrrnty registrtion informtion WHAT IS NOT COVERED: This limited wrrnty does not cover the following: Routine mintennce items Adjustments Norml wer nd ter Dmge cused y use Anorml use Use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge. Refer to the Opertion, Mintennce nd Wrrnty mnul. Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce nd Wrrnty mnul Neglect Accident Sumersion Improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Improper service Use of n ccessory or prt tht ws not mnufctured or sold y Mercury Mrine nd tht dmges the Mercury product Opertion with oils or luricnts tht re not suitle for use with the product. Refer to the Opertion, Mintennce nd Wrrnty mnul. Altertion or removl of prts Dmge to the product from insufficient cooling wter cused y lockge of the cooling system y foreign ody Use of the product for rcing or other competitive ctivity, even y previous owner of the product, voids the wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered y this wrrnty. Also, expenses ssocited with the removl or replcement of ot prtitions or other mteril in order to gin ccess to the product re not covered y this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y Mercury Mrine to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty. If such ffirmtion, representtion, or wrrnty is mde, it shll not e enforcele ginst Mercury Mrine. Pge M eng OCTOBER 2013

11 Section 1 - Wrrnty Informtion DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Zeus Drive Intermittent Commercil Use Limited Wrrnty WHAT IS COVERED: Mercury Mrine wrrnts ech new Zeus drive system (Product) to e free of defects in mteril nd workmnship during the period s descried in the following. DURATION OF COVERAGE: The wrrnty period egins on the dte the product is first sold to n intermittent commercil use retil purchser or the dte on which the product is first put into service, whichever occurs first. This Limited Wrrnty provides coverge for 24 months or 3000 hours of use, whichever occurs first. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of the wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cnnot e trnsferred. INTERMITTENT COMMERCIAL RATING: Intermittent Commercil pplies to vrile lod pplictions where full power is limited to two (2) hours out of every eight (8) hours of opertion. Reduced power opertion (the 6 hours out of 8 hours in which the engine is not operted t full power) must e t or elow cruise speed. Cruise speed is dependnt on the engine's mximum engine rted speed (RPM): Full Power Engine Rted Speed (RPM) (Full Power is defined s n RPM tht exceeds cruise speed) Cruise Speed Reduction from Engine Rted Speed (RPM) RPM 200 RPM RPM 300 RPM RPM 400 RPM Commercil use is defined s ny work or employment relted use of this product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. Opertion of the product in excess of the intermittent commercil use specifictions will void the wrrnty. CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is ville only to retil customers tht purchse from deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified predelivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Routine mintennce outlined in the Opertion, Mintennce, nd Wrrnty Mnul must e timely performed in order to otin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. NOTE: The product ppliction must e reviewed nd pproved y Mercury Mrine. WHAT MERCURY WILL DO: Mercury Mrine s sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: Wrrnty clims must e mde through Mercury Mrine uthorized repir fcility. The customer must provide Mercury Mrine with resonle opportunity to repir nd resonle ccess to the product for wrrnty service. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. TERMINATION OF COVERAGE: Wrrnty coverge my e terminted for used product otined in ny of the following wys: Repossession from retil customer Purchsed t n uction Purchsed from slvge yrd Purchsed from n insurnce compny tht otined the product s result of n insurnce clim Inccurte wrrnty registrtion informtion WHAT IS NOT COVERED: This limited wrrnty does not cover the following: Routine mintennce items 90-8M eng OCTOBER 2013 Pge 5

12 Section 1 - Wrrnty Informtion Adjustments Norml wer nd ter Dmge cused y use Anorml use Use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge. Refer to the Opertion, Mintennce nd Wrrnty mnul. Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce nd Wrrnty mnul Neglect Accident Sumersion Improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Improper service Use of n ccessory or prt tht ws not mnufctured or sold y Mercury Mrine nd tht dmges the Mercury product Opertion with oils or luricnts tht re not suitle for use with the product. Refer to the Opertion, Mintennce nd Wrrnty mnul. Altertion or removl of prts Dmge to the product from insufficient cooling wter cused y lockge of the cooling system y foreign ody Use of the product for rcing or other competitive ctivity, even y previous owner of the product, voids the wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered y this wrrnty. Also, expenses ssocited with the removl or replcement of ot prtitions or other mteril in order to gin ccess to the product re not covered y this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y Mercury Mrine to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty. If such ffirmtion, representtion, or wrrnty is mde, it shll not e enforcele ginst Mercury Mrine. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Zeus Drive Limited Wrrnty Aginst Corrosion WHAT IS COVERED: Mercury Mrine wrrnts tht ech new (noncommercil use) Zeus drive system (Product) will not e rendered inopertive s direct result of corrosion for the period of time descried in the following. DURATION OF COVERAGE: This limited corrosion wrrnty provides coverge for 36 months or 1500 hours of use from either the dte the product is first sold, or the dte on which the product is first put into service, whichever occurs first. The repir nd replcement of prts, or the performnce of service under this wrrnty does not extend the life of this wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred to susequent purchser upon proper registrtion of the product. CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is ville only to retil customers tht purchse from deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified predelivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Corrosion prevention devices specified in the Opertion, Mintennce nd Wrrnty mnul must e in use on the ot, nd routine mintennce outlined in the Opertion, Mintennce nd Wrrnty mnul must e timely performed (including without limittion the replcement of scrificil nodes, use of specified luricnts, nd touch up of nicks nd scrtches) in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. Pge M eng OCTOBER 2013

13 Section 1 - Wrrnty Informtion WHAT MERCURY WILL DO: Mercury Mrine's sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury Mrine with resonle opportunity to repir, nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde y delivering the product for inspection to Mercury Mrine deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must e given to Mercury Mrine. We will then rrnge for the inspection nd ny covered repir. The purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered y this wrrnty, purchser shll py for ll relted lor nd mteril, nd ny other expenses ssocited with tht service. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge. TERMINATION OF COVERAGE: Wrrnty coverge my e terminted for used product otined in ny of the following wys: Repossession from retil customer Purchsed t n uction Purchsed from slvge yrd Purchsed from n insurnce compny tht otined the product s result of n insurnce clim WHAT IS NOT COVERED: This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge, corrosion which cuses purely cosmetic dmge, use or improper service; corrosion to ccessories, instruments, steering systems; dmge due to mrine growth; product sold with less thn one yer limited product wrrnty; replcement prts (prts purchsed y the Customer); products used in commercil ppliction; corrosion dmge s result of improper pint ppliction (refer to the Opertion, Mintennce nd Wrrnty mnul for cceptle pint pplictions). Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Trnsfer of Wrrnty The limited wrrnty is trnsferle to susequent purchser, ut only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the susequent owner, send or fx copy of the ill of sle or purchse greement, new owner s nme, ddress nd engine seril numer to Mercury Mrine s Wrrnty Registrtion Deprtment. In the United Sttes nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product y mil. There is no chrge for this service. 90-8M eng OCTOBER 2013 Pge 7

14 Section 1 - Wrrnty Informtion For products purchsed outside the United Sttes nd Cnd, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Wrrnty Policy Austrli nd New Zelnd MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy This Limited Wrrnty is given y Mrine Power Interntionl Pty Ltd ACN of Bessemer Drive, Dndenong South, Victori 3175 Austrli (telephone (61) (3) ), e mil: merc_info@mercmrine.com. WHAT IS COVERED: Mercury Mrine wrrnts its new products to e free of defects in mteril nd workmnship during the period descried elow. The enefits to the consumer given y the wrrnty re in ddition to other rights nd remedies of the consumer under lw in reltion to the goods or services to which the wrrnty reltes. GUARANTEES UNDER AUSTRALIAN CONSUMER LAW: Our goods come with gurntees tht cnnot e excluded under the Austrlin Consumer Lw. You re entitled to replcement or refund for mjor filure nd compenstion for ny other resonly foreseele loss or dmge. You re lso entitled to hve the goods repired or replced if the goods fil to e of cceptle qulity nd the filure does not mount to mjor filure. DURATION OF COVERAGE FOR THIS LIMITED WARRANTY: You re only entitled to clim this Limited Wrrnty for defects which pper during the relevnt wrrnty period. Refer to Glol Wrrnty Chrts for the wrrnty period specific to the model nd region where the power pckge ws purchsed. Your clim must lso e received y us efore the wrrnty period expires. WARRANTY COVERAGE FOR RECREATIONAL USE: The wrrnty period egins on the dte the product is first sold to recretionl use retil purchser, or the dte on which the product is first put into service, whichever occurs first. The repir or replcement of prts or the performnce of service under this wrrnty does not extend the life of this limited wrrnty eyond its originl expirtion dte. The wrrnty period is specific to the model covered. Refer to your model for the se coverge period. WARRANTY COVERAGE FOR COMMERCIAL USE: The wrrnty period egins on the dte the product is first sold to commercil use retil purchser, or the dte on which the product is first put into service, whichever occurs first. Commercil users of these products receive wrrnty coverge for either one (1) yer from the dte of first retil sle or the ccumultion of 500 hours of opertion, whichever occurs first. Commercil use is defined s ny work relted or employment relted use of the product, or ny use of the product tht genertes income for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. The repir or replcement of prts or the performnce of service under this wrrnty does not extend the life of this wrrnty eyond its originl expirtion dte. TRANSFER OF COVERAGE: Unexpired wrrnty coverge cn e trnsferred to susequent recretionl use customer upon proper registrtion of the product. Unexpired wrrnty coverge cnnot e trnsferred either to or from commercil use customer. TERMINATION OF COVERAGE: Wrrnty coverge under this Limited Wrrnty is terminted for used product otined in ny of the following wys: Purchsed from n insurnce compny tht otined the product s result of n insurnce clim Purchsed from slvge yrd Repossession from retil customer Purchsed t n uction CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge under this Limited Wrrnty is ville only to retil customers tht purchse from deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the predelivery inspection process specified y Mercury Mrine is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use or susequent chnge of use from recretionl to commercil (unless properly registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce must e performed ccording to the mintennce schedule in the Opertion, Mintennce, nd Wrrnty mnul in order to otin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. WHAT MERCURY WILL DO: Mercury Mrine's sole nd exclusive oligtion under this Limited Wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. Pge M eng OCTOBER 2013

15 Section 1 - Wrrnty Informtion HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury Mrine with resonle opportunity to repir nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde y delivering the product for inspection to Mercury Mrine deler uthorized to service the product. A list of delers nd their contct detils is ville t If the purchser cnnot deliver the product to such deler, written notice must e given to Mercury Mrine t the ddress shown ove. Mercury Mrine will then rrnge for the inspection nd ny covered repir. This Limited Wrrnty will not cover the purchser for ll relted trnsporttion chrges nd trvel time. If the service provided is not covered y this limited wrrnty, the purchser shll py for ll relted lor nd mteril nd ny other expenses ssocited with tht service, provided tht consumer will not e oligted to py where the service hs een crried out to remedy filure of n cceptle qulity gurntee which is inding on Mercury Mrine under the Austrlin Consumer Lw. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge under this Limited Wrrnty. WHAT IS NOT COVERED: This limited wrrnty does not cover the following: Operting the ot with the engine overtrimmed Routine mintennce items Adjustments Norml wer nd ter Dmge cused y use Anorml use Use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge. Refer to the Opertion, Mintennce, nd Wrrnty mnul. Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce, nd Wrrnty mnul. Neglect Accident Sumersion Improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Improper service Use of n ccessory or prt tht ws not mnufctured or sold y Mercury Mrine tht cuses dmge to the Mercury product Jet pump impellers nd liners Opertion with fuels, oils, or luricnts tht re not suitle for use with the product. Refer to the Opertion, Mintennce nd Wrrnty mnul. Altertion or removl of prts Wter entering the engine through the fuel intke, ir intke, or exhust system or dmge to the product from insufficient cooling wter cused y lockge of the cooling system y foreign ody Running the engine out of wter Mounting the engine too high on the trnsom Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny point, even y previous owner of the product, voids this limited wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered y this limited wrrnty. Also, expenses ssocited with the removl or replcement of ot prtitions or other mteril in order to gin ccess to the product re not covered y this limited wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y Mercury Mrine to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty. If such ffirmtion, representtion, or wrrnty is mde, it shll not e enforcele ginst Mercury Mrine. EXPENSE OF CLAIMING THIS LIMITED WARRANTY: This Limited Wrrnty does not cover ny expenses you my incur climing the wrrnty. 90-8M eng OCTOBER 2013 Pge 9

16 Section 1 - Wrrnty Informtion DISCLAIMERS AND LIMITATIONS: EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS AND REMEDIES THAT A CONSUMER MAY HAVE UNDER THE AUSTRALIAN CONSUMER LAW OR OTHER LAW IN RELATION TO WHICH THE PRODUCTS RELATE, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS LIMITED WARRANTY. Trnsfer of Wrrnty Austrli nd New Zelnd Policy The limited wrrnty is trnsferle to susequent purchser, ut only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the susequent owner, send or fx copy of the Bill of Sle or Purchse Agreement, new owner s nme, ddress, nd hull identifiction numer (HIN) to Mercury Mrine s Wrrnty Registrtion Deprtment. In Austrli nd New Zelnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment Brunswick Asi Pcific Group Privte Bg 1420 Dndenong South, Victori 3164 Austrli Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product y mil. There is no chrge for this service. You my chnge your ddress t ny time, including t the time of the wrrnty clim, y clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd hull identifiction numer (HIN) to Mercury Mrine s Wrrnty Registrtion Deprtment. Glol Wrrnty Chrts United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord MerCruiser TowSport MerCruiser SeCore MerCruiser Inord MPI, 8.2 H.O. MerCruiser Inord Horizon Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 3 yers 3 yers 4 yers 4 yers 1 yer 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside United Sttes For product purchsed outside of United Sttes, contct the distriutor in your country, or the uthorized Mrine Power Service Center closest to you. Pge M eng OCTOBER 2013

17 Section 1 - Wrrnty Informtion Cnd Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord MerCruiser TowSport MerCruiser SeCore MerCruiser Inord MPI, 8.2 H.O. MerCruiser Inord Horizon Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 3 yers 3 yers 4 yers 4 yers 1 yer 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Cnd For product purchsed outside of Cnd, contct the distriutor in your country, or the uthorized Mrine Power Service Center closest to you. Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Stndrd Limited Wrrnty 2 yers 3 yers MerCruiser SeCore 3 yers 4 yers MerCruiser TowSport 3 yers 3 yers Mercury Diesel Sterndrive nd Inord 2 yers 3 yers Stndrd Limited Corrosion Wrrnty Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Austrli nd New Zelnd For product purchsed outside of Austrli nd New Zelnd, contct the distriutor in your country, or the uthorized Mrine Power Service Center closest to you. South Pcific Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty 2 yers 3 yers 2 yers 3 yers Stndrd Limited Corrosion Wrrnty Commercil Appliction Contct the Mrine Power Service Center closest to you Outside of the South Pcific For product purchsed outside of the South Pcific, contct the distriutor in your country, or the uthorized Mrine Power Service Center closest to you. 90-8M eng OCTOBER 2013 Pge 11

18 Section 1 - Wrrnty Informtion Asi Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Gsoline Sterndrive nd Inord Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty 1 yer 3 yers 1 yer 3 yers Stndrd Limited Corrosion Wrrnty Commercil Appliction Contct the Mrine Power Service Center closest to you Outside of Asi For product purchsed outside of the Asin region, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Europe nd the Confedertion of Independent Sttes (CIS) Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 2 yers 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Europe nd CIS For products purchsed outside of Europe nd CIS regions, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Middle Est nd Afric (excluding South Afric) Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 4 yers 1 yer Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Middle-Est nd Afric For products purchsed outside of Middle Est nd Afric regions, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Pge M eng OCTOBER 2013

19 Section 1 - Wrrnty Informtion South Afric Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 4 yers 1 yer Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside South Afric For products purchsed outside of South Afric, contct the distriutor in your country, or the Mrine Power Service Center closest to you. 90-8M eng OCTOBER 2013 Pge 13

20 Section 1 - Wrrnty Informtion Notes: Pge M eng OCTOBER 2013

21 Section 2 - Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tle of Contents Generl Informtion Models Covered...16 Drive Seril Numer nd Decl Plcement Fetures nd Controls Audio Wrning System Instrumenttion VesselView SmrtCrft Speedometer, Tchometer, nd Digitl Guges System Link Digitl Guges Key Switch Emergency Stop Switch...19 Lnyrd Stop Switch Vessel Interfce Pnel (VIP) Overlod Strting nd Stopping the Engines Strting n Engine Using the VIP SmrtStrt Switch Stopping the Engine Using the VIP SmrtStrt Switch Electronic Helm Steering Trim T Pnel Dul Hndle Electronic Remote Control (ERC) Opertion nd Adjustment Opertion Adjustment Dul Hndle Ycht Console Control Opertion nd Adjustment Opertion Adjustment Bsic Joystick Opertion Auxiliry Joystick Sttion Fetures Generl Informtion Electricl System Overlod Protection Vessel Interfce Pnel (VIP) Overlod Protection Overlod Protection for the DC Voltge Regultor System, If Equipped Overlod Protection for Other Circuits Shdow Mode Control Opertion nd Fetures Triple Engine Throttle nd Shift Opertion Qud Engine Throttle nd Shift Opertion...28 Corrosion Protection Glvnic Isoltor nd Monitor Theory of Opertion Fult Codes Anodes nd MerCthode System Reference Electrode Wire MerCthode Assemly Pinting the Bot M eng OCTOBER 2013 Pge 15

22 Section 2 - Getting to Know Your Power Pckge Generl Informtion Models Covered Models Covered Zeus 3000 Series Pod Drive Seril Numer 0M nd ove Drive Seril Numer nd Decl Plcement Seril numers re the mnufcturer's key to numerous engineering detils tht pply to your drive. Refer to the engine owner's mnul supplied with the engine for the loction of the engine dt tg tht contins the engine seril numer nd model numer. Drive seril numer loctions - Trnsmission seril numer plte - Drive seril numer decl nd stmping Fetures nd Controls Audio Wrning System Your power pckge is equipped with n udio wrning system. The udio wrning system monitors criticl components nd informs the opertor when mlfunction hs occurred. The wrning system is not cple of protecting the power pckge from dmge cused y mlfunction. When n electronic control system detects recordle mlfunction, the udio wrning system will sound to lert the opertor. The durtion nd type of horn sound depend upon the nture of the fult condition. In the cse of ny horn sounding, the user should refer to the helm displys to understnd the specific sitution. For the opertor to view the fult code of the mlfunction indicted nd ny recommended ctions, the power pckge must e equipped with guge pckge tht supports the wrning system nd cn disply fult codes. The following instruments hve screens tht disply fult codes: VesselView SmrtCrft System Tchometer SmrtCrft System Speedometer NOTICE The sound from n udio wrning horn indictes tht criticl fult mlfunction hs occurred. Operting power pckge with criticl fult cn dmge components. If the udio wrning horn emits sound, do not continue opertions unless voiding hzrdous sitution. If the udio wrning sounds, stop the engine immeditely if you re not in hzrdous sitution. Investigte the cuse nd correct it, if possile. If you cnnot determine the cuse, consult n uthorized repir fcility. Instrumenttion VesselView Your power pckge my e connected to SmrtCrft VesselView disply. VesselView 7 is comprehensive ot informtion center tht cn disply informtion for up to four gsoline or diesel engines. It continuously monitors nd reports sic operting dt including detiled informtion such s sewter temperture nd depth, trim sttus, ot speed nd steering ngle, nd the sttus of fuel, oil, wter, nd wste tnks Pge M eng OCTOBER 2013

23 Section 2 - Getting to Know Your Power Pckge VesselView cn e fully integrted with vessel s glol positioning system (GPS) or other NMEA comptile device to provide up to the minute nvigtion, speed, nd fuel to destintion informtion. VesselView 4 nd 7 re equipped with micro SD crd port tht llows n uthorized OEM or delership to import the VesselView personlity configurtion. It cn lso e used y the owner to import pictures or grphics. When more thn one VesselView is used, either s triple or qud engine ppliction for multiple helms, the sme micro SD crd cn e used to downlod those configurtions. VesselView Refer to your VesselView opertions mnul for detiled instructions on how to operte this disply. SmrtCrft Speedometer, Tchometer, nd Digitl Guges The SmrtCrft instrument pckge ugments the informtion provided y VesselView. The instrument pckge my disply: Engine RPM Bot speed Coolnt temperture Oil pressure Bttery voltge Fuel consumption Engine operting hours SmrtCrft tchometer nd speedometer - Tchometer - Speedometer c - LCD disply c The SmrtCrft instrument pckge lso ids in identifying the fult codes ssocited with the engine udio wrning system. The SmrtCrft instrument pckge displys criticl engine lrm dt nd other potentil prolems on its LCD disply. For sic opertion informtion on the SmrtCrft instrument pckge nd for detils on the wrning functions monitored y the system, refer to the mnul provided with your guge pckge. 90-8M eng OCTOBER 2013 Pge 17

24 Section 2 - Getting to Know Your Power Pckge System Link Digitl Guges Some instrumenttion pckges include guges tht ugment the informtion provided y VesselView nd the SmrtCrft tchometer nd speedometer. The owner nd opertor should e fmilir with ll the instruments nd their functions on the ot. Hve your ot deler explin the guges nd norml redings tht pper on your ot. The following types of digitl guges my e included with your power pckge. c d System Link digitl guges Item Guge Indictes Oil pressure guge Engine oil pressure Voltmeter Bttery voltge c Wter temperture guge Engine operting temperture d Fuel guge Quntity of fuel in tnk Key Switch The key switch provides switched power to the control system, nd cn e used to strt nd/or stop n engine. There will e one key switch, for ech engine nd they re only instlled t the min sttion. For ot tht is equipped with two sttions, the min sttion will hve the key switches nd the other sttion will hve strt/stop pnel. In the event tht key switch extension hrness is used, strt/stop pnel will hve to e used t the min sttion due to the crnk circuit eing sent from the key switch extension hrness Pge M eng OCTOBER 2013

25 Emergency Stop Switch Section 2 - Getting to Know Your Power Pckge An emergency stop (E stop) switch is used to turn off the engines in n emergency sitution, such s person overord or tngled propeller. When ctivted, n E stop switch interrupts the power supply to the engine nd trnsmission. If the ot is equipped with n E stop switch, the E stop switch turns off ll of the engines. Typicl E-stop switch Activtion of n E stop switch stops the engine, or engines, immeditely, ut the ot cn continue to cost for some distnce depending upon the velocity nd degree of ny turn t shutdown. While the ot is costing, it cn cuse injury to nyone in the ot's pth s seriously s the ot would when under power. We recommend instructing other occupnts on proper strting nd operting procedures should they need to operte the engine in n emergency. Accidentl or unintended ctivtion of the switch during norml opertion is lso possile, which cn cuse ny or ll of the following potentilly hzrdous situtions: Occupnts cn e thrown forwrd due to unexpected loss of forwrd motion, nd pssengers in the front of the ot could e ejected over the ow nd possily struck y the propulsion or steering components. The opertor cn lose power nd directionl control in hevy ses, strong current, or high winds. The opertor cn lose control of the vessel when docking. Restrting n engine using the key switch or strt utton fter n E stop shutdown without first turning the key switch to the off position for t lest 30 seconds will restrt the engine ut cuse fult codes to e set. Unless you re in potentilly hzrdous sitution, turn the key switch off nd wit t lest 30 seconds efore restrting the engine or engines. If fter restrting, some fult codes re still eing displyed, contct your uthorized Mercury Diesel repir fcility. Lnyrd Stop Switch The purpose of lnyrd stop switch is to turn off the engine when the opertor moves outside the opertor's position (s in ccidentl ejection from the opertor's position). A decl ner the lnyrd stop switch is visul reminder for the opertor to ttch the lnyrd to their personl flottion device (PFD) or wrist ATTACH LANYARD RUN OFF - Lnyrd cord clip - Lnyrd decl c - Lnyrd stop switch c Accidentl ejections, such s flling overord, re more likely to occur in: low sided sport ots ss ots high performnce ots 90-8M eng OCTOBER 2013 Pge 19

26 Section 2 - Getting to Know Your Power Pckge Accidentl ejections cn lso occur from: poor operting prctices sitting on the set or gunwle t plning speeds stnding t plning speeds operting t plning speeds in shllow or ostcle infested wters relesing your grip on the steering wheel tht is pulling in one direction consuming lcohol or drugs high speed oting mneuvers The lnyrd cord is usully cm (4 5 feet) in length when stretched out, with n element on one end mde to e inserted into the switch nd clip on the other end for ttching to the opertor's PFD or wrist. The lnyrd is coiled to mke its t rest condition s short s possile to minimize the likelihood of lnyrd entnglement with nery ojects. Its stretched out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor's position. If it is desired to hve shorter lnyrd, wrp the lnyrd round the opertor's wrist or leg, or tie knot in the lnyrd. Activtion of the lnyrd stop switch will stop the engine immeditely, ut the ot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the ot will not complete full circle. While the ot is costing, it cn cuse injury to nyone in the ot's pth s seriously s the ot would when under power. We strongly recommend tht other occupnts e instructed on proper strting nd operting procedures should they e required to operte the engine in n emergency (if the opertor is ccidentlly ejected).! WARNING If the opertor flls out of the ot, stop the engine immeditely to reduce the possiility of serious injury or deth from eing struck y the ot. Alwys properly connect the opertor to the stop switch using lnyrd. Accidentl or unintended ctivtion of the switch during norml opertion is lso possiility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could e thrown forwrd due to unexpected loss of forwrd motion, prticulr concern for pssengers in the front of the ot who could e ejected over the ow nd possily struck y the propulsion or steering components. Loss of power nd directionl control in hevy ses, strong current, or high winds. Loss of control when docking.! WARNING Avoid serious injury or deth from decelertion forces resulting from ccidentl or unintended stop switch ctivtion. The ot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor. Vessel Interfce Pnel (VIP) Overlod A vessel interfce pnel (VIP) is typiclly mounted in the engine comprtment. The VIP contins circuit rekers tht help protect the system wiring. c d - Min circuit reker (25 mp) - VIP dignostic circuit reker (10 mp) c - Helm circuit reker (10 mp) d - SIM/vessel circuit reker (10 mp) e - Ger circuit reker (15 mp) e Strting nd Stopping the Engines Your Zeus power pckge is equipped with SmrtStrt system, tht includes strt/stop utton for emergency use tht is remotely mounted in the vessel interfce pnel (VIP). The VIP is usully locted in the engine room. In norml circumstnces, strt nd stop the engine from the helm using the strt/stop utton of the SmrtStrt system. Pge M eng OCTOBER 2013

27 NOTICE Section 2 - Getting to Know Your Power Pckge The sewter pumps on vessels equipped with Zeus pod drives cn e dmged y excessive exhust ertion due to indequte wter flow. To ensure dequte wter flow cross the sewter inlets, mke sure tht the vessel is underwy efore exceeding 1500 RPM. Strting n Engine Using the VIP SmrtStrt Switch You my desire to strt n engine from the engine room or under certin circumstnces the engine control systems my not e le to utomticlly strt n engine. The engines cn e strted using the "SMARTSTART" (strt/stop) switch on the VIP for ech engine. 1. Perform the checks nd steps listed in the engine's opertion nd mintennce mnul ville for this pckge. NOTE: Some vessels re not equipped with sewter return secock. 2. Open the sewter return secock, if equipped. Rotte the hndle in the direction indicted y the rrow. Drive cover removed for clrity - Hndle in open position - Sewter return (overord) secock, if equipped 3. Open the secock for the sewter inlet. Rotte the hndle in the direction indicted y the rrow Typicl inlet secock port orienttion (strord similr) - Secock for sewter inlet - Hndle in open position c - Former position (closed) c 4. Open the secock (if equipped) for ny ccessory equipment. NOTE: When the key switch is turned to the on position, the neutrl LED lights on the ERC trckpd flsh on nd off if the ERC hndles re not in the neutrl position. Before strting the engines the ERC hndles must e in the neutrl position. 5. At the ctive stndrd helm, move the ERC hndles to the neutrl position. NOTE: Ask your deler for the loction of the key switches if the key switches re not locted t the helm. 6. Turn the key switch to the on position for ech engine to e strted. 7. Verify it is sfe to strt the engines. 8. In the engine room, locte the VIP for ech engine. IMPORTANT: The strt/stop switch or "SMARTSTART" switch on VIP will strt the corresponding engine regrdless of which helm sttion is ctive or previously ctive M eng OCTOBER 2013 Pge 21

28 Section 2 - Getting to Know Your Power Pckge 9. Press nd relese the strt/stop switch or green "SMARTSTART" (strt/stop) switch on the VIP corresponding to the engine eing strted. The control system utomticlly controls the strter to chieve successful strt. - "E STOP" switch for emergency use only - "START/STOP" switch IMPORTANT: To void excessive exhust ertion of the sewter, do not operte the engines over 1500 RPM when the vessel is t rest. 10. If you must operte the engines ove 1500 RPM, put the vessel underwy with light throttle lod until the engines rech norml operting temperture. Stopping the Engine Using the VIP SmrtStrt Switch You my desire to stop n engine from the engine room or under certin circumstnces when the engine control system my not e le to utomticlly stop n engine. The engines cn e stopped using the "SMARTSTART" (strt/stop) switch on the VIP for ech engine. 1. Move the ERC hndles to the neutrl position. 2. Locte the VIP for ech engine in the engine room. 3. When the engines re running, press nd relese the strt/stop switch or the green "SMARTSTART" (strt/stop) switch for ech engine you wnt to stop. - "E STOP" switch for emergency use only - "START/STOP" switch Turn the key switch to the off position for ech engine tht ws stopped. 5. Close the sewter return secock, if equipped. Rotte the hndle in the direction indicted y the rrow. Drive cover removed for clrity - Sewter return secock, if equipped - Hndle in closed position Pge M eng OCTOBER 2013

29 Section 2 - Getting to Know Your Power Pckge 6. Close the secock for the sewter inlet. Rotte the hndle in the direction indicted y the rrow. Typicl inlet secock port orienttion (strord similr) - Secock for sewter inlet - Former position (open) c - Hndle in closed position Electronic Helm Steering The electronic helm steering opertes using electricl signls. A computer controlled electric motor ttched to the steering wheel simultes the resistnce feedck found in hydrulic steering systems. We recommend tht you drive crefully (in n open re cler of ostructions or other ot trffic) until you re fmilir with the system's hndling chrcteristics nd the ot's response. The electronic steering my provide fster steering response thn expected. To confirm your steering rnge from lock to lock, ensure tht the strord engine key switch is on. The engines do not hve to e running. Turn the wheel to strord until the wheel stops t the strord lock or end stop. The end stop is electroniclly set y the electric motor ttched to the steering wheel. Begin turning the wheel to port nd count the numer of revolutions until the wheel stops t the port lock. The numer of wheel revolutions you counted moves the drives from the mximum strord ngle to mximum port ngle, with the center (stright hed position) eing 0. The mximum steering ngles re controlled within the vessel personlity developed y the drive mnufcturer nd the ot OEM. In certin situtions the electronic end stops of the wheel re not felt. The sence of noticele end stops does not ffect the steering. The drives will still stop when they rech the full turn position t ech lock. The sence of end stops cn e the result of the strord key switch in the off position, low strord ttery voltge, or steering wheel motor fult. Your vessel's personlity, s developed y the vessel mnufcturer in prtnership with the drive mnufcturer, determines the numer of turns lock to lock. Typiclly, this is pproximtely 2 3/4 revolutions of the wheel. The OEM my request different lock to lock settings for other ot models. Trim T Pnel c The trim t pnel consists of switches tht interlock to form smll pnel. The switches llow for mnully setting or djusting the trim t on ech drive pckge nd lso enles the uto t function tht controls the trim ts utomticlly. You cn lso mke t djustments when in utomtic trim control mode. The ts cn e djusted independently to llow for externl conditions or personl preferences Dul Hndle Electronic Remote Control (ERC) Opertion nd Adjustment Opertion The electronic remote control (ERC) hndle controls the shift nd throttle opertion. Push the control hndle forwrd from neutrl to the first detent for forwrd ger. Continue pushing the hndle forwrd to increse speed. Pull the control hndle from the forwrd position to the neutrl position to decrese speed nd eventully stop. Pull the control hndle ck from neutrl to the first detent for reverse ger. Continue pulling the hndle ck to increse speed in reverse M eng OCTOBER 2013 Pge 23

30 Section 2 - Getting to Know Your Power Pckge NOTE: In certin modes, the ger position is determined y the electronic shift control, not the position of the ERC levers. When using the joystick or while in Skyhook, the computer controls the shifting even though the ERC levers re in neutrl. - Forwrd - Neutrl c - Reverse c To help prevent unwnted motion, the mount of force needed to move the levers is djustle. Adjustment NOTE: The control hndle tension nd detent tension my require periodic mintennce using the djustment screws. To djust the hndle detent tension: 1. Remove the side cover plugs of the hndle tht needs djustment. 2. Turn the djustment screw clockwise to increse tension on the control hndle nd counterclockwise to decrese tension. 3. Adjust the screw until the desired hndle detent tension is chieved. To djust hndle tension: 1. Remove the side cover plugs of the hndle tht needs djustment. 2. Turn the djustment screw clockwise to increse tension on the control hndle nd counterclockwise to decrese tension. 3. Adjust the screw until the desired hndle tension is chieved. - Detent tension djustment screw - Hndle tension djustment screw Pge M eng OCTOBER 2013

31 Dul Hndle Ycht Console Control Opertion nd Adjustment Opertion Section 2 - Getting to Know Your Power Pckge Opertion of shift nd throttle is controlled y the movement of the control hndle. Push the control hndle forwrd from neutrl to the first detent for forwrd ger. Continue pushing the hndle forwrd to increse speed. Pull the control hndle ck from neutrl to the first detent for reverse ger. Continue pulling the hndle ck to increse speed. F N R 78 O 78 O Adjustment 1. Control hndle tension djustment screw This screw cn e djusted to increse or decrese the tension on the control hndle (cover must e removed). This will help prevent unwnted motion of the hndle in rough wter. Turn the screw clockwise to increse tension nd counterclockwise to decrese tension. Adjust to tension desired. 2. Detent tension djustment screw This screw cn e djusted to increse or decrese the effort to move control hndle out of detent positions (cover must e removed). Turning the screw clockwise will increse tension. Adjust to tension desired. - Detent tension djustment - Control hndle tension djustment Bsic Joystick Opertion The joystick offers precise, intuitive control of your ot during low speed nd docking mneuvers. The joystick trnsltes the movement of the joystick into similr movement in the ot. Engine speed is limited in this mode to prevent uncceptle ot dynmics during mneuvers. While opertion with the joystick is esy to lern, we recommend tht you drive the ot in the trditionl wy until you cn spend time in n open re free of ostructions nd trffic to lern how your ot responds to inputs. Further, we recommend tht you occsionlly prctice mneuvering in the trditionl wy to mintin your trditionl drive docking skills in cse joystick control is temporrily not ville. Auxiliry Joystick Sttion Fetures Generl Informtion Depending on the version of the SmrtCrft engine control system used to operte the vessel, there my e multiple uxiliry joystick sttions. 90-8M eng OCTOBER 2013 Pge 25

32 Section 2 - Getting to Know Your Power Pckge Ech uxiliry joystick sttion is equipped with n E stop switch, uxiliry joystick, nd trckpd. c h d e CENTER PORT STBD ALARM TRANSFER f g Typicl uxiliry joystick sttion components for triple drives - E stop switch - Auxiliry joystick c - Joystick trckpd for triple instlltions d - Port drivetrin sttus indictor light e - Center drivetrin sttus indictor light f - Strord drivetrin sttus indictor light g - Trnsfer utton nd indictor light h - Alrm nd fult indictor light c i d e f g PORT STBD ALARM TRANSFER h Typicl uxiliry joystick sttion components for qud drives - E stop switch - Auxiliry joystick c - Joystick trckpd for qud instlltions d - Port outer drivetrin sttus indictor light e - Port center drivetrin sttus indictor light f - Strord center drivetrin sttus indictor light g - Strord outer drivetrin sttus indictor light h - Trnsfer utton nd indictor light i - Alrm nd fult indictor light Electricl System Overlod Protection If n electricl overlod occurs, fuse or circuit reker opens. Find nd correct the cuse for the electricl overlod efore replcing the fuse or resetting the circuit reker. NOTE: In n emergency, when you must operte the engine nd cnnot locte or correct the cuse for the electricl overlod (high current drw), turn off or disconnect ll the ccessories connected to the engine nd instrumenttion wiring. Reset the circuit reker or replce the fuse. If the circuit remins open, the electricl overlod hs not een eliminted. Contct your Mercury Diesel uthorized repir fcility to check the electricl system. Circuit rekers nd fuses provide protection for the electricl system s indicted. The circuit rekers nd fuses re locted in vrious loctions throughout the ot. Hve your deler show you the loction nd identify the circuit tht they protect. After finding nd correcting the cuse of the overlod, reset the circuit reker y pressing the reset utton. Vessel Interfce Pnel (VIP) Overlod Protection The vessel interfce pnel (VIP) contins five circuit rekers tht help protect the trnsmission hrness, engine hrness, vessel sensor hrness, nd helm hrness. Pge M eng OCTOBER 2013

33 BATTERY - Section 2 - Getting to Know Your Power Pckge NOTE: A VIP for ech engine is locted in the engine room. c d - Min circuit reker (25 mp) - VIP dignostic circuit reker (10 mp) c - Helm circuit reker (10 mp) d - SIM/vessel circuit reker (10 mp) e - Ger circuit reker (15 mp) e Item Circuit Breker Rting Protection Loction on VIP 25 A Min Lower left 5 A VIP dignostics Upper left c 10 A Helm Upper right d 10 A SIM/vessel Lower right e 15 A Ger Lower center Overlod Protection for the DC Voltge Regultor System, If Equipped If the vessel is equipped with 24 volt system, DC voltge regultor is required to supply 12 volt power to the VIP nd the other 12 volt circuits. The power pckge mnufcturer provides protective fuse for the 24 volt DC to 12 volt DC voltge regultor system, if equipped. The spde style, in line fuse is locted in the hrness etween the voltge regultor nd the 24 volt ttery system. The fuse protects the wiring nd the regultor ginst overlods. NOTE: For dditionl informtion on the on off switch for the DC voltge regultor, refer to your owner's mnul. c BATTERY + d e DC voltge regultor - Wiring to DC voltge regultor c - 30 mp fuse nd holder d - To 24 volt ttery system positive ( +) e - To 24 volt ttery system negtive ( ) The ot mnufcturer my replce the fuse nd holder with circuit reker. Hve your ot mnufcturer or deler show you the loction nd identify the fuse or circuit reker for your reference. Overlod Protection for Other Circuits Other circuits my e protected y circuit rekers or fuses instlled y the ot mnufcturer nd cn vry in ppernce nd loction. For exmple, the MerCthode system hs 20 mp in line fuse in the wire tht connects from the positive (+) ttery terminl to the positive (+) terminl on the controller. If the fuse is defective (open), the system will not operte, resulting in loss of corrosion protection. Hve your deler show you the loction of nd service procedures for the fuse. 90-8M eng OCTOBER 2013 Pge 27

34 Section 2 - Getting to Know Your Power Pckge Ask your deler for the loction nd opertion instructions of ll overlod protection devices. Shdow Mode Control Opertion nd Fetures Triple Engine Throttle nd Shift Opertion Movement of the hndles on the remote control llows the ot opertor to control the engine throttle speed nd ger shift positions of ll three engines. The throttle nd shift function is dependnt on wht engines re running. Refer to the following tle. Port Engine Center Engine Strord Engine Control Hndle Function Running Running Running Running Running Off Off Running Running Running Off Running Port engine throttle nd shift = controlled y port control hndle Strord engine throttle nd shift = controlled y strord control hndle Center engine throttle = verge of port nd strord engines Center engine shift = neutrl unless oth engines re in the sme ger Port nd center engine throttle nd shift = controlled y port control hndle Strord nd center engine throttle nd shift = controlled y strord control hndle Port engine throttle nd shift = controlled y port control hndle Strord engine throttle nd shift = controlled y strord control hndle Running Off Off Port engine throttle nd shift = controlled y port control hndle Off Off Running Off (ignition key switch turned on) Running Off (ignition key switch turned on) Strord engine throttle nd shift = controlled y strord control hndle Center engine throttle nd shift = neutrl/idle unless oth control hndles re in the sme ger Turning off one of the outer engines while underwy will cuse the center engine to go into forced neutrl/idle. Opertion to the center engine cn e restored y moving the control hndle of the functioning outer engine ck into neutrl position nd then engging. The center engine speed nd ger shift will then e controlled y the functioning outer engine. Turning off the center engine while underwy will hve no effect on the opertion of the outer engines. If filure should occur while underwy which cuses one of the outer engines into forced neutrl/idle condition, the center engine will lso e forced to neutrl/idle. Opertion to the center engine cn e restored y moving the control hndle of the functioning outer engine ck into neutrl nd then engging. Qud Engine Throttle nd Shift Opertion Movement of the hndles on the remote control llows the ot opertor to control the engine throttle speed nd ger shift positions of ll four engines. The throttle nd shift function is dependent on wht engines re running. Refer to the following tle. Port Outer Engine Port Inner Engine Strord Inner Engine Running Running Running Running Running Running Off Off Off Off Running Running Off (ignition key switch turned on) Running Running Running Strord Outer Engine Control Hndle Function Port inner nd outer engines throttle nd shift = controlled y port control hndle Strord inner nd outer engines throttle nd shift = controlled y strord control hndle Port inner nd outer engine throttle nd shift = controlled y port control hndle Strord inner nd outer engine throttle nd shift = controlled y strord control hndle Port inner engine throttle nd shift = controlled y port control hndle Pge M eng OCTOBER 2013

35 Section 2 - Getting to Know Your Power Pckge Port Outer Engine Port Inner Engine Strord Inner Engine Running Running Running Off (ignition key switch turned off) Running Running Running Running Running Running Running Off Off Running Off (ignition key switch turned on) Running Running Strord Outer Engine Off (ignition key switch turned on) Off (ignition key switch turned off) Off (ignition key switch turned on) Control Hndle Function Strord inner engine throttle nd shift = controlled y strord control hndle Port inner engine throttle nd shift = controlled y strord control hndle Strord inner engine throttle nd shift = controlled y port control hndle Port outer engine throttle nd shift = controlled y port control hndle Strord outer engine throttle nd shift = controlled y strord control hndle Port inner engine throttle nd shift = controlled y port control hndle Strord inner engine throttle nd shift = controlled y strord control hndle Turning off the strord outer engine while underwy will cuse the strord inner engine to go into forced neutrl/idle. Opertion to the inner engine cn e restored y turning the strord outer engine ignition key to the on position nd moving the strord control hndle ck into neutrl position nd then engging. The inner engine speed nd ger shift will then e controlled y the strord control hndle. Turning off the port outer engine while underwy will cuse the port inner engine to go into forced neutrl/idle. Opertion to the inner engine cn e restored y turning the port outer engine ignition key to the on position nd moving the port control hndle ck into neutrl position nd then engging. The inner engine speed nd ger shift will then e controlled y the port control hndle. Turning off one of the inner engines while underwy will hve no effect on the opertion of the outer engines. If filure should occur while underwy which cuses the strord outer engines into forced neutrl/idle condition, the inner strord engine will lso e forced to neutrl/idle. Opertion to the inner engine cn e restored y moving the strord control hndle ck into neutrl nd then engging. If filure should occur while underwy which cuses the port outer engines into forced neutrl/idle condition, the inner port engine will lso e forced to neutrl/idle. Opertion to the inner engine cn e restored y moving the port control hndle ck into neutrl nd then engging. Corrosion Protection Zeus pod drives re equipped with nodes s stndrd equipment to help protect them from glvnic corrosion under moderte conditions. However, we recommend tht trnsom mounted node e used for dded protection to the vessel's components. The MerCthode System nd scrificil nodes will provide corrosion protection under norml usge. However, ots connected to AC shore power require dditionl protection to prevent destructive low voltge glvnic currents from pssing through the shore power ground wire. A Quicksilver glvnic isoltor cn e instlled to lock the pssge of these currents while providing pth to ground for dngerous fult (shock) currents. Refer to the Diesel Prts nd Accessories Guide ( ) or the Mercury Accessories Guide (90 8M ) for prt numers. IMPORTANT: If AC shore power is not isolted from the ot ground, the MerCthode System nd nodes my e unle to hndle the incresed glvnic corrosion potentil. Glvnic Isoltor nd Monitor These power pckges feture nodes s stndrd equipment to help protect them from glvnic corrosion under moderte conditions. The MerCthode System nd scrificil nodes provide corrosion protection under norml usge. Bots connected to AC shore power require dditionl protection to prevent destructive low voltge glvnic currents from pssing through the shore power ground wire. A Quicksilver Glvnic Isoltor or equivlent isoltion device is recommended to lock the pssge of these currents while providing pth to ground for dngerous fult (shock) currents. IMPORTANT: If AC shore power is not isolted from ot ground, the MerCthode System nd nodes my e unle to hndle the incresed glvnic corrosion potentil. A Quicksilver Glvnic Isoltor kit includes n udio nd visul monitor to lert you to fults tht occur. The monitor is microprocessor controlled, solid stte device tht will test the integrity of the Quicksilver Glvnic Isoltor nd the sfety grounding led. This device will lso supply impressed current to the drive to id in corrosion protection. 90-8M eng OCTOBER 2013 Pge 29

36 Section 2 - Getting to Know Your Power Pckge! WARNING Improperly conducted AC shore power is n electric shock hzrd tht cn result in dmge nd injury. The AC grounding conductor green wire must e connected etween the ots electricl system nd the shore power connection in order to provide pth for fult current nd to ssist the MerCthode in preventing glvnic corrosion on drive components. Instll glvnic isoltor or similr isoltion device in the AC shore power system in the vessel. Consult qulified mrine electricin for more informtion. IMPORTANT: If the Glvnic Isoltor lrm sounds nd the monitor will not respond to the reset utton, AC fult current my e present nd the shore power sfety grounding conductor circuit to shore my e n open circuit. Disconnect shore power immeditely. Refer to Trouleshooting Glvnic Isoltor for n explntion of the conditions or fults tht my e displyed y the monitor Glvnic Isoltor Monitor nd conditions NOTE: If your vessel is equipped with glvnic isoltor from mnufcturer other thn Quicksilver, refer to the instructions provided y the mnufcturers. Theory of Opertion The MerCthode system provides utomtic protection ginst glvnic corrosion. A solid stte device tht opertes off vessel's ttery, the MerCthode system provides protection y impressing reverse locking current tht stops the destructive flow of glvnic currents. The red MerCthode controller will regulte output to mintin 0.94 volts t the reference electrode. A solid green LED indictes tht the system is operting correctly. A flshing LED indictes tht fult hs occurred, or tht n norml condition exists. IMPORTANT: When ot or new drive is first put into service the LED my initilly indicte tht the protective current is not eing supplied through the MerCthode node. This condition is norml nd, in such cses, the LED my flsh for period of time. The green LED will ecome stedy fter the ot is moored for period of eight hours without opertion. Fult Codes LED Fult Codes 1 flsh every 0.5 seconds Reference volts elow flsh every 4 seconds Reference volts ove long nd 1 short flsh every 10 seconds Thermo shutdown 105 C (221 F) or higher 1 long flsh every 10 seconds Shorted or open reference terminl 2 long flshes every 10 seconds Shorted or open node terminl 1 long flsh every 60 seconds Open node nd reference terminls (dry docked) Anodes nd MerCthode System Anodes help protect ginst glvnic corrosion y scrificing their metl to e slowly eroded insted of the metl components on the drive or vessel. Fult Pge M eng OCTOBER 2013

37 H z OFF IG IP TEMP Section 2 - Getting to Know Your Power Pckge Corrosion protection for the drive is provided y scrificil nodes instlled on the trim ts. Other scrificil nodes my e mounted on the vessel to ensure ginst corrosion of vessel components. IMPORTANT: Scrificil nodes must e inspected periodiclly. Replce the scrificil nodes if they re eroded 50 percent or more. Refer to Scheduled Mintennce. Anodes nd MerCthode System Loctions Description Loction Figure Trim t node pltes Mounted on the trim t The MerCthode system uses reference electrode nd n node ssemly to help protect ginst glvnic corrosion. The MerCthode controller is mounted on the trnsmission. The system should e tested to ensure dequte output. The test should e performed where the ot is moored, using the Quicksilver Reference Electrode nd DMT 2004 digitl multimeter. For testing, contct Mercury Diesel uthorized repir fcility or refer to the pproprite service mnul. Reference Electrode T 1 Senses nd electricl current in the wter when testing the MerCthode system. Use to check hull potentil DMT 2004 Digitl Multimeter A01 V mv H z TEMP m A A Mesures RPM on sprk ignition (SI) engines, ohms, mperes, AC nd DC voltges; records mximums nd minimums simultneously, nd ccurtely reds in high RFI environments. A m A C O M V H z 4516 Anodes nd MerCthode System Loctions Description Loction Figure MerCthode system The MerCthode reference electrode nd node re mounted to the composite cover on the underside of the drive. The MerCthode controller is mounted on the trnsmission. The controller hrness connects the components Other scrificil nodes, if equipped, my e mounted on the vessel to protect ginst glvnic corrosion. Refer to the opertion nd mintennce mnul provided y the ot mnufcturer for dditionl informtion out vessel mounted nodes. 90-8M eng OCTOBER 2013 Pge 31

38 Section 2 - Getting to Know Your Power Pckge Other Anodes nd Loctions Description Loction Figure Anode kit (if equipped) Mounted to the ot trnsom Reference Electrode Wire MerCthode Assemly NOTICE Wshing the MerCthode ssemly cn dmge components nd led to rpid corrosion. Do not use ny clening equipment such s rushes or high pressure wshers to clen the MerCthode ssemly. Do not pressure wsh the reference electrode of the MerCthode ssemly. Doing so dmges the coting on the reference electrode wire nd decreses the corrosion protection. - Anode - Reference electrode wire Pinting the Bot IMPORTANT: The limited wrrnty does not cover corrosion dmge s result of improper pint ppliction. IMPORTANT: Pint on the nodes or reference electrode renders the MerCthode system ineffective. The underwter portion of the drive cn e pinted in order to inhiit mrine growth. Conventionl ntifouling cotings (ottom pint) cn e used, s well s more specilized foul relese cotings (like PropSpeed ). If ottom pint is used, est results will e seen using pint contining copper oxide plus n lgecide dditive. NOTE: PropSpeed is registered U.S. trdemrk of Ocenmx Interntionl, Limited. When pinting drive or ot hull with ntifouling pint, oserve the following: Follow the pint mnufcturer s recommendtions regrding preprtion nd ppliction. Use high qulity, ntifouling pint designed for mrine use. If using copper sed or tin sed pints is necessry, ensure tht you oserve ll locl nd federl lws regulting or prohiiting their use. Do not pint drin holes or items s specified y the ot mnufcturer. Do not pint ny nodes or the MerCthode system components. Pge M eng OCTOBER 2013

39 Section 2 - Getting to Know Your Power Pckge Avoid ny electricl interconnection etween the pinted hull nd the drive, nodic locks, trim t nodes, or the MerCthode system. Allow minimum of 25 mm (1 in.) of unpinted re on the hull of the ot round the interfce ring sel (grommet) on models with molded in tunnel opening or round the olt on interfce ring ssemly (if equipped), s shown. If this guideline is not followed, the MerCthode corrosion protection system will e rendered ineffective. Pinted nd unpinted res - Pinted hull - Pinted drive c - Minimum unpinted 25 mm (1 in.) re c If desired, nonconductive ntifouling pint cn e used to inhiit mrine growth in the 25 mm (1 in.) minimum re etween conductive hull nd pinted drive. The propellers cn e coted with foul relese coting (like PropSpeed ) or my remin uncoted. IMPORTANT: The ppliction of ntifouling pint my ffect ot speed nd engine RPM. Wter testing must e performed to ensure tht engines still chieve the minimum rted RPM fter the ppliction of ottom pint M eng OCTOBER 2013 Pge 33

40 Section 2 - Getting to Know Your Power Pckge Notes: Pge M eng OCTOBER 2013

41 Tle of Contents Section 3 - On the Wter Section 3 - On the Wter Sfe Boting Suggestions Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Sfe Boting Recommendtions Bsic Bot Opertion Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge Drin Plug nd Bilge Pump...39 Protecting People in the Wter While the Bot is Moving While the Bot is Sttionry Wve nd Wke Jumping Impct with Underwter Hzrds...40 Zeus Drive Impct Protection Zeus Drive Alignment Conditions Affecting Bot Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Bottom Of Bot Cvittion Ventiltion Propeller Selection...41 Getting Strted Brek In Period (New or With Replcement Gers) DC Voltge Regultor Switch, If Equipped Strting nd Stopping the Engines Strting n Engine Using the VIP SmrtStrt Switch Stopping the Engine Using the VIP SmrtStrt Switch Trditionl Mneuvering with Steering nd Thrust To Mneuver the Bot in Forwrd To Steer the Bot in Tight Turns t Low Speeds To Spin the Bot on its Axis t Low Speeds Mneuvering with the Joystick Trim Ts...49 Automtic Control Mnul Control Using Trim T Offset Specil Digitl Throttle nd Shift (DTS) Fetures Troll nd Throttle Response Dock Throttle Only Single Lever (1 Lever) Opertion Synchronizing the Engines Cruise Control Helm Trnsfer Requesting Helm Trnsfer Helm Trnsfer nd Precision Pilot Autopilot Trckpd Fetures Chrtplotter Requirements...56 Response Settings...56 VesselView Autopilot Screen Autopilot Trckpd Lights Autopilot Modes Skyhook Sttion Keeping...58 Importnt Sfety Considertions Engging Skyhook Disengging Skyhook Using Skyhook Auto Heding Engging Auto Heding Course Adjustment Using the Turn Buttons or Joystick To Resume Heding Disengging Auto Heding Trck Wypoint Engging Trck Wypoint Mode Disengging Trck Wypoint Mode Turn Buttons in Trck Wypoint Mode Auto Heding Button in Trck Wypoint Mode Acknowledging Turn During Wypoint Arrivl Wypoint Sequence Cruise Control Contingent Opertions Steering Emergency Alterntive Method...68 Port Engine Only Opertion Ger Enggement Emergency Procedure Steering nd Trim Mnul Override Procedure for Stuck Steering Control Vlve Procedure for Stuck Trim T Control Vlve End of First Seson Checkup M eng OCTOBER 2013 Pge 35

42 Section 3 - On the Wter Sfe Boting Suggestions Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Cron monoxide (CO) is dedly gs tht is present in the exhust fumes of ll internl comustion engines, including the engines tht propel ots, nd the genertors tht power ot ccessories. By itself, CO is odorless, colorless, nd tsteless, ut if you cn smell or tste engine exhust, you re inhling CO. Erly symptoms of cron monoxide poisoning, which re similr to the symptoms of sesickness nd intoxiction, include hedche, dizziness, drowsiness, nd nuse.! WARNING Inhling engine exhust gses cn result in cron monoxide poisoning, which cn led to unconsciousness, rin dmge, or deth. Avoid exposure to cron monoxide. Sty cler from exhust res when engine is running. Keep the ot well ventilted while t rest or underwy. Sty Cler of Exhust Ares Engine exhust gses contin hrmful cron monoxide. Avoid res of concentrted engine exhust gses. When engines re running, keep swimmers wy from the ot, nd do not sit, lie, or stnd on swim pltforms or ording ldders. While underwy, do not llow pssengers to e positioned immeditely ehind the ot (pltform drgging, tek/ody surfing). This dngerous prctice not only plces person in n re of high engine exhust concentrtion, ut lso sujects them to the possiility of injury from the ot propeller. Good Ventiltion Ventilte the pssenger re, open side curtins or forwrd htches to remove fumes. Exmple of desired ir flow through the ot: Poor Ventiltion Under certin running or wind conditions, permnently enclosed or cnvs enclosed cins or cockpits with insufficient ventiltion my drw in cron monoxide. Instll one or more cron monoxide detectors in your ot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n open re of sttionry ot tht contins or is ner running engine my e exposed to hzrdous level of cron monoxide. 1. Exmples of poor ventiltion while the ot is sttionry: - Operting the engine when the ot is moored in confined spce - Mooring close to nother ot tht hs its engine operting Pge M eng OCTOBER 2013

43 Section 3 - On the Wter 2. Exmples of poor ventiltion while the ot is moving: Operting the ot with the trim ngle of the ow too high - Operting the ot with no forwrd htches open (sttion wgon effect) Sfe Boting Recommendtions To sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl oting regultions nd restrictions nd consider the following suggestions. Know nd oey ll nuticl rules nd lws of the wterwys. We recommend tht ll powerot opertors complete oting sfety course. In the U.S., the U.S. Cost Gurd Auxiliry, the Power Squdron, the Red Cross, nd your stte or provincil oting lw enforcement gency provide courses. For more informtion in the U.S., cll the Bot U.S. Foundtion t BOAT (2628). Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Check sfety equipment onord. Here re some suggestions of the types of sfety equipment to crry when oting: Approved fire extinguishers Signl devices: flshlight, rockets or flres, flg, nd whistle or horn Tools necessry for minor repirs Anchor nd extr nchor line Mnul ilge pump nd extr drin plugs Drinking wter Rdio Pddle or or Spre propeller, thrust hus, nd n pproprite wrench First id kit nd instructions Wterproof storge continers Spre operting equipment, tteries, uls, nd fuses Compss nd mp or chrt of the re Personl flottion device (one per person onord) Wtch for signs of wether chnge nd void foul wether nd rough se oting. Tell someone where you re going nd when you expect to return. Pssenger ording. Stop the engine whenever pssengers re ording, unloding, or re ner the ck (stern) of the ot. Shifting the drive unit into neutrl is not sufficient. Use personl flottion devices. Federl lw requires tht there e U.S. Cost Gurd pproved life jcket (personl flottion device), correctly sized nd redily ccessile for every person onord, plus throwle cushion or ring. We strongly dvise tht everyone wer life jcket t ll times while in the ot. Prepre other ot opertors. Instruct t lest one person onord in the sics of strting nd operting the engine nd ot hndling in cse the driver ecomes disled or flls overord. Do not overlod your ot. Most ots re rted nd certified for mximum lod (weight) cpcities (refer to your ot's cpcity plte). Know your ot's operting nd loding limittions. Know if your ot will flot if it is full of wter. When in dout, contct your uthorized Mercury Mrine deler or the ot mnufcturer. 90-8M eng OCTOBER 2013 Pge 37

44 Section 3 - On the Wter Ensure tht everyone in the ot is properly seted. Do not llow nyone to sit or ride on ny prt of the ot tht ws not intended for such use. This includes the cks of sets, gunwles, trnsom, ow, decks, rised fishing sets, nd ny rotting fishing set. Pssengers should not sit or ride nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of ot control, or sudden ot movement could cuse person to e thrown overord or into the ot. Ensure tht ll pssengers hve proper set nd re in it efore ny ot movement. Never operte ot while under the influence of lcohol or drugs. It is the lw. Alcohol or drugs cn impir your judgment nd gretly reduce your ility to rect quickly. Know your oting re nd void hzrdous loctions. Be lert. The opertor of the ot is responsile y lw to mintin proper lookout y sight nd hering. The opertor must hve n unostructed view prticulrly to the front. No pssengers, lod, or fishing sets should lock the opertor's view when the ot is ove idle or plning trnsition speed. Wtch out for others, the wter, nd your wke. Never drive your ot directly ehind wter skier. Your ot trveling t 40 km/h (25 mph) will overtke fllen skier who is 61 m (200 ft) in front of you in five seconds. Wtch fllen skiers. When using your ot for wterskiing or similr ctivities, lwys keep fllen or down skier on the opertor's side of the ot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never ck up to the skier or nyone in the wter. Report ccidents. Bot opertors re required y lw to file oting ccident report with their stte oting lw enforcement gency when their ot is involved in certin oting ccidents. A oting ccident must e reported if 1) there is loss of life or prole loss of life, 2) there is personl injury requiring medicl tretment eyond first id, 3) there is dmge to ots or other property where the dmge vlue exceeds $500.00, or 4) there is complete loss of the ot. Seek further ssistnce from locl lw enforcement. Bsic Bot Opertion Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge IMPORTANT: Mercury Mrine strongly recommends tht this service e performed y Mercury Diesel uthorized repir fcility. Dmge cused y freezing is not covered y the Mercury Mrine Limited Wrrnty. NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or efore ny length of storge in freezing tempertures. If the ot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing ck into the cooling system. If the ot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. NOTE: As precutionry mesure, ttch tg to the key switch or steering wheel of the ot reminding the opertor to open the secock or unplug nd reconnect the wter inlet hose efore strting the engine. A ot is considered to e in storge whenever it is not in opertion. The mount of time tht the power pckge is not operted my e for rief period, such s during dy, overnight, for seson, or for n extended period of time. Certin precutions nd procedures must e oserved to protect the power pckge from freeze dmge, corrosion dmge, or oth types of dmge during storge. Freeze dmge cn hppen when wter trpped in the sewter cooling system freezes. For exmple, fter operting the ot, exposure to freezing tempertures for even rief period of time could result in freeze dmge. Corrosion dmge is the result of sltwter, polluted wter, or wter with high minerl content trpped in the sewter cooling system. Sltwter should not sty in n engine's cooling system for even rief storge time; drin nd flush the sewter cooling system fter ech outing. Cold wether opertion refers to operting the ot whenever the possiility of freezing tempertures exists. Likewise, cold wether (freezing temperture) storge refers to whenever the ot is not eing operted nd the possiility of freezing tempertures exists. In such cses, the sewter section of the cooling system must e completely drined immeditely fter opertion. Sesonl storge refers to when the ot is not eing operted for one month or more. The length of time vries depending on the geogrphic loction of the ot in storge. Sesonl storge precutions nd procedures include ll of the steps for cold wether (freezing temperture) storge nd some dditionl steps tht must e tken when storge will lst longer thn the short time of cold wether (freezing temperture) storge. Pge M eng OCTOBER 2013

45 Section 3 - On the Wter Extended storge mens storge for period of time tht my lst for severl sesons or longer. Extended storge precutions nd procedures include ll of the steps for cold wether (freezing temperture) storge nd sesonl storge plus some dditionl steps. Refer to the specific procedures in this section relted to the conditions nd the length of storge for your ppliction. Drin Plug nd Bilge Pump The engine comprtment in your ot is nturl plce for wter to collect. For this reson, ots re normlly equipped with drin plug, ilge pump, or oth drin plug nd ilge pump. Instll the drin plug nd check the opertion of the ilge pump, if equipped, efore putting the ot in the wter. Check these items on regulr sis to ensure tht the level of wter does not come into contct with your power pckge. Components on your engine will e dmged if sumerged. Dmge cused y sumersion is not covered y the Mercury Diesel Limited Wrrnty. Protecting People in the Wter While the Bot is Moving A person in the wter my find it very difficult to tke quick ction to void ot heding in their direction, even t slow speeds Alwys slow down nd exercise extreme cution ny time you re oting in n re where there might e people in the wter. Whenever ot is moving (even costing) nd the ger shift is in neutrl, there is sufficient force y the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. While the Bot is Sttionry! WARNING A spinning propeller, moving ot, or ny solid device ttched to the ot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your ot. Shift into neutrl nd shut off the engines efore llowing people to swim or e in the wter ner your ot. Do not llow people to swim round the ot with the Skyhook Electronic Anchor engged. The Skyhook Electronic Anchor cuses the drives to move nd the propellers to turn without notice. Hving the engines in neutrl does not protect the swimmers. Swimmers in the re of the propellers re t risk of getting injured. Wve nd Wke Jumping! WARNING Wve or wke jumping cn cuse serious injury or deth from occupnts eing thrown within or out of the ot. Avoid wve or wke jumping whenever possile. mc Operting recretionl ots over wves nd wkes is nturl prt of oting. However, when this ctivity is done with enough speed to force the ot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the ot re enters the wter. 90-8M eng OCTOBER 2013 Pge 39

46 Section 3 - On the Wter The primry concern is the ot chnging direction while in the midst of the jump. In such cses the lnding my cuse the ot to violently veer in new direction. Such shrp chnge in direction or turn cn cuse occupnts to e thrown out of their sets or out of the ot. Impct with Underwter Hzrds Reduce speed nd proceed with cution whenever you re driving ot in shllow wter or in res where the wters re suspected of hving floting or underwter ostcles tht could e struck y the underwter drive components, skegs, or the ot ottom IMPORTANT: The most importnt thing you cn do to help reduce injury or impct dmge from striking floting or underwter oject is control the ot speed. Under these conditions, reduce ot speed to minimum. The following demonstrte some, ut not ll, exmples of wht cn hppen if the ot strikes floting or underwter oject: The ot could move in new direction. Such n unexpected chnge in direction or turn cn throw occupnts out of their sets or out of the ot. A rpid reduction in speed. This cn cuse occupnts to e thrown forwrd, even out of the ot. Impct dmge to the underwter drive components, skeg, or ot. Keep in mind tht one of the most importnt things you cn do to help reduce injury or impct dmge in these situtions is control the ot speed when driving in wters known to hve underwter ostcles. After striking sumerged oject, stop the engine s soon s possile nd inspect the drive systems for ny roken or loose prts, nd the hull for ny dmge. If dmge is present or suspected, the power pckge should e tken to Mercury Diesel uthorized repir fcility for thorough inspection nd ny necessry repir. The ot should e checked for hull frctures, trnsom frctures, nd wter leks.! WARNING Operting ot or engine with impct dmge cn result in product dmge, serious injury, or deth. If the vessel experiences ny form of impct, hve n uthorized Mercury Mrine deler inspect nd repir the vessel or power pckge. Operting with dmged underwter drive components or ot ottom could cuse dditionl dmge to other prts of the power pckge, or could ffect control of the ot. If continued opertion is necessry, do so t gretly reduced speeds. Zeus Drive Impct Protection IMPORTANT: Although the design of the Zeus drive provides some impct protection, no design cn ensure totl protection from impct dmge under ll conditions. The Zeus drive hs some impct protection y design, since the drive is mounted in tunnel ove the ottom of the hull. If the drive strikes floting or sumerged oject while the ot is moving, the skeg is designed to rek wy, soring some of the impct nd possily reducing dmge to the propellers nd the exposed lower prt of the drive. In extreme cses, lrge fixed or floting ojects struck y the skeg nd the exposed lower prt of the drive my cuse the lower prt of the drive to sher off. This shering off of the lower prt of the drive is design feture to protect the hull nd drive system. NOTE: If the lower prt of the drive shers off due to severe impct, mke immedite note of the GPS loction to ssist in recovery efforts. If recovery of the dmged prts of the drive is possile, return the dmged prts to your uthorized Mercury Diesel repir fcility for possile repir nd reuse. If n impct occurs nd dmge is present or suspected, if the ot does not respond s it should, or if wter is present in the ger lue monitor ottle, hve your ot inspected t the nerest Mercury Diesel uthorized repir fcility. Pge M eng OCTOBER 2013

47 Section 3 - On the Wter Operting in reverse ger offers less impct protection. Use extreme cution when operting in shllow wter or where underwter ojects re known to e present. Use extreme cre to prevent striking sumerged ojects while operting in reverse. Zeus Drive Alignment The Zeus drives re ligned y the ot mnufcturer, nd must not e djusted y nyone other thn your Mercury Diesel uthorized service nd repir fcility. The Zeus drives will utomticlly reclirte to this setting t ech strtup. The drives do not need to e religned under norml use. Conditions Affecting Bot Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Shifting weight to the rer (stern): Cuses the ow to ounce in choppy wter. Increses the dnger of following wve splshing into the ot when coming off plne. Cn cuse the ot to porpoise t extremes. Shifting weight to the front (ow): Improves ese of plning. Improves rough wter ride. Cn cuse the ot to veer ck nd forth (ow steer) t extremes. Bottom Of Bot To mintin mximum speed, the ot ottom should e: Clen nd free of rncles nd mrine growth. Stright nd smooth (fore nd ft). Mrine vegettion cn ccumulte when the ot is docked. Remove this growth efore opertion; it cn clog the wter inlets nd outlets, cusing the engine to overhet. Cvittion Cvittion occurs when wter flow cnnot follow the contour of fst moving underwter oject, such s ger housing or propeller. Cvittion increses propeller speed while reducing ot speed. Cvittion cn seriously erode the surfce of the ger housing or the propeller. Common cuses of cvittion re: Weeds or other deris sngged on the propeller Bent propeller lde Rised urrs or shrp edges on the propeller Ventiltion Ventiltion is cused y surfce ir or exhust gses tht re introduced round the propeller resulting in propeller speed up nd reduction in ot speed. Air ules strike the propeller lde nd cuse erosion of the lde surfce. If llowed to continue, eventul lde filure (rekge) will occur. Excessive ventiltion is usully cused y: A missing propeller diffuser ring. A dmged propeller or ger housing, which llows exhust gses to escpe etween propeller nd ger housing. Propeller Selection IMPORTANT: The instlled propellers must llow the engine to rech engine rted speed (RPM) with the ot fully loded nd with ll customer stores onord. With the ot less thn fully loded the engines should rech engine rted speed (RPM) with less thn 100% lod. Use the VesselView disply to verify engine RPM nd percent lod. It is the responsiility of the ot mnufcturer or the selling deler to equip the power pckge with the correct propellers. Refer to the engine informtion dt tg locted on the engine for the specified engine rted speed (RPM). Informtion for the loction of the engine dt tg cn e found in the engine owner's mnul. If full throttle engine RPM is elow the engine rted speed (RPM), the propellers will hve to e chnged to prevent loss of performnce nd possile engine dmge. After initil propeller selection, certin issues my require propeller with lower pitch. They include: Operting with incresed lod (dditionl pssengers or ger). Shifting the center of grvity of the vessel. The ddition of towers or cnvs. Fouling of the hull nd running ger. 90-8M eng OCTOBER 2013 Pge 41

48 Section 3 - On the Wter High mient tempertures. Operting t high elevtion. It is the responsiility of the ot owner to ensure tht the correct propellers re instlled t delivery nd mintined over the life of the ot. Becuse of the mny vriles of ot design, only testing will determine the est propeller for prticulr ot. If the engine is not le to rech the engine rted speed (RPM), contct your otuilder, ot deler, or n uthorized Mercury Diesel repir fcility for ssistnce in propeller selection. A list of propellers for the Zeus drive cn e locted in the Zeus drive prts mnul. Refer to the Zeus drive Mercury Prts Mnul Getting Strted Brek In Period (New or With Replcement Gers) Alwys perform these procedures on new drive units. This rek in procedure llows the proper seting of drive unit gers nd relted components, which gretly reduces the likelihood of prolems. Avoid full throttle strts. Do not operte t ny one constnt speed for extended periods of time. Do not exceed 75% of full throttle during the first five hours. During the next five hours, operte t intermittent full throttle. Shift the drive into forwrd ger minimum of 10 times during rek in, with run in time t moderte RPM fter ech shift. After the first 25 hours nd not to exceed 30 hours, chnge the trnsmission fluid nd filter including the trnsmission fluid in the drop ox, if equipped. After the first 25 hours nd not to exceed 30 hours, replce the drive gercse fluid with High Performnce Ger Luricnt nd replce the trnsmission fluid with Synthetic Power Steering Fluid SAE 0W 30. Tue Ref No. Description Where Used Prt No. 87 High Performnce Ger Luricnt Drive gercse K Synthetic Power Steering Fluid SAE 0W-30 Trnsmission fluid K01 DC Voltge Regultor Switch, If Equipped If the vessel is equipped with 24 volt system, DC voltge regultor is required to supply 12 volt power to the VIP nd the other 12 volt circuits. To llow the regultor to e turned on nd off switch is provided y the ot mnufcturer. The switch is on seprte circuit. Switching the power on provides regulted power to the VIP nd other 12 volt circuits to llow the vessel to strt. Switching the DC voltge regultor off prevents the regultor from drwing power when the vessel is not operted. Hve your mnufcturer or deler show you the loction nd identify the DC voltge regultor switch for reference. 1. Turn the switch on efore ttempting to strt the engine. 2. Leve the switch on when the vessel is operting. 3. Turn the switch off when the vessel is not operting. Strting nd Stopping the Engines Your Zeus power pckge is equipped with SmrtStrt system, tht includes strt/stop utton for emergency use tht is remotely mounted in the vessel interfce pnel (VIP). The VIP is usully locted in the engine room. In norml circumstnces, strt nd stop the engine from the helm using the strt/stop utton of the SmrtStrt system. NOTICE The sewter pumps on vessels equipped with Zeus pod drives cn e dmged y excessive exhust ertion due to indequte wter flow. To ensure dequte wter flow cross the sewter inlets, mke sure tht the vessel is underwy efore exceeding 1500 RPM. Strting n Engine Using the VIP SmrtStrt Switch You my desire to strt n engine from the engine room or under certin circumstnces the engine control systems my not e le to utomticlly strt n engine. The engines cn e strted using the "SMARTSTART" (strt/stop) switch on the VIP for ech engine. 1. Perform the checks nd steps listed in the engine's opertion nd mintennce mnul ville for this pckge. NOTE: Some vessels re not equipped with sewter return secock. Pge M eng OCTOBER 2013

49 2. Open the sewter return secock, if equipped. Rotte the hndle in the direction indicted y the rrow. Section 3 - On the Wter Drive cover removed for clrity - Hndle in open position - Sewter return (overord) secock, if equipped 3. Open the secock for the sewter inlet. Rotte the hndle in the direction indicted y the rrow Typicl inlet secock port orienttion (strord similr) - Secock for sewter inlet - Hndle in open position c - Former position (closed) c 4. Open the secock (if equipped) for ny ccessory equipment. NOTE: When the key switch is turned to the on position, the neutrl LED lights on the ERC trckpd flsh on nd off if the ERC hndles re not in the neutrl position. Before strting the engines the ERC hndles must e in the neutrl position. 5. At the ctive stndrd helm, move the ERC hndles to the neutrl position. NOTE: Ask your deler for the loction of the key switches if the key switches re not locted t the helm. 6. Turn the key switch to the on position for ech engine to e strted. 7. Verify it is sfe to strt the engines. 8. In the engine room, locte the VIP for ech engine. IMPORTANT: The strt/stop switch or "SMARTSTART" switch on VIP will strt the corresponding engine regrdless of which helm sttion is ctive or previously ctive. 9. Press nd relese the strt/stop switch or green "SMARTSTART" (strt/stop) switch on the VIP corresponding to the engine eing strted. The control system utomticlly controls the strter to chieve successful strt "E STOP" switch for emergency use only - "START/STOP" switch IMPORTANT: To void excessive exhust ertion of the sewter, do not operte the engines over 1500 RPM when the vessel is t rest. 90-8M eng OCTOBER 2013 Pge 43

50 Section 3 - On the Wter 10. If you must operte the engines ove 1500 RPM, put the vessel underwy with light throttle lod until the engines rech norml operting temperture. Stopping the Engine Using the VIP SmrtStrt Switch You my desire to stop n engine from the engine room or under certin circumstnces when the engine control system my not e le to utomticlly stop n engine. The engines cn e stopped using the "SMARTSTART" (strt/stop) switch on the VIP for ech engine. 1. Move the ERC hndles to the neutrl position. 2. Locte the VIP for ech engine in the engine room. 3. When the engines re running, press nd relese the strt/stop switch or the green "SMARTSTART" (strt/stop) switch for ech engine you wnt to stop. - "E STOP" switch for emergency use only - "START/STOP" switch Turn the key switch to the off position for ech engine tht ws stopped. 5. Close the sewter return secock, if equipped. Rotte the hndle in the direction indicted y the rrow. Drive cover removed for clrity - Sewter return secock, if equipped - Hndle in closed position Close the secock for the sewter inlet. Rotte the hndle in the direction indicted y the rrow. Typicl inlet secock port orienttion (strord similr) - Secock for sewter inlet - Former position (open) c - Hndle in closed position Trditionl Mneuvering with Steering nd Thrust c You cn mneuver your Zeus equipped vessel much like trditionl inord ot. However, the Zeus drive system expnds the mneuvering cpility of your vessel t oth slow nd plning speeds. At slow speeds, the drive system is cple of directing the thrust to produce more responsive turning of the vessel. The Zeus drive system fetures counter rotting propellers tht do not produce ny sidewys motion when ccelerting or slowing down Pge M eng OCTOBER 2013

51 Section 3 - On the Wter NOTE: During slow speed turning with the wheel, the drive on the inside turns s much s 42 to crete very tight turns. Different from trditionl ots, to tighten the turn, you cn increse power to the inside drive. To Mneuver the Bot in Forwrd Plce one or oth engines in forwrd ger nd steer with the steering wheel s you would ny comprle ot. To Steer the Bot in Tight Turns t Low Speeds 1. To turn the ot in tight turns t low speeds, turn the wheel in the direction of the turn. 2. To increse the turn rte of the ot fter the wheel is completely turned, you my increse the power to the inside drive. To Spin the Bot on its Axis t Low Speeds 1. Center the steering wheel. 2. To spin to the right, plce the strord engine in reverse nd the port engine in forwrd. 3. To spin to the left, plce the port engine in reverse nd the strord engine in forwrd. 4. To increse the rte of turn, simultneously djust ech ERC lever for more throttle. Mneuvering with the Joystick The joystick provides single lever interfce to mneuver the vessel. Operting the vessel with the joystick is well suited for close qurter opertions nd when docking. The joystick cuses the control system to independently control ech pod ngle nd thrust to move or rotte the ot in desired direction. For exmple, if you move the joystick sidewys, the control system commnds the ot in the sidewys direction. The joystick gives three xis control: fore nd ft, port nd strord, nd rottionl, or ny comintion thereof. For exmple, moving the joystick to port cuses the ot to move sidewys to port. Rotting the joystick cuses the ot to rotte round its center. You cn move nd rotte the joystick t the sme time, llowing for very intricte movements for mneuvering in tight qurters. The control system utomticlly ttempts to dmpen ow nd stern swinging (referred to s yw) during joystick opertion. An onord sensor mesures the yw rte of the ot nd ctively countercts the yw motion of the ot. Fctors, such s wind, wter conditions, or vessel loding, my ct upon the vessel eyond the systems cpility to correct yw. Mnul yw correction my e required when commnding the ot in the fore nd ft, port nd strord, or digonl directions. To correct for unintended yw during ny mneuver just rotte the joystick in the direction the ow is desired to rotte. The following tle gives some limited exmples of the sic responses to inputs from the joystick. The joystick is proportionl, which mens tht the frther from the center the joystick is moved, the more thrust is pplied to the ot in tht direction. To mneuver the ot with the joystick: 1. Move oth electronic remote control (ERC) levers to the neutrl position. 2. Move the joystick in the direction tht you wnt the ot to move, or twist the joystick in the direction tht you wnt the ot to rotte. The joystick cn e moved nd rotted t the sme time. Joystick Input nd Bot Response Tle Joystick Input Bot Response Movement (shown from light gry to drk gry) Bot t rest M eng OCTOBER 2013 Pge 45

52 Section 3 - On the Wter Joystick Input Bot Response Movement (shown from light gry to drk gry) Bot moves forwrd Bot moves ft Bot moves to strord without rotting Bot moves to port without rotting Pge M eng OCTOBER 2013

53 Joystick Input Bot Response Section 3 - On the Wter Movement (shown from light gry to drk gry) Bot moves digonlly forwrd nd to the strord without rotting NOTE: In this mneuver move nd twist the joystick for yw correction, if required. Bot moves digonlly forwrd nd rottes strord for yw correction Bot moves digonlly ft nd to the strord without rotting Bot moves digonlly ft nd to the port without rotting M eng OCTOBER 2013 Pge 47

54 Section 3 - On the Wter Joystick Input Bot Response Movement (shown from light gry to drk gry) Bot moves digonlly forwrd nd to the port without rotting Bot rottes clockwise Bot rottes counterclockwise Bot moves digonlly forwrd nd to the strord while rotting clockwise Pge M eng OCTOBER 2013

55 Joystick Input Bot Response Section 3 - On the Wter Movement (shown from light gry to drk gry) Bot moves digonlly forwrd nd to the strord while rotting counterclockwise Bot moves digonlly forwrd nd to the port while rotting counterclockwise Bot moves to the port while rotting clockwise Trim Ts Automtic Control The Zeus drive comes equipped with n utomtic trim t control feture tht opertes through the vessel control system to provide sic performnce nd efficiency improvements under norml conditions. The utomtic trim t control feture cn e engged (turned on) or disengged (turned off). To engge the feture, press the "AUTO" trim t utton once. The trim ts will utomticlly djust s the speed of the ot is chnged. Pressing it gin will disengge the feture. With the utomtic trim t control feture engged, the port nd strord trim t switches cn e used to djust the ts (offset) for nturl conditions tht ffect the ttitude of the ot. This setting of the trim t offset continues until the utomtic control feture is disengged nd engged gin or when the key switch is cycled (turned off nd on). 90-8M eng OCTOBER 2013 Pge 49

56 Section 3 - On the Wter Mnul trim t control is ville to llow trim t djustment when not using the utomtic trim t control feture. See Mnul Control Typicl utomtic nd mnul trim t switches NOTE: The port or strord mnul trim t rocker switches llow some control of the ttitude of the vessel. As n exmple, to chieve port ow down ttitude, you my press the port ow down rocker switch to deploy the trim t on the strord drive nd provide the requested vessel ttitude djustment. Mnul Control To mnully control or djust the offset of the trim ts for your conditions, use the individul port or strord trim t switches s needed. When the engine is running, mnully djusted trim ts will sty in the position set y the opertor until the key switch is cycled off nd on or the "AUTO" utton is pressed. If the "AUTO" utton is pressed, the utomtic trim t control feture is engged nd the trim ts move to position sed on ot speed. Refer to Automtic Control. IMPORTANT: When the engines re strted, the trnsmission must chnge ger position efore the trim t rocker switches will function. This must e done every time the engines re strted. NOTE: When controlled mnully the trim ts do not move during ccelertion unless the opertor presses the trim t uttons. Using Trim T Offset Automtic or mnul control of trim t offset could e eneficil in the following conditions. Getting on Plne Smoothing the Ride Correcting List Low Speed Trim During initil ccelertion the trim ts re utomticlly djusted (utomtic control) or must e mnully djusted (mnul control) to ring the ot on plne fster (ow down), to improve forwrd visiility, nd use less power. As the ot comes on plne in utomtic control, the trim ts re rought up so the ot does not run with the ow too fr down. For the est performnce s the ot comes on plne in mnul control, the port nd strord trim ts must e djusted up so the ot does not run with the ow too fr down. In utomtic control, the trim ts cn e djusted (offset) with the port nd strord trim t switches for est performnce when the ot conditions re temporrily outside the norml operting conditions. To void n uncomfortle, jrring ride in certin se conditions, djust the trim ts using either utomtic control or mnul control. As the wve throws the ow up trim ts dmpen the ot's rection, leveling nd smoothing the ride. In following se, put the trim ts up. This llows the ow to lift, offsetting the wves, which lift the stern. In milder wter some ots gently porpoise. Lower the trim ts, little t time, until the lope disppers. A ot list (lening to port or strord) cn e cused y n unlnced lod or severl se nd wether conditions. Using the port or strord trim t switches, individul trim t djustments cn e mde in utomtic control or mnul control to correct list. In controlled speed zones, mny ots strt to fll off plne s speed decreses, therey reducing visiility. In utomtic control or mnul control, lowered trim ts keep the ot on plne longer t lower speeds while mintining level ot ttitude. Specil Digitl Throttle nd Shift (DTS) Fetures The DTS system fetures severl lternte opertionl modes for the electronic remote control (ERC) levers. Most of the listed fetures cn e operted simultneously nd cn help you with: Wrming the engines. Trolling the vessel. Pge M eng OCTOBER 2013

57 Section 3 - On the Wter Docking the vessel. Synchronizing the engines. Dul helm sttion trnsfer. g h c f e d ERC with DTS trckpd Item Control Function c "NEUTRAL" lights "TROLL" "TRANSFER" Illuminte when the trnsmission is in the neutrl ger position. The lights flsh when the engine is in throttle only mode. Troll reduces the propeller speed to lower thn tht of engine speed for the first 25% of lever trvel. Allows ot control to e trnsferred to different helm. Refer to Dul Helm Sttion Trnsfer. d "DOCK" Reduces the throttle cpcity to pproximtely 50% of norml throttle. e f g h "THROTTLE ONLY" "1 LEVER" "SYNC" "+" (increse) nd " " (decrese) NOTE: Not ll functions my e ctive. Allows the ot opertor to increse engine RPM for wrm up, without shifting the trnsmission into ger. Enles the throttle nd shift functions of oth engines to e controlled y the strord lever. Turns the uto synchroniztion feture off or on. Refer to Synchronizing Engines. Increses nd decreses idle speed only. The RPM rnge vries depending on ppliction nd engine model. 90-8M eng OCTOBER 2013 Pge 51

58 Section 3 - On the Wter Troll nd Throttle Response Troll mode llows the vessel to operte t very low speeds y controlling the trnsmission. The trnsmission is cple of reducing the propeller speed lower thn the engine speed. Lever control is djusted so tht trolling occurs within the first 25% of lever trvel. From 26% to 100% lever trvel the engine opertes etween idle speed nd mximum rted engine speed Dock To engge Troll mode: 1. Plce oth ERC levers in neutrl. "TROLL" utton 2. Press the "TROLL" utton, locted on the DTS trckpd ttched to the ERC levers. 3. Plce either ERC lever into ger. 4. The "TROLL" utton lights when the lever or levers re moved out of neutrl. 5. The RPM of the engines do not chnge for the first 25% of ERC lever trvel while the trnsmissions llow some slippge t lower speeds. Engine RPM rises through the remining 75% of lever trvel. To disengge Troll mode: 1. Bring oth ERC levers to neutrl. 2. Press the "TROLL" utton. The "TROLL" utton light turns off. Dock mode reduces the percent of throttle throughout the rnge y 50%. This llows etter control of engine power in close qurter situtions "DOCK" utton To engge Dock mode: 1. Plce oth ERC levers in neutrl. 2. Press the "DOCK" utton locted on the DTS trckpd ttched to the ERC levers. Pge M eng OCTOBER 2013

59 Section 3 - On the Wter 3. The "DOCK" utton light turns on. 4. Plce either ERC lever into ger. 5. The engines rise the RPM t proportionlly lower RPM for the ERC lever position, nd with hlf the power tht is usully ville. To disengge Dock mode: NOTE: Dock only disengges with the levers in detent. 1. Bring oth ERC levers to forwrd, neutrl, or reverse detent. 2. Press the "DOCK" utton. Dock mode disengges nd the "DOCK" utton light turns off. Throttle Only To engge Throttle Only mode: 1. Plce oth ERC levers in neutrl. 2. Press the "THROTTLE ONLY" utton, locted on the DTS trckpd "THROTTLE ONLY" utton 3. The "THROTTLE ONLY" utton light illumintes nd the neutrl lights link. 4. Plce either ERC lever into ger. 5. The RPM of the engines cn e rised, while the trnsmissions remin in neutrl. To disengge Throttle Only mode: NOTE: Pressing the "THROTTLE ONLY" utton while the ERC levers re in ger, turns off the utton light, ut the ot remins in Throttle Only mode until you plce the levers in neutrl. 1. Bring oth ERC levers to neutrl. Throttle Only will not disengge unless the ERC levers re in neutrl. 2. Press the "THROTTLE ONLY" utton. The "THROTTLE ONLY" utton light turns off. 3. Notice tht the neutrl lights remin on. Single Lever (1 Lever) Opertion The Zeus single lever (1 Lever) feture simplifies engine mngement during rough se conditions y llowing you to grsp single lever to commnd oth engines simultneously. To engge the single lever (1 Lever) mode: 1. Plce oth ERC levers in neutrl. 90-8M eng OCTOBER 2013 Pge 53

60 Section 3 - On the Wter 2. Press the "1 LEVER" utton locted on the DTS trckpd ttched to the ERC levers The "1 LEVER" utton light turns on. 4. Plce the strord ERC lever into ger. "1 LEVER" utton 5. The engine RPM rises nd lowers simultneously while the trnsmissions remin in the sme ger. To disengge the single lever (1 Lever) mode: 1. Plce oth ERC levers in neutrl. 2. Press the "1 LEVER" utton. The "1 LEVER" utton light turns off. Synchronizing the Engines The system fetures n utomtic engine synchroniztion feture clled Sync. Sync engges utomticlly t key up. The synchroniztion feture monitors the position of oth ERC levers. If oth levers re within 10% of one nother, the port engine synchronizes to the strord engine's RPM. VesselView shows n ornge icon if the RPM of the engines re not within 10% of ech other, nd the icon turns green when they synchronize. The icon turns grey when Sync mode is off. To disengge Sync mode: 1. Plce the ERC levers in ny detent. 2. Press the "SYNC" utton To re engge Sync mode, press the "SYNC" utton. "SYNC" utton Pge M eng OCTOBER 2013

61 Cruise Control Section 3 - On the Wter The VesselView system fetures integrted throttle cruise control clled Cruise, which llows the opertor to limit the pek RPM of choice elow wide open throttle (WOT). Refer to the owners mnul provided with your VesselView for opertion instructions. These dditionl notes re exclusive to your pckge: You cn chnge or disengge Cruise through the VesselView screen t ny time. Cruise resets when the key is turned off. If the cruise limit is chnged while the levers re t WOT, Cruise grdully chnges to the new speed. Cruise does not disengge if the ERC levers re t higher engine speed thn the ctul RPM. Bring the levers ck to the forwrd detent, then use VesselView to disengge Cruise. Skyhook does not function if Cruise is engged. Helm Trnsfer Some ots re designed to llow control of the vessel from more thn one loction. These loctions re commonly referred to s helms or sttions. Helm trnsfer is term used to descrie the method of trnsferring control from one helm (or sttion) to nother helm.! WARNING Avoid serious injury or deth from loss of ot control. The ot opertor should never leve the ctive sttion while engine is in ger. Helm trnsfer should only e ttempted while oth sttions re mnned. One person helm trnsfer should only e performed while engine is in neutrl. The helm trnsfer function llows the ot opertor to select which helm is in control of the vessel. Before trnsfer cn e initited the ERC levers t the ctive helm nd t the helm intended for the trnsfer must e in the neutrl position. NOTE: If you ttempt to trnsfer helm control when the ERC levers re not in neutrl, eep will sound nd the helm trnsfer will not succeed until the levers t the helms re moved to neutrl nd trnsfer is requested gin. Some fult codes my pper on VesselView if other control or nvigtion functions re ttempted fter the helm trnsfer procedure is strted. To remove the fult codes it my e necessry to cycle the key switch off nd on, nd then restrt the helm trnsfer procedure. Ensure tht other control nd nvigtion inputs re performed fter helm trnsfer is complete to void setting fult codes. NOTICE The ERC levers must e in neutrl to perform helm trnsfer. While in neutrl your vessel could drift nd collide with ojects nery resulting in dmge. Keep n dequte look out while performing the helm trnsfer. To void dmge, use extr cre when ttempting helm trnsfer while the vessel is close to docks, piers, or other fixed items or when ner other vessels. Requesting Helm Trnsfer NOTE: Any movement of the joystick or ERC levers fter pressing the "TRANSFER" utton termintes the helm trnsfer request. A single eep sounds nd the trnsfer utton light turns off signling the end of the trnsfer request. To request the trnsfer of vessel control from one helm to nother: 1. At the helm you re requesting e mde ctive nd with the ERC levers in neutrl, press the "TRANSFER" utton one time. After the "TRANSFER" utton is pressed, the trnsfer utton light turns on nd one eep will sound confirming the impending trnsfer. NEUTRAL - TROLL + SYNC TRANSFER 1 LEVER THROTTLE ONLY DOCK "TRANSFER" utton NOTE: If the ERC levers t the helms re not in neutrl, the neutrl lights will flsh. Move ll the ERC levers to neutrl nd the neutrl light should then e on. 90-8M eng OCTOBER 2013 Pge 55

62 Section 3 - On the Wter 2. With the "TRANSFER" utton light nd neutrl light on, press the "TRANSFER" utton second time to complete the helm trnsfer. 3. When the helm trnsfer is complete, nother eep sounds nd the trnsfer utton light turns off. NOTE: If the helm trnsfer is not completed in ten seconds the request is utomticlly cncelled nd doule eep sounds. Control will remin t the existing ctive helm. Press the "TRANSFER" utton gin to restrt helm trnsfer. 4. The helm where the trnsfer request ws initited is now ctive nd controls the vessel. Helm Trnsfer nd Precision Pilot Trnsferring control from n ctive helm to n inctive helm (from one sttion to nother sttion) ffects the functionlity of Precision Pilot modes. Some of the effects re listed. Auto Heding mode is disengged when the ERC levers re moved to neutrl for helm trnsfer. You must re engge Auto Heding t the newly ctive helm. Requesting helm trnsfer cuses Pilot to go to Stndy mode. You will need to input informtion t the new helm in control. If engged, Skyhook will disengge when the "TRANSFER" utton is pressed the second time. You must engge Skyhook t the the newly ctive helm. The Resume feture for Auto Heding does not trnsfer utomticlly. After engging the previous Auto Heding course t the newly ctive helm, the resume feture works the sme s t ny ctive sttion. In Trck Wypoint mode the control of the route nd disply of route dt on your chrt plotter does not utomticlly trnsfer to the chrt plotter t the requested helm. You must turn on the chrt plotter t the newly ctive helm, input the wypoint or wypoint route to e trcked, nd re engge Trck Wypoint. Autopilot Trckpd Fetures Chrtplotter Requirements Mny of the fetures nd functions of utopilot use informtion from chrtplotter. However, not ll chrtplotters hve the qulity of informtion needed to llow these fetures to work properly. The chrtplotter on your ot hs een selected from n pproved list creted nd mintined y Mercury Mrine. These chrtplotters use specific softwre to meet the stringent demnds to properly interfce with the utopilot nd joystick. Poor qulity or inccurte informtion generted y unpproved chrtplotters or softwre cn cuse the fetures to ehve errticlly, unexpectedly, or not function t ll. Updting softwre to n unpproved version cn lso cuse the system to not function correctly. See your uthorized deler or cll Mercury Customer Service for list of pproved chrtplotters. IMPORTANT: When using utopilot, the chrtplotter rrivl zone must e chnged to 0.05 or more nuticl miles. Chnging the rrivl zone to 0.05 or more nuticl miles, llows utopilot to trnsition the turn without n rupt chnge in the vessel direction. Response Settings Press the response utton to increse or decrese how ggressively the vessel rects to progrmmed chnges when in utopilot modes. How ggressively the vessel rects equls response setting in VesselView. Ech time you press RESPONSE, the response light links to indicte you chnged the response setting for tht mode. Numer of links Response setting indicted Aggressiveness of correction VesselView Autopilot Screen 1 1 Mild (for gentle or clm conditions) 2 2 Medium (for moderte conditions) 3 3 Aggressive (for severe conditions) The VesselView utopilot screen displys: The ngle of the drives when in stndy mode A digitl compss vlue of the current heding Three icons to indicte the currently selected response level Engine RPM Pge M eng OCTOBER 2013

63 Section 3 - On the Wter NOTE: Not ll of the functions of the utopilot work when DTS functions re engged. Disengge the DTS functions to use the utopilot functions. Qud-engine disply - Heding - Drive ngle reference c - Engine RPM d - Response level d c Autopilot Trckpd Lights The utopilot trckpd includes lights to indicte when n utopilot mode is ctive (engged) or in stndy (disengged). If the stndy light is illuminted, then the utopilot is disengged (off). If the ctive light is illuminted, then the utopilot is engged (on). Pressing the utton for uto heding, trck wypoint, or Skyhook will engge tht mode, turning on oth its respective light nd the ctive light. NOTE: The stndy light will flsh on nd off when the system is ttempting to cquire the necessry GPS signls Stndy light - Active light Autopilot Modes 51879! WARNING Avoid serious injury or deth. Inttentive ot opertion cn result in collision with other wtercrft, ostcles, swimmers, or underwter terrin. The utopilot nvigtes preset course, nd does not utomticlly respond to hzrds in the vicinity of the ot. The opertor must sty t the helm, redy to evde hzrds nd wrn pssengers of course chnges. The utopilot includes severl modes tht cn steer your vessel to specific compss heding or to destintions generted from chrtplotter nd GPS unit. If using device to generte course informtion, you must e fmilir with the opertion of tht chrtplotter nd GPS unit efore ttempting to use the utopilot to steer your vessel. The utopilot does not control speed, only direction, nd it cnnot sense hzrds to nvigtion. These utomtic modes do not relieve the opertor of the responsiility to sty t the helm nd keep vigilnt lookout for other vessels, persons in the wter, or hzrds to nvigtion. When using the utopilot with chrtplotter nd GPS unit to nvigte long series of wypoints ( route), e wre tht the ot will not trvel to the precise loction of the wypoint efore inititing turn to the next wypoint. Your chrtplotter estlishes zone clled n rrivl circle round the point, nd the utopilot will nnounce rrivl t the wypoint when the ot enters tht zone. 90-8M eng OCTOBER 2013 Pge 57

64 Section 3 - On the Wter Skyhook Sttion Keeping Your vessel is equipped with the Skyhook sttion keeping feture. This system uses glol positioning system (GPS) technology nd n electronic compss to utomticlly control shifting, throttling, nd steering to mintin heding nd pproximte position. This feture cn e helpful when witing for spce ner fuel dock, witing for ridges to open, or when the wter is too deep for n nchor. Skyhook does not mintin n exct fixed position, ut rther will hold the vessel in fixed compss heding within n pproximte re. The size of this re is ffected y the ccurcy of the glol positioning stellite system, the stellite signl qulity, the physicl position of the stellites reltive to the receiver, solr flres, nd the proximity of the receiver on the vessel to lrge structures (for exmple, ridges or uildings) nd trees. Under some of these conditions Skyhook my e ffected enough tht the system will disengge. The opertor must remin t the helm whenever Skyhook is engged nd e vigilnt for chnging conditions such s the presence of other vessels or swimmers or the disenggement of Skyhook. Under typicl operting conditions, Skyhook is cple of holding the vessel within rdius of 10 m (30 ft). However this distnce my sometimes increse to rdius of 30 m (100 ft). Becuse Skyhook holds the ot in n pproximte position, not precise one, it cn cuse your ot to collide with other ojects close to your ot nd cuse dmge. Do not use Skyhook when your ot is close to dock, piling, ridge, nother vessel, or swimmer.! WARNING Skyhook is n utomtic system. Use of this system does not relieve the opertor of the responsiility to remin t the helm nd keep wtch for chnging conditions. The presence of swimmers or other vessels, or if Skyhook ecomes disengged, will require the opertor to ssume mnul control of the vessel. Importnt Sfety Considertions Activities in the wter ner the vessel while Skyhook is engged my result in injury. The opertor should red nd oserve the wrning lels on the ot, nd instruct pssengers how Skyhook opertes efore using the feture. Lel ner the utopilot trckpd Lel in the vicinity of the trnsom ording re IMPORTANT: If either of these lels cnnot e locted or re not legile, they must e replced efore engging Skyhook. For replcement lels, contct the mnufcturer of your ot or Mercury Mrine uthorized repir fcility. Before engging (ctivting) Skyhook, the opertor must: 1. Inform pssengers how Skyhook opertes, to sty out of the wter nd off the swim pltform nd ording ldder, nd to e lert for ny sudden shifts in the ot position. 2. Inform pssengers of ny udile or visul wrning systems tht my e instlled on the ot, nd when they cn expect them to e ctive. 3. Check to see tht no one is ner the ck of the ot or nywhere in the wter ner the ot Pge M eng OCTOBER 2013

65 Section 3 - On the Wter After engging (ctivting) Skyhook, the opertor must: 1. Remin t the helm nd mintin vigilnt wtch 2. Disengge (dectivte) Skyhook if nyone enters the wter or pproches the ot from the wter! WARNING A rotting propeller, moving ot, or device ttched to moving ot cn cuse serious injury or deth to people in the wter. When Skyhook is engged, the propellers rotte nd the ot moves to mintin the position of the ot. Stop the engines immeditely whenever nyone is in the wter ner the ot. Engging Skyhook Skyhook will not engge unless the joystick nd control levers re in neutrl. 1. Mneuver the ot to the desired position. 2. Ensure tht ll engines re operting nd the ERC levers re in neutrl. 3. Confirm tht the re round the ot is cler of swimmers nd ostcles. 4. Press the Skyhook utton. When the Skyhook utton is pressed on the utopilot trckpd, VesselView will disply the Skyhook wrning popup. After the wrning popup hs een cknowledged, VesselView will disply Skyhook wrning in the contextul re nd show the ger positions in ornge Skyhook wrning - Ger position Disengging Skyhook Skyhook cn e disengged severl different wys: Move the steering wheel. Press the Skyhook utton on the utopilot trckpd. Move the joystick nd return to the originl neutrl position. Move the ERC levers. Turn off one or more engines. 90-8M eng OCTOBER 2013 Pge 59

66 Section 3 - On the Wter Skyhook does not utomticlly resume when the steering wheel, levers, or joystick re returned to their originl position. The Skyhook utton must e pressed gin to re engge the feture. Using Skyhook Skyhook system response will chnge with wind nd current conditions. Fmilirize yourself with how est to position your vessel regrding the speed nd direction of wind nd current. Prctice with Skyhook to determine wht works est for your vessel in vrious situtions. In extreme wether nd se conditions, Skyhook my not e le to mintin vessel's heding nd position. This is especilly true if the vessel's heding is perpendiculr to the wind or current. If the wind or current forces the vessel wy from the position where Skyhook ws set, Skyhook will strt to turn the ow of the vessel ck to the originl set point. As the vessel is pushed further wy, Skyhook will continue to rotte the ow to the set point until the ow eventully points directly t the set point. If t ny time in this process Skyhook is le to overcome the conditions enough to hold position, it will cese turning the ow. If the conditions lessen nd Skyhook is le to mneuver the vessel ck towrd the originl set point, Skyhook will rotte the ow ck to the originl heding s it mneuvers the vessel towrd tht set point. If the vessel is forced fr enough wy from the set point, Skyhook will notify the opertor tht it is not le to mintin position. Skyhook will continue to ttempt to return to the set point, unless the opertor ssumes control of the vessel. To minimize the effects of extreme conditions on the opertion of Skyhook, Mercury Mrine recommends djusting the vessel's heding so tht its ow (or for some vessels, its stern) fces into the wind or the current. Skyhook cn unexpectedly disengge due to loss of engine power or GPS signl. If this hppens Skyhook will sound n lrm, the engines will return to neutrl, nd the vessel will drift with the wind nd current. You must e redy to tke control of the helm t ll times. Auto Heding Auto heding llows the ot to utomticlly mintin compss heding while the ot is underwy. Engging Auto Heding 1. Ensure tht the strord engine key switch is in the run position. 2. Plce t lest one running engine in forwrd ger. NOTE: Auto heding does not function with the ERC levers in neutrl or reverse. 3. Steer the ot to the desired compss heding. 4. Press the uto heding utton. The utton illumintes nd single eep sounds cknowledging enggement. A doule horn eep sounds if the uto heding mode does not engge. - Port turn (course djust) utton - Strord turn (course djust) utton c - Auto heding utton nd light d - Resume utton nd light d c The VesselView screen will chnge to utopilot. The steering wheel will self center nd e held in n electronic detent position. NOTE: If you must turn the steering wheel for ny reson, you will need to pply sufficient force to overcome the electronic detent. Pge M eng OCTOBER 2013

67 Section 3 - On the Wter The utopilot will hold the compss heding tht the ot ws following when AUTO HEADING ws pressed. 5. To djust your course while in uto heding mode, refer to Course Adjustment Using the Turn Buttons or Joystick. 6. To disengge uto heding mode, refer to Disengging Auto Heding. 7. Press AUTO HEADING second time to plce utopilot in stndy mode nd turn off ll lights other thn the stndy light. Course Adjustment Using the Turn Buttons or Joystick While in uto heding mode, the turn uttons (course djust uttons) chnge the set course heding ech time they re pressed. Holding the joystick left or right for one second will lso djust your course. Press the turn utton in the direction of the desired heding chnge. Ech press of the utton chnges the desired heding y Port turn (course djust) utton - Strord turn (course djust) utton c - Auto heding utton nd light d - Resume utton nd light d c Deflect nd hold the joystick in the desired direction for one second to mke smll djustments in the chosen heding. Ech recognized movement djusts the chosen heding y M eng OCTOBER 2013 Pge 61

68 Section 3 - On the Wter NOTE: The joystick must move over 50% of its trvel for the movement to e recognized s input. A eep will sound. To Resume Heding Adjusting heding to strord The resume light is on if the previous course heding is ville to resume. IMPORTANT: The previous heding cn only e resumed within one minute of the uto heding eing disengged or if the steering wheel hs een turned no more thn 90. Press the resume utton to resume the previous heding if you: Turned the steering wheel nd disengged uto heding Pressed one of the turn (course djust) uttons with uto heding engged Port turn (course djust) utton - Strord turn (course djust) utton c - Auto heding utton nd light d - Resume utton nd light d c Disengging Auto Heding 1. Disengge the uto heding mode with ny of the following ctions: Plce the ERC hndles for ll engines in neutrl. The uto heding light turns off nd the stndy light comes on. Turn the steering wheel eyond the electronic detent. The uto heding light turns off nd the resume light comes on. Press the uto heding utton on the utopilot trckpd. The uto heding light turns off nd the stndy light comes on. 2. A single eep sounds nd the VesselView disply will turn grey, showing tht the mode is in stndy. Pge M eng OCTOBER 2013

69 Section 3 - On the Wter 3. If the resume light is on, you cn press RESUME to resume the course in uto heding. Refer to To Resume Heding. If you do not wish to resume the course, press the uto heding utton once to enter stndy mode. 4. If the stndy light is on nd the resume light is not, you cnnot resume your course y pressing the resume utton. Refer to To Resume Heding. Press the uto heding utton to fully exit the uto heding mode. Trck Wypoint! WARNING Avoid serious injury or deth. Inttentive ot opertion cn result in collision with other wtercrft, ostcles, swimmers, or underwter terrin. The utopilot nvigtes preset course, nd does not utomticlly respond to hzrds in the vicinity of the ot. The opertor must sty t the helm, redy to evde hzrds nd wrn pssengers of course chnges. Trck wypoint llows the ot to utomticlly nvigte to specific wypoint or sequence of wypoints, clled wypoint route. This feture is intended for use in open wters, free from ostructions ove nd elow the wterline. Use the exmple route shown in the following illustrtion: Wypoints re shown in numered squres within the rrivl circle ( dshed line circle round the numered squre). A hzrd is present etween wypoints 1 nd 2. If these wypoints re used for the route, the utopilot will ttempt to nvigte through the hzrd. It is the cptin's responsiility to select wypoints tht void ll hzrds. Wypoint 4 is too close to 3 to e used in the sme route. Wypoints must e fr enough prt tht the rrivl circles do not intersect M eng OCTOBER 2013 Pge 63

70 Section 3 - On the Wter A route, including wypoints 1, 2, nd 3, is represented y the stright dshed line. The utopilot system will ttempt to nvigte this route. It is the responsiility of the cptin to ensure tht the route does not contin ny hzrds, nd to keep wtch while underwy. Exmple route When the trck wypoint feture is ctivted nd the ot is put into opertion: The opertor must remin t the helm t ll times. The feture is not designed to llow unttended opertion of the vessel. Do not use trck wypoint s the sole source of nvigtion. IMPORTANT: Trck wypoint cn e used only with chrtplotters pproved y Mercury Mrine. Wypoint dt needs to e provided to VesselView y third prty chrtplotter. The rrivl rdius must e set to 0.05 nuticl miles or greter. Refer to the chrtplotter's user mnul for detils. The ccurcy of the feture cn e ffected y environmentl conditions nd incorrect use. Oserve the following informtion when using the trck wypoint nd wypoint sequencing feture. Wypoint dt distnce settings Between wypoints Between rrivl lrms Greter thn 1.0 nuticl mile (1.15 mile) No less thn 0.1 nuticl mile (0.12 mile) Engging Trck Wypoint Mode To engge the trck wypoint mode: 1. Turn on the chrtplotter nd select single wypoint or wypoint route to e trcked. 2. Plce t lest one ERC lever in forwrd ger. Trck wypoint does not function if oth levers re in neutrl or reverse. 3. Mnully steer the ot to the direction of the first wypoint nd hold the ot stedy t sfe operting speed.! CAUTION Avoid injury from unexpected turns t high speeds. Engging the Trck Wypoint or Wypoint Sequence feture while on plne cn cuse the ot to turn shrply. Confirm the direction of the next wypoint efore engging these utopilot fetures. When underwy in Wypoint Sequence mode, e prepred to tke pproprite ction when reching wypoint. 4. Press TRACK WAYPOINT on the utopilot trckpd. The trck wypoint light turns on nd single eep sounds, indicting trck wypoint mode is engged. NOTE: Two horn eeps sound if trck wypoint mode does not engge. Pge M eng OCTOBER 2013

71 Section 3 - On the Wter The utopilot trcks to the first wypoint on the chrtplotter course Trck wypoint utton nd light 5. VesselView displys the utopilot trck wypoint. The disply shows the digitl heding tht the ot is trveling nd tht the utopilot is locked ering to wypoint (BTW). NOTE: The utopilot trckpd turn uttons will not initite turns while the trck wypoint mode is engged. Turn fetures re only ville in uto heding mode. Disengging Trck Wypoint Mode Disengge the trck wypoint mode y one of the following methods: Press TRACK WAYPOINT on the utopilot trckpd. The trck wypoint light turns off nd the stndy light turns on. Turn the steering wheel hrd enough to overcome the force feedck. The utopilot enters stndy. Move oth ERC levers to neutrl. The utopilot enters stndy mode. Press AUTO HEADING. The utopilot enters uto heding mode. Turn off the chrtplotter. The utopilot enters stndy mode. Turn Buttons in Trck Wypoint Mode While in trck wypoint mode, pressing the left or right turn uttons on the utopilot trckpd chnges the mode to uto heding. Auto Heding Button in Trck Wypoint Mode While in trck wypoint mode, pressing AUTO HEADING chnges utopilot to uto heding mode. Acknowledging Turn During Wypoint Arrivl IMPORTANT: Unlike wypoint sequence mode, trck wypoint mode will not utomticlly turn the ot upon rrivl t plotted wypoint. 1. When the ot enters wypoint rrivl zone s indicted y the chrtplotter: M eng OCTOBER 2013 Pge 65

72 Section 3 - On the Wter There will e one long nd two short eeps. The wypoint sequencing light will strt linking to inform the opertor of the rrivl. VesselView will chnge its displyed informtion. 2. If it is sfe to chnge course to the next wypoint, the opertor should press WAYPOINT SEQUENCE to cknowledge the wypoint. The utopilot will utomticlly turn the ot nd mneuver to the new course. 3. If it is not sfe to chnge course to the next wypoint, the opertor should ssume control of the vessel. IMPORTANT: If the wypoint is not cknowledged or the opertor does not ssume control of the ot, the utopilot will revert to uto heding nd remin on its current course. The utopilot will continue on the course until the opertor tkes control. If dequte lookout is not mintined, the ot my strike nother ot, strike n oject in the wter, or run ground. 4. If the wypoint is not cknowledged, the utopilot exits trck wypoint mode nd continues on its current heding in utopilot mode. 5. At the end of the route, input new wypoint or wypoint route, or tke control of the ot. Otherwise, the utopilot reverts to uto heding mode nd continues to pilot the ot on its lst heding Wypoint Sequence IMPORTANT: Unlike trck wypoint mode, wypoint sequence mode will utomticlly turn the ot upon rrivl t plotted wypoint. NOTE: The chrtplotter wypoint rrivl zone rdius must e 0.05 nuticl miles or greter for Wypoint Sequence to function properly. 1. Plce t lest one ERC lever into forwrd. Wypoint sequence mode will not engge if oth levers re in neutrl or reverse. 2. If the trck wypoint light is not on, press TRACK WAYPOINT. 3. Press WAYPOINT SEQUENCE to engge the wypoint sequence mode. Pge M eng OCTOBER 2013

73 Section 3 - On the Wter 4. VesselView will sound eep, indicte tht the system is in utopilot wypoint sequence, disply the compss direction, nd indicte tht utopilot is locked ering to wypoint (BTW). 5. If you re in wypoint rrivl zone set y the chrtplotter, wypoint sequence mode only informs the utopilot it is oky to proceed to the next wypoint. The wypoint sequence mode cts s wypoint cknowledge function, nd the utopilot sounds eep when in the zone. 6. If you re not in previously set wypoint rrivl zone, wypoint sequence mode strts uto sequencing to the wypoints in the route. Acknowledge tht you understnd the informtion presented in the VesselView pop up wrning, nd press the wypoint sequence utton Sty lert. The ot turns utomticlly in this mode. You must know if it is sfe to turn when the vessel is entering wypoint rrivl zone. Inform pssengers tht the ot utomticlly turns so tht they cn e prepred. 8. To disle the uto sequence mode, press the wypoint sequence utton when the ot is not in wypoint rrivl zone. 9. Press the trck wypoint utton second time to put the system in stndy mode. All lights other thn stndy turn off. Cruise Control The VesselView system fetures integrted throttle cruise control, which llows the opertor to limit the pek RPM of choice elow wide open throttle (WOT). This feture requires VesselView. Refer to the owner's mnul provided with your VesselView for opertion instructions. These dditionl notes re exclusive to your pckge: You cn chnge or disengge cruise control through the screen t ny time. Cruise control resets when the key is turned off. If the cruise limit is chnged while the levers re t WOT, the setting grdully chnges to the new speed. Cruise control does not disengge if the ERC levers re t higher engine speed thn the ctul RPM. Bring the levers ck to the forwrd detent to disengge M eng OCTOBER 2013 Pge 67

74 Section 3 - On the Wter Contingent Opertions Steering Emergency Alterntive Method If the electronic steering wheel ceses to operte, the engine throttle hndles (ERC hndles), trim ts, nd the vessel joystick should still operte. Engine throttles nd trim ts cn e used s n emergency lterntive for steering in open wter where there re no ojects or other vessels in close vicinity. To mintin steering nd course heding, closely oserve the mount of engine speed used with ech throttle hndle. Trim ts cn e djusted to ssist in steering the vessel. An opertor should regulrly prctice steering the vessel in this mnner to e fmilir with using their vessel's throttles nd trim ts for steering. The joystick cn e used s n lterntive method of steering when operting the vessel in close vicinity of ojects, docks, nd other vessels. Engine RPM is limited with joystick opertion. Port Engine Only Opertion The force feedck feture of the steering wheel is only ville when the strord key switch is in the on position. If the strord key switch is off or there hs een dmge to the strord electricl system, the steering wheel will e monitored y the port control system. However, if only the port side is opertionl, or only the port key switch is in the on position, the steering wheel will not hve end stops provided y the force feedck system. In this cse, the drive will lwys turn in the direction tht the steering wheel is eing rotted until the mechnicl limits of the drive re reched. If there is dmge to the port electricl system, the steering wheel will operte normlly with complete force feedck nd end stops. The ot cn operte s single engine vessel. Note tht joystick nd sttion keeping re not ville in this condition. However, Zeus fetures redundnt AutoPilot systems, so Auto Heding nd Trck Wypoint mode re still ville during single engine opertion. Ger Enggement Emergency Procedure If trnsmission or electricl system is dmged or hs experienced condition resulting in fult such tht trnsmission does not respond to the helm controls, it is possile to mnully engge ger. In n emergency you cn mnully plce trnsmission into ger y using suitle wrench to ctute the pproprite ger shifting solenoid. Note the following: It is etter to use one drive tht works properly thn locking nd operting the drive tht is not functioning properly. This procedure is for when oth drives re not responding to helm control. Auto Heding nd Trck Wypoint will work when emergency ger enggement is in use. Moving the ERC hndle into reverse stops the engine.! CAUTION Locking the trnsmission in ger using the emergency procedure renders the helm s shifting control inoperle. Drive crefully with the ger lock engged. To shift out of ger, turn the key switch to "OFF." 1. Determine the trnsmission tht is not engging ger. 2. Stop the engines nd remove the key from the key switch.! WARNING Engine components nd fluids re hot nd cn cuse serious injury or deth. Allow the engine to cool efore removing ny components or opening ny fluid hoses. 3. Remove the drive cover of the ffected trnsmission. Refer to your owner's mnul. 4. Locte the forwrd ger solenoid on the port side of the ffected trnsmission (the wire is tgged "Forwrd Ger"). NOTE: Do not distur the reverse ger solenoid on the strord side of the trnsmission (the wire is tgged "Reverse Ger"). 5. Using 3 mm hex hed wrench, turn the solenoid screw in the center of the top of the forwrd ger solenoid clockwise until it stops. Pge M eng OCTOBER 2013

75 Section 3 - On the Wter 6. The trnsmission is now mnully engged in the ger nd will not respond to the helm controls for shifting in nd out of tht ger. - Forwrd ger solenoid - Solenoid screw! WARNING A spinning propeller, moving ot, or ny solid device ttched to the ot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your ot. 7. Ensure tht the re round the propellers is cler efore strting the engine since the propeller will e turning whenever the engine is operting. IMPORTANT: The engine does not strt with the ERC lever in ger, even though the drive is mnully engged in ger. 8. When you re redy to strt the engine, position the ERC lever in neutrl ger efore turning the key switch to the strt position. NOTE: Due to the extr lod of turning the drive gers nd propeller, the strter my turn slower when strting the engine connected to the drive in the emergency setting. 9. Use extr cre nd cution when operting your ot in this emergency mode. On the drive with the mnully engged ger, you must turn tht engine off to stop the propeller from turning or providing thrust. NOTE: Putting the drive with the ger mnully engged into reverse stops the engine. 10. Immeditely tke your ot to Mercury Diesel uthorized repir fcility nd inform them tht the drive ger hs een mnully engged. Steering nd Trim Mnul Override The steering nd trim system operte using hydrulic mnifold fitted with control vlves. If mlfunction occurs in the mnifold for the steering nd trim system, VesselView should disply fult code. The steering ctutor, trim cylinder, or oth my not respond to helm control resulting in the loss of norml steering or trim control.! CAUTION A fult in the steering control vlve or trim control vlve will temporrily cuse mlfunction of the steering or trim helm controls on the ffected drive. If you lose norml steering or trim control, reduce speed to operte the ot sfely The tle provides mtrix of relted drive nd trim t informtion in the event of mlfunction or filure. Filure Mode Fult Codes Drive or T Position Engine Mngement Bot Speed Steering control vlve stuck Steering_Spool_Stuck_Fult Stuck in ny position Fult code is seen on VesselView Drive is in reduced opertion mode Engine throttle percentge is reduced The mximum ot speed tht cn e chieved on single engine, with one engine shut down, or with one drive tht is not steerle, will vry on different models. Except in n emergency, norml opertion on single engine should not exceed 50% throttle. Trim t control vlve stuck T_Spool_Stuck_Fult Stuck in ny position No effect on engine mngement Proceed t reduced sfe operting speed within the duty cycle. 90-8M eng OCTOBER 2013 Pge 69

76 Section 3 - On the Wter In n emergency, if steering or trim control vlve is stuck, it my e possile to cler the steering fult code y mnully overriding the system. A decl with informtion out the loction of specific control vlves is ffixed to the drive cover (if equipped) nd on the rcket ttched to the steering mnifold on ll models. Refer to the Procedure for Stuck Steering Control Vlve or the Procedure for Stuck Trim T Control Vlve for dditionl informtion. - Decl - Hydrulic mnifold for steering nd trim c Mnul-override uttons on front of mnifold - Steer to strord override utton - Trim down override utton c - Hydrulic mnifold c Mnul-override uttons on rer of mnifold - Hydrulic mnifold - Trim up override utton c - Steer to port override utton! WARNING Accidentl engine strting cn cuse serious injury or deth. Remove the key from the ignition switch nd engge the lnyrd stop or E stop switch to prevent the engine from strting when performing service or mintennce on the power pckge. Pge M eng OCTOBER 2013

77 Procedure for Stuck Steering Control Vlve 1. Determine the drive tht is not responding to steering control. 2. Shut down the engine nd turn the key switch off. Wit t lest 30 seconds, if possile. 3. Restrt the engine. Confirm the steering fult hs clered. 4. If the steering fult did not cler, repet the strt/stop routine up to three times. Section 3 - On the Wter 5. If the steering fult does not cler using the ove procedure, then shift the trnsmission into neutrl, shut down the engine, turn the key switch off, nd lterntely push the port nd strord steering mnul override uttons to relese the spool. Refer to the decl on the mnifold rcket or on the port side of the drive cover, if equipped, for dditionl informtion. 6. Restrt the engine. At the helm, steer the drive to the port nd strord to confirm the fult hs clered. If the Steering_Spool_Stuck fult remins, then shut down the engine nd turn the key switch off on the unresponsive drive. Operte on nother engine nd drive. Refer to Port Engine Only Opertion, if the strord drive is shut down. NOTE: Bot speed nd mneuverility will e reduced. Procedure for Stuck Trim T Control Vlve 1. Determine the drive tht is not responding to trim control. 2. Shut down the engine nd turn the key switch off. Wit t lest 30 seconds, if possile. 3. Restrt the engine. Confirm the trim t fult hs clered. 4. If the trim t fult did not cler, repet the strt/stop routine up to three times. 5. If the trim t fult does not cler using the ove procedure, then shift the trnsmission into neutrl, shut down the engine, turn the key switch off, nd lterntely push the trim up nd trim down mnul override uttons to relese the spool. Refer to the decl on the mnifold rcket or on the port side of the drive cover, if equipped, for dditionl informtion. 6. Restrt the engine. At the helm, trim the t up nd down to confirm the fult hs clered. If the T_Spool_Stuck fult remins, then shut down the engine nd turn the key switch off on the unresponsive drive. Operte on nother engine nd drive. Refer to Port Engine Only Opertion, if the strord drive is shut down. NOTE: Bot speed nd mneuverility will e reduced. Oversteer or ot listing my occur with t in the down position. End of First Seson Checkup At the end of the first seson of opertion, contct n uthorized repir fcility to discuss or perform scheduled mintennce items. If you re in n re where the product is operted continuously, yer round, you should contct your deler t the end of the first 100 hours of opertion or once yerly, whichever occurs first. 90-8M eng OCTOBER 2013 Pge 71

78 Section 3 - On the Wter Notes: Pge M eng OCTOBER 2013

79 Tle of Contents Section 4 - Specifictions Section 4 - Specifictions Drive Ger Luricnt Trnsmission Steering Actutor nd Trim Oil Approved Pints Approved Luricnts M eng OCTOBER 2013 Pge 73

80 Section 4 - Specifictions Drive Ger Luricnt Model Fluid Cpcity (includes the drive nd the ger lue monitor) Fluid Type Fluid Prt Numer Zeus (during rek in) 5 1/4 L (5 1/2 US qt) Premium Ger Luricnt K01 Zeus (fter rek in) 5 1/4 L (5 1/2 US qt) High Performnce Ger Lue Trnsmission IMPORTANT: Alwys use the dipstick to determine the exct quntity of luricnt (fluid) required. Trnsmission Without Drop Box K01 Description Fluid Cpcity Fluid Type Fluid Prt Numer Trnsmission only (without drop ox) Trnsmission With Drop Box 4 L (4 1/4 US qt) Synthetic Power Steering Fluid SAE 0W K01 Description Fluid Cpcity Fluid Type Fluid Prt Numer Trnsmission nd drop ox 5 1/4 L (5 1/2 US qt) Synthetic Power Steering Fluid SAE 0W 30 Trnsmission With Drop Box nd Remote (Engine Mounted) Trnsmission Oil Cooler K01 Description Fluid Cpcity Fluid Type Fluid Prt Numer Trnsmission, drop ox nd remote (engine mounted) oil cooler Steering Actutor nd Trim Oil 5 1/2 L (6 US qt) Synthetic Power Steering Fluid SAE 0W K01 Description Fluid Cpcity Fluid Type Fluid Prt Numer Steering ctutor nd trim system Approved Pints Description Mrine Cloud White 5 3/4 6 L (6 6 1/3 US qt) Synthetic Power Steering Fluid SAE 0W K01, 1/4 L (8 oz) K01, 1 L (1 US qt) Prt Numer 8M Mercury Light Gry Primer Mercury Phntom Blck Q1 Approved Luricnts Tue Ref No. Description Where Used Prt No. 120 Corrosion Gurd Drive exterior surfces Extreme Grese Driveshft slip-joint, Propeller shfts 8M Pge M eng OCTOBER 2013

81 Tle of Contents Section 5 - Mintennce Section 5 - Mintennce Product Responsiilities Owner nd Opertor Responsiilities Deler Responsiilities Do It Yourself Mintennce Suggestions Generl Inspection of Power Pckge Drive Service Point Loctions Strord Port Top...78 Drop Box Mintennce Schedules Appliction Routine Mintennce Scheduled Mintennce Zeus Pod Scrificil Anode Inspection Drive Cover, If Equipped Removing the Drive Cover...80 Clening nd Inspecting the Drive Cover Instlling the Drive Cover...80 Drive Ger Lue Drive Ger Luriction Checking Filling Chnging Drive Ger Luricnt With the Bot in the Wter With the Bot Out of the Wter Steering Actutor nd Trim Hydrulic Fluid Steering Actutor nd Trim Hydrulic Fluid Reservoir Checking Filling Trnsmission Oil (Fluid) nd Filter Checking the Trnsmission Oil Level Filling Chnging Sewter System Drining the Sewter System Bot out of the Wter Bot in the wter Checking the Sewter Pickup on the Drive Flushing the Sewter System Bttery Electricl System Cooling System nd Exhust System Luriction Driveshft Slip Joint Driveshft U Joints Propeller Shft Corrosion nd Corrosion Protection The Cuses of Corrosion Corrosion Protection Theory of Opertion Fult Codes Anodes nd MerCthode System Reference Electrode Wire MerCthode Assemly MerCthode Anode Checking Replcing MerCthode System Testing Trim T Anode Checking Replcing Continuity Circuits Inhiiting Corrosion Pinting the Bot Propellers Propeller Removl Propeller Repir Propeller Instlltion M eng OCTOBER 2013 Pge 75

82 Section 5 - Mintennce Product Responsiilities Owner nd Opertor Responsiilities It is the opertor's responsiility to perform ll sfety checks, to ensure tht ll luriction nd mintennce instructions re complied with for sfe opertion, nd to return the unit to Mercury Diesel uthorized repir fcility for periodic checkup. Norml mintennce service nd replcement prts re the responsiility of the owner or opertor nd, s such, re not considered defects in workmnship or mteril within the terms of the wrrnty. Individul operting hits nd usge contriute to the need for mintennce service. Proper mintennce nd cre of your power pckge will ensure optimum performnce nd dependility nd will keep your overll operting expenses t minimum. See your Mercury Diesel uthorized repir fcility for service ids. Deler Responsiilities In generl, deler's responsiilities to the customer include predelivery inspection nd preprtion such s: Mke certin tht the power pckge nd other equipment re in proper operting condition efore delivery. Mke ll necessry djustments for mximum efficiency. Explin nd demonstrte the opertion of the power pckge nd ot. Provide you with copy of Predelivery Inspection Checklist. Fill out the Wrrnty Registrtion Crd completely nd mil it to the fctory immeditely upon sle of the new product. All power pckges must e registered for wrrnty purposes. Do It Yourself Mintennce Suggestions Mercury power pckges re highly technicl, complex pieces of mchinery. Only qulified personnel using the proper tools should ttempt mjor repir. Your sfety is our concern. Alwys red nd understnd the Cutions, Wrnings, Importnt Notices, nd Notes. Do not ttempt repirs unless specificlly trined in tht procedure. Reference the correct service mnul for the product. Do not ttempt repirs unless qulified. Specil tools nd equipment re required to perform certin repirs. Filure to use the correct specil tools nd equipment cn result in severe dmge to the product. Alwys hve Mercury Diesel uthorized repir fcility service your power pckge nd do periodic mintennce inspections to help provide sfe nd troule free oting. Generl Inspection of Power Pckge Inspect your power pckge t regulr intervls to help mintin top operting performnce nd void potentil prolems efore they occur. Check the entire power pckge crefully, including ll ccessile engine nd drive prts. For engine inspection informtion, refer to the pproprite mnul. 1. Check for loose, dmged, or missing prts, hoses, nd clmps. Tighten or replce s necessry. 2. Check electricl connections nd leds for dmge. 3. Remove nd inspect the propellers. If nicked, ent, or crcked, contct your Mecury Diesel uthorized repir fcility. 4. Repir nicks nd corrosion dmge on the power pckge exterior finish. Contct your Mecury Diesel uthorized repir fcility. While inspecting the power pckge nd drive, certin components cn e dmged y the weight of n individul nd must not e used s step. Decls on top of the drive components indicte where no step is llowed. Do not step on components with decl Decl plced where no step is llowed Pge M eng OCTOBER 2013

83 Section 5 - Mintennce The Zeus drive cover protects nd seprtes some components fter the drive is instlled. The drive cover provides dded protection ginst dmge to the hoses nd other components s result of mechnicl hose rsion during opertion or dmge to the hoses, such s eing stepped on during service or mintennce. Keep the drive cover instlled except when removed for service. Typicl drive cover For informtion on removing the drive cover, refer to Drive Cover, If Equipped. Drive Service Point Loctions Strord c j d h f g e - Sewter return (dischrge) vlve (if equipped) - Trnsmission fluid drin plug c - Hydrulic oil cooler d - Exhust outlet connection e - Engine sewter return outlet f - Muffler sewter ypss g - Sewter inlet secock h - Hydrulic oil drin plug i - Gercse drin plug j - Hydrulic oil reservoir Port i c d e f - Sewter inlet secock (if drive mounted) - Driveshft (under shield, if equipped) c - Ger lue monitor fill d - MerCthode e - Hydrulic fluid filter f - Trim t nd node pltes g - Propeller shft g M eng OCTOBER 2013 Pge 77

84 Section 5 - Mintennce Top c d - Trnsmission dipstick - Hydrulic fluid reservoir c - Driveshft shield screw (4) d - Sewter inlet secock e - Exhust elow f - Exhust clmps g - Trnsmission filter g f e Drop Box Mintennce Schedules Appliction Drin plug or cp The following schedules pply to the Zeus drive nd driveshft connection, not to the engine. For the engine mintennce schedule nd procedures, refer to the Opertion nd Mintennce Mnul ville from the mnufcturer of the engine. NOTE: In the mintennce lists, the word check mens to visully inspect nd then ccordingly, correct, replce, or repir the tsk item. Routine Mintennce Tsk Intervl Ech dy strt nd when refueling Every two months of opertion Mintennce to e Performed Check the steering ctutor nd trim t oil (fluid) level. Check the ger lue level in the ger lue monitor. Check the trnsmission oil (fluid) level. Check the ttery connections nd fluid level. Tret the power pckge components inside the ot with Corrosion Gurd to protect the product from corrosion. Ensure tht the guges nd the wiring connections re secure. Clen the guges (every two months or every 50 hours, whichever occurs first. If operting in sltwter, the intervl is reduced to every 25 hours or 30 dys, whichever occurs first). Pge M eng OCTOBER 2013

85 Section 5 - Mintennce Scheduled Mintennce IMPORTANT: The drive gercse nd ger lue monitor in the vessel hve een filled with rek in ger lue. Brek in ger lue must e chnged fter 25 hours nd not to exceed 30 hours of opertion to prevent premture ger wer. The color of rek in ger lue is rown. Drin the drive nd ger lue monitor of the rek in ger lue nd fill with the specified ger luricnt. Refer to Drive Ger Lue. Tsk Intervl After the first 25 hours of opertion nd not to exceed 30 hours of opertion Every 250 hours of opertion or once yer (whichever occurs first) Every 500 hours of opertion or once yer (whichever occurs first) Every 1000 hours of opertion or two yers (whichever occurs first) Whenever the VesselView fult code "Filter Dirty Fult" or "Filter Clog Fult" is displyed Mintennce to e Performed Chnge the trnsmission oil (fluid) nd filter, including the trnsmission oil in the drop ox, if equipped. Chnge the ger lue in the drive gercse nd ger lue monitor. The tsk cn e performed with the vessel in the wter. Tighten the driveshft connecting olts nd nuts to specifiction. Inspect nd luricte the driveshft slip joint. Inspect the driveshft U joints; luricte if equipped with grese fittings. Chnge the ger lue in the drive gercse nd ger lue monitor. Chnge the trnsmission oil (fluid) nd filter, including the trnsmission oil in the drop ox, if equipped. Check the MerCthode controller module LED light to ensure the module is functionl. Luricte the propeller shft splines nd tighten the propeller nuts to specifiction. Inspect the hydrulic system fittings nd hoses found on the drive for leks or dmge. Check the hose fittings for tightness. Check the onding (continuity) circuit for loose or dmged connections. Test the MerCthode unit output. Inspect the electricl system for loose, dmged, or corroded fsteners. Check for loose, dmged, or corroded wiring nd connectors. Inspect the cooling system components found on the drive for dmge or leks. Check the hose clmps on the hoses for tightness. Check tht the wter inlet openings on the sewter pickup re clen nd not ostructed. Inspect the exhust system connections on the drive for dmge or leks. Check the hose clmps on the hoses for tightness. Tret the power pckge components inside the ot with Corrosion Gurd to protect the product from corrosion. Replce the driveshft U joints. Chnge the hydrulic oil nd filter for the steering nd trim system. Refer to Steering Actutor nd Trim Hydrulic Fluid. Zeus Pod Scrificil Anode Inspection IMPORTANT: Scrificil nodes re mde of specific types of metls or lloys. Aluminum nodes re ment to corrode nd scrifice themselves in order to protect the luminum section of the power pckge tht is in the wter. The scrificil nodes on Zeus pod drive must e inspected periodiclly. In most pplictions, the scrificil nodes on the pod drive trim t re difficult to inspect while the vessel is in the wter nd my not e visile until the vessel is removed from the wter. Wter conditions where the vessel is moored, my cuse the nodes to erode quickly, decresing the corrosion protection for the pod drive. An increse in wter velocity through currents or tides increses the corrosion rte of metls. This is ecuse flowing wter puts more wter in contct with the metl nd therefore, more oxygen in contct with the metl s well. Mercury Mrine recommends visul inspection of the pod drive nodes every 30 dys, more often if the vessel is moored in swift currents or tides. This inspection schedule my not e prcticl in certin situtions. You should consult the locl uthorized Mercury Mrine repir fcility for options on inspecting the nodes of the pod drive. 90-8M eng OCTOBER 2013 Pge 79

86 Section 5 - Mintennce Drive Cover, If Equipped Removing the Drive Cover NOTE: The top of the drive cover contins n ccess pnel which provides ccess to the fill cp on the ger lue monitor nd the trnsmission fluid dipstick without removing the entire cover. 1. Remove the three upper screws (port nd strord) holding the side cover to the top cover. 2. Remove the two lower screws holding the port side cover to the center section. 3. Remove the one lower screw holding the strord side cover to the center section. 4. Remove the two side covers 5. Remove the two top screws. 6. Lift nd remove the top of the drive cover. f e d c Typicl drive cover - Upper screw (6) - Lower screw (3) c - Port side cover d - Top of the drive cover e - Strord side cover f - Top screw (2) Clening nd Inspecting the Drive Cover 1. Clen nd wx the cover ssemly often using mrine cleners nd wxes. 2. Inspect the individul cover prts for crcks or dmge; replce if crcked or dmged. Instlling the Drive Cover 1. Crefully instll the top cover on the drive. Align the cover with the two threded holes in the trnsmission where the lifting rings were removed. - Top cover - Threded holes Instll one lrge wsher on ech of the top cover screws. Pge M eng OCTOBER 2013

87 Section 5 - Mintennce 3. Instll the two screws. Tighten the screws to specifiction. c - Top cover screw - Wsher c - Torque wrench Description Nm l in. l ft Top cover screw Instll the strord side cover using four screws Strord cover - Screw (4) Align nd insert the strord cover into the groove of the H trim section on the port cover. 90-8M eng OCTOBER 2013 Pge 81

88 Section 5 - Mintennce 6. Instll the port side cover using five screws. NOTICE Push-T rim Down Push- Steer to STBD Steering nd Trim Mnul Override Buttons. Refer to Opertion mnul for procedure. 8M Push-T rim Up Push- Steer to POR T d c Typicl port side cover - Screw (5) - Port cover c - H trim d - Informtion decl 7. Tighten the three lower nd six upper cover screws to specifiction. Description Nm l in. l ft Cover upper screws Cover lower screws Instll the ccess cover.. Insert the molded clip on the ft end of the ccess cover under the indented edge of the cover top. - Access cover - Molded clip c - Indented edge. Align the ccess cover with the opening in the top cover. c Pge M eng OCTOBER 2013

89 Section 5 - Mintennce c. Press down evenly on the front end of the ccess cover. The ccess cover snps into its instlled position. Drive Ger Lue Drive Ger Luriction Completing the ccess cover instlltion NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. The drive ger luriction system includes trnslucent white plstic ottle tht is used to monitor the level of the drive ger luricnt (lue). The monitor includes switch tht cn detect low level of ger luricnt nd set n udio or visul lrm. The Checking nd Filling procedures s provided re for situtions where the ger luricnt level in the monitor is low ut luricnt is visile. Filling the monitor to the specified level whenever luricnt is still visile in the monitor is correct. In some events, such s sel leking, the ger luricnt level my hve dropped low enough tht no luricnt is visile in the monitor. In these situtions the opertor should hve received n udile or visul lrm of low ger luricnt level. If there hs een n udile or visul lrm for low ger luricnt level nd the monitor is found empty, filling the system through the ger lue monitor (when no luricnt is visile in the monitor) is not correct nd requires dditionl steps s outlined in the Event Summry tle. IMPORTANT: If the ger lue monitor is empty, ir my e trpped in the drive luriction system y ttempting to fill the monitor through the opening in the monitor. Trpped ir my cuse the luricnt level to pper correct in the monitor ut still e low or insufficient in the system. The steps for correct mintennce of the drive ger luriction level cn e summrized y the following tle: Event Summry Tle Event Low without n lrm Low with n lrm, luricnt low ut visile in monitor Monitor empty nd with n lrm Tsk Fill the ger lue monitor to the specified level. Refer to Filling. Remove the drive side cover, if equipped. Pressure fill the drive unit through the steering ctutor until the ger lue ppers in the ger lue monitor t the "COLD FILL LEVEL" line. Refer to the pproprite steps in Chnging With the Bot in the Wter nd fill the drive through the steering ctutor. Checking IMPORTANT: The ger lue level in the ger lue monitor rises nd flls during drive opertion; lwys check the ger lue level when the drive is cool nd the engine is shut down. NOTE: It is norml to dd smll mount of ger lue etween chnge intervls. IMPORTANT: If the ger lue level is elow the "COLD FILL LEVEL" line when checked (especilly fter the first couple of times the ot is operted for long period) or if ger lue must e dded frequently, there could e luricnt loss, such s sel lek. Leks could result in lck of luriction tht will dmge the drive. Inspect the drive if luricnt loss occurs. Contct your Mercury Diesel uthorized repir fcility. 90-8M eng OCTOBER 2013 Pge 83

90 Section 5 - Mintennce 1. On models equipped with drive cover:. Inspect the ger lue level in the monitor. c - Port side cover - Ger lue monitor c - Access cover If necessry, remove the ccess cover from the drive cover. - Access cover - Molded clip c - Indented edge c. Remove the cp from the ger lue monitor. 2. To check the drive ger lue with the optionl drive cover removed, refer to Removing the Drive Cover. 3. Inspect the ger lue level in the ger lue monitor. The ger lue level should e etween the "COLD FILL LEVEL" (cold full line) nd the "MAX OPERATING LEVEL" (hot full line). c "COLD FILL LEVEL" (cold full line) Pge M eng OCTOBER 2013

91 Section 5 - Mintennce NOTE: After the drive hs een operted nd the ger lue is hot, the fluid expnds nd my e up to the "MAX OPERATING LEVEL" (hot full line). "MAX OPERATING LEVEL" (hot full line) IMPORTANT: If ny wter is visile t the ottom of the ger lue monitor or if the ger lue ppers discolored, contct your Mercury Diesel uthorized repir fcility immeditely. These conditions my indicte wter lek in the drive. 4. If the level is lower thn the "COLD FILL LEVEL" (cold full line), refer to Filling. NOTE: Premium Ger Luricnt used during the rek in period is rown in color nd must e chnged fter the 25 hour rek in. The color of High Performnce Ger Lue, used fter rek in, is lue. Do not mix the ger luricnts. 5. If the cp ws removed, ensure tht the gsket for the ger lue monitor cp is properly positioned nd instll the cp. Do not overtighten Ger lue monitor - Cp Instll the drive cover if removed. Refer to Instlling the Drive Cover. 7. If your model is equipped with drive cover, instll the ccess cover.. Insert the molded clip on the ft end of the ccess cover under the indented edge of the cover. - Access cover - Molded clip c - Indented edge. Align the ccess cover with the opening in the top cover. c M eng OCTOBER 2013 Pge 85

92 Section 5 - Mintennce c. Press down evenly on the front of the ccess cover. A click sound cn e herd when the ccess cover snps into finl position. Filling Completing the ccess cover instlltion If the ger lue level is elow the "COLD FILL LEVEL" line, dd the specified ger lue. 1. Remove the cp from the ger lue monitor Shown without drive cover - Ger lue monitor - Cp NOTE: Premium Ger Luricnt used during the rek in period is rown in color nd must e chnged fter the 25 hour rek in. The color of High Performnce Ger Lue, used fter rek in, is lue. Do not mix the ger luricnts. 2. Fill the ger lue monitor with the specified ger lue so tht the ger lue is level with the "COLD FILL LEVEL" line (cold full line). Do not overfill. "COLD FILL LEVEL" line (cold full line) Tue Ref No. Description Where Used Prt No. 82 Premium Ger Luricnt Ger housing nd ger lue monitor during rek-in (the first 25 hours ut not to exceed 30 hours of opertion) K01 87 High Performnce Ger Lue Ger housing nd ger lue monitor fter rek-in (fter the first hours of opertion) 3. Ensure tht the ruer gsket is inside the cp for the ger lue monitor nd instll the cp. Do not overtighten K01 Pge M eng OCTOBER 2013

93 Section 5 - Mintennce NOTE: After the drive hs een operted nd the ger lue is hot, the fluid expnds nd my e up to the "MAX OPERATING LEVEL" line (hot full line). Chnging Drive Ger Luricnt "MAX OPERATING LEVEL" line (hot full line) NOTE: Chnge the drive ger luricnt when the drive is t operting temperture. Wrmer luricnt flows more freely, crries wy more impurities, nd is esier to remove from the drive. With the Bot in the Wter Plce oil sorent wipes or mteril round the re to contin ny spilled luricnt. 2. Remove the fill nd drin screw from the steering ctutor. Drop ox model shown, ll similr - Fill nd drin screw - Steering ctutor 3. Quickly instll the specil ger lue dpter with wsher into the threded hole for the drin nd fill screw. c Coupling nut nd wsher - Adpter c - Threds into steering ctutor (3/8 in. 16 UNC) Outord Jet Pump Flushing Device 24789A Allows for running n engine with jet pump out of the wter t idles speeds. Will ttch to most outord jet pump models. Cn lso e ttched to the ger housing for flushing erly HP model outords. 90-8M eng OCTOBER 2013 Pge 87

94 Section 5 - Mintennce 4. Instll suitle doule ended mle dpter to the ger lue dpter. Typicl dpter - Doule ended mle dpter - Ger lue dpter nd wsher Attch the crnkcse oil pump or suitle ger lue pump. Shown unttched for visul clrity - Ger lue dpter nd wsher - Crnkcse oil pump c - Doule ended mle dpter c Crnkcse Oil Pump A1 Aids in the removl of engine oil without drining the crnkcse Remove the ger lue monitor cp. Shown without drive cover - Ger lue monitor - Cp Operte the crnkcse oil pump nd remove the ger lue from the drive. Pump the ger lue into suitle continer. Properly dispose of the ger lue. IMPORTANT: If ny wter exits the fill nd drin hole, or if the ger lue ppers milky, the drive is leking. Contct your Mercury Diesel uthorized repir fcility immeditely. 8. Remove the crnkcse oil pump nd the two dpters. 9. Attch the specified ger lue pump or equivlent.. Locte the dpter provided with the ger lue pump. Pge M eng OCTOBER 2013

95 Section 5 - Mintennce Ger Lue Pump Q1 Ger lue pump for 9.5 L (2.5 US Gl) ottle Assemle the seling wsher, spcer, nd seling wsher on the threded end of the dpter. NOTE: The spcer is required to prevent the dpter from threding in pst the orifice in the fill nd drin hole of the steering ctutor. The dpter should thred pproximtely 7 mm (1/4 in.) into the ctutor housing. c - Adpter - Seling wsher c - Spcer Qty. Description Prt Numer 1 Spcer Seling wsher c. Instll nd hnd tighten the dpter ssemly into the fill nd drin hole of the steering ctutor. IMPORTANT: Use Mercury or Quicksilver High Performnce Ger Lue in the drive. d. Attch the ger lue pump to continer of the specified ger lue. - Adpter ssemly - Ger lue pump Drive Model Zeus Fluid Cpcity (includes the drive nd the ger lue monitor) 5 1/4 L (5 1/2 US qt) 10. Operte the ger lue pump nd egin to fill the drive. Fluid Type High Performnce Ger Lue Fluid Prt Numer K01, 1 L (1 US qt) Q01, 9.5 L (2.5 US gl) 90-8M eng OCTOBER 2013 Pge 89

96 Section 5 - Mintennce 11. Continue to pump ger lue into the drive until the ger lue ppers in the ger lue monitor t the "COLD FILL LEVEL" line. Do not overfill. "COLD FILL LEVEL" line 12. Remove the ger lue pump nd dpter ssemly. Quickly instll the steering ctutor fill nd drin wsher nd screw. Tighten the fill nd drin screw to specifiction. Description Nm l in. l ft Steering ctutor fill nd drin screw If the level is low, fill the ger lue monitor to the "COLD FILL LEVEL" line. Refer to Filling. 14. Ensure tht the ruer gsket is inside the cp for the ger lue monitor nd instll the cp. Do not overtighten. 15. Recheck the ger lue level t the ger lue monitor fter the first use. Refer to Checking. IMPORTANT: The ger lue level in the ger lue monitor rises nd flls during drive opertion; lwys check the ger lue level when the drive is cool nd the engine is shut down. With the Bot Out of the Wter! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, remove the key from the key switch, plce the drive in neutrl, nd engge the E stop switch to prevent the engine from strting. 1. Remove the drive propellers. Refer to Propellers. 2. Remove the gercse fill nd drin screw nd seling wsher. - Gercse - Fill nd drin screw nd seling wsher Pge M eng OCTOBER 2013

97 Section 5 - Mintennce 3. Remove the ger lue monitor cp. Shown without drive cover - Ger lue monitor - Cp Drin the ger lue into suitle continer. IMPORTANT: If ny wter exits the fill nd drin hole, or if the ger lue ppers milky, the drive is leking. Contct your Mercury Diesel uthorized repir fcility immeditely. 5. Allow the ger lue to drin completely. Properly dispose of the ger lue. IMPORTANT: Use Mercury or Quicksilver High Performnce Ger Lue in the drive. 6. Instll suitle ger lue pump into the gercse fill nd drin hole. Fill the drive with the specified ger lue. - Fill nd drin hole - Ger lue nd pump Ger Lue Pump Q1 Ger lue pump for 9.5 L (2.5 US Gl) ottle Drive Model Fluid Cpcity (includes the drive nd the ger lue monitor) Fluid Type Fluid Prt Numer Zeus 5 1/4 L (5 1/2 US qt) High Performnce Ger Lue K01, 1 L (1 US qt) Q01, 9.5 L (2.5 US gl) 90-8M eng OCTOBER 2013 Pge 91

98 Section 5 - Mintennce 7. Continue to pump ger lue into the drive until the ger lue ppers in the ger lue monitor t the "COLD FILL LEVEL" line. Do not overfill. "COLD FILL LEVEL" line 8. Remove the ger lue pump nd quickly reinstll the gercse fill nd drin screw nd wsher. Description Nm l in. l ft Gercse fill nd drin screw Fill the ger lue monitor to the "COLD FILL LEVEL" line, if the level is low. Refer to Filling. 10. Ensure tht the ruer gsket is inside the cp for the ger lue monitor nd instll the cp. Do not overtighten. 11. Instll the drive propellers. Refer to Propellers. 12. Check the ger lue level t the ger lue monitor fter the first use. Refer to Checking. NOTE: After the drive hs een operted nd the ger lue is hot, the fluid will expnd nd my rech the "MAX OPERATING LEVEL" line (hot full line). "MAX OPERATING LEVEL" line (hot full line) Steering Actutor nd Trim Hydrulic Fluid Steering Actutor nd Trim Hydrulic Fluid Reservoir The steering ctutor nd trim system use common hydrulic pump, filtering system, nd hydrulic fluid reservoir for luriction nd pressure. The pump, filter, nd storge system re the sme on ll models. Checking 1. Using clen, lint free cloth, wipe the dirt nd deris wy from the cp nd exterior of the steering ctutor nd trim fluid reservoir. 2. Turn the reservoir cp counterclockwise to remove the cp nd dipstick Pge M eng OCTOBER 2013

99 Section 5 - Mintennce 3. Lift the cp nd dipstick from the neck of the reservoir. - Screen - Reservoir cp nd dipstick Inspect the fluid level. The fluid level should e t the full cold mrk on the dipstick. - Operting rnge - Full cold mrk c - Low cold mrk c If the fluid level is elow the low cold mrk, refer to Filling. 6. If the level is correct, insert the dipstick into the reservoir nd turn the reservoir cp clockwise to tighten securely. - Screen - Reservoir cp nd dipstick M eng OCTOBER 2013 Pge 93

100 Section 5 - Mintennce Filling 1. Using clen, lint free cloth, wipe the dirt nd deris wy from the cp nd exterior of the steering ctutor nd trim fluid reservoir. IMPORTANT: A screen is locted elow the reservoir cp to prevent contminnts or deris from entering the system during the filling procedure. Reservoir fill neck screen 2. Fill the hydrulic fluid reservoir with the specified fluid to ring the level up to the full cold mrk. Do not overfill Operting rnge - Full cold mrk c - Low cold mrk c Tue Ref No. Description Where Used Prt No. 138 Synthetic Power Steering Fluid SAE 0W-30 Hydrulic system K01 3. When the level is correct, insert the dipstick into the reservoir nd turn the reservoir cp clockwise to tighten securely. Trnsmission Oil (Fluid) nd Filter Checking the Trnsmission Oil Level If the drive is equipped with drive cover, you cn check the trnsmission oil (fluid) level through the ccess cover or with the drive cover removed, if equipped. Pge M eng OCTOBER 2013

101 Section 5 - Mintennce 1. If equipped with drive cover, lift the front of the ccess cover from the drive cover or remove the drive cover, to ccess the trnsmission dipstick. - Access cover - Molded clip c - Indented edge 2. Remove the dipstick. Wipe the dipstick with clen, lint free cloth. c Trnsmission dipstick, with cover removed for clrity 3. Insert the dipstick, resting it on the top of the threded hole. 4. Remove the dipstick nd check the oil level indicted. The oil level should e etween the mximum nd minimum mrks on the dipstick. NOTE: Oil from the trnsmission oil cooler nd hoses my drin into the trnsmission, cusing n oil level slightly ove the mximum mrk. d Checking dipstick resting on top of threded hole - Mximum mrk - Minimum mrk c - Top of threded hole d - Dipstick c 5. If the level is correct, instll the dipstick. 6. If the level is low, dd the specified trnsmission oil through the dipstick threded hole to ring the level up to the mximum mrk on the dipstick. Description Fluid Type Fluid Prt Numer Trnsmission nd drop ox Synthetic Power Steering Fluid SAE 0W K01 NOTE: If the trnsmission oil level is extremely low, contct your locl Mercury Diesel uthorized repir fcility M eng OCTOBER 2013 Pge 95

102 Section 5 - Mintennce IMPORTANT: For more ccurte mesurement, operte the engine t 1500 RPM for three minutes immeditely efore checking the oil level. NOTICE The sewter pumps on vessels equipped with Zeus pod drives cn e dmged y excessive exhust ertion due to indequte wter flow. To ensure dequte wter flow cross the sewter inlets, mke sure tht the vessel is underwy efore exceeding 1500 RPM. 7. Strt the engine nd operte t 1500 RPM for three minutes to fill ll the hydrulic circuits. To void excessive exhust ertion of the sewter, do not operte the engine ove 1500 RPM. 8. Stop the engine nd quickly check the oil level. 9. If the oil level is low, dd the specified trnsmission oil to ring the level up to the mximum mrk on the dipstick. 10. Instll the dipstick. 11. If your model is equipped with drive cover, instll the ccess cover.. Insert the molded clip on the ft end of the ccess cover under the indented edge of the cover. - Access cover - Molded clip c - Indented edge. Align the ccess cover with the opening in the top cover. c. Press down evenly on the front of the ccess cover. A click sound cn e herd when the ccess cover snps into finl position. c Filling Completing the ccess cover instlltion You cn fill the trnsmission with oil through the ccess cover on the drive cover or with the drive cover removed Pge M eng OCTOBER 2013

103 Section 5 - Mintennce 1. To ccess the trnsmission dipstick, you must remove the ccess cover or remove the drive cover, if equipped. Refer to Removing the Drive Cover. c - Access cover - Trnsmission c - Trnsmission dipstick Remove the dipstick. Wipe the dipstick with clen, lint free cloth. Check the oil level s outlined in Checking. Trnsmission dipstick 3. Add the specified trnsmission oil through the dipstick threded hole to ring the level up to the mximum mrk on the dipstick. Description Fluid Cpcity Fluid Type Fluid Prt Numer Trnsmission only (without drop ox) Trnsmission nd drop ox Trnsmission, drop ox, nd remote (engine mounted) trnsmission oil cooler 4 L (4 1/4 US qt) 5 1/4 L (5 1/2 US qt) 5 1/2 L (6 US qt) Synthetic Power Steering Fluid SAE 0W K01 1 Liter (1 US qt) IMPORTANT: For more ccurte mesurement, operte the engine t 1500 RPM for three minutes immeditely efore checking the oil level. NOTE: Additionl trnsmission oil my e required to fill empty cvities in the trnsmission filter nd oil coolers fter chnging the trnsmission oil. Alwys use the dipstick to estlish the correct oil level. NOTICE The sewter pumps on vessels equipped with Zeus pod drives cn e dmged y excessive exhust ertion due to indequte wter flow. To ensure dequte wter flow cross the sewter inlets, mke sure tht the vessel is underwy efore exceeding 1500 RPM. 4. Strt the engine nd operte t 1500 RPM for three minutes to fill ll of the hydrulic circuits nd empty cvities. To void excessive exhust ertion of the sewter, do not operte the engine ove 1500 RPM. 5. Stop the engine. Quickly unscrew nd remove the dipstick. 90-8M eng OCTOBER 2013 Pge 97

104 Section 5 - Mintennce 6. Check the oil level. Refer to Checking. d - Mximum mrk - Minimum mrk c - Top of threded hole d - Dipstick 7. If the oil level is low, dd the specified trnsmission oil to ring the level up to the mximum mrk on the dipstick. 8. Instll the dipstick. 9. Instll the ccess cover onto the drive cover if it ws removed. 10. Instll the drive cover if it ws removed. Refer to Instlling the Drive Cover. Chnging c NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required.! WARNING The ruer interfce ring sel hs n outside coting tht protects the inner core. Ters, cuts, scrpes, or exposure to luricnts or seling compounds cn dmge this coting nd the inner core cusing wter to lek into the ot. Use cution when instlling nd working round the interfce ring sel to prevent dmge. Do not use ny luricnts or seling compounds during instlltion. 1. Remove the drive cover, if equipped. Refer to Removing the Drive Cover. 2. Ly down oil soring wipes or mteril to ctch excess trnsmission oil. 3. Remove the M30 drin plug nd seling wsher from the ft, strord end of the trnsmission nd drin the trnsmission oil (fluid) into suitle continer Trnsmission - Drin plug nd seling wsher Pge M eng OCTOBER 2013

105 Section 5 - Mintennce 4. On models with drop ox, remove the drin cp from the lower, port side of the drop ox. Drin the trnsmission oil into suitle continer. - Drop ox - Drin cp NOTE: Except in the cses of extreme contmintion or mechnicl filure, it is not necessry to drin the oil from the engine mounted trnsmission oil cooler, if equipped. Engine-mounted trnsmission oil cooler 5. Dispose of the trnsmission oil properly. 6. Clen the exterior of the trnsmission round the oil filter ssemly. 7. Use 6M Allen wrench nd remove the oil filter ssemly screw Fluid filter ssemly - Assemly screw 8. Remove the filter cover ssemly M eng OCTOBER 2013 Pge 99

106 Section 5 - Mintennce 9. Remove nd discrd the filter element nd the O rings. 10. Cot the new O rings with trnsmission oil. 11. Instll the new O rings nd filter element. c d e f g h i Assemly screw - Wsher c - Cover d - Filter cover ssemly e - O ring f - O ring g - Filter element h - Sel i - Oil pipe NOTICE Improper instlltion of the trnsmission fluid filter ssemly my cuse the fluid to fom or lek out, resulting in decresed efficiency nd dmge to the trnsmission. Properly set the trnsmission fluid filter during instlltion. 12. Instll the oil filter ssemly in the trnsmission cvity y turning the ssemly clockwise during instlltion. 13. Using 6M Allen wrench, tighten the filter ssemly screw to specifiction. - Assemly screw - Fluid filter ssemly Description Nm l in. l ft Filter ssemly screw 7 62 IMPORTANT: Use new seling wshers to void leks. 14. On models with drop ox, instll the drin cp. Tighten the drin cp to specifiction. - Drop ox - Drin cp Description Nm l in. l ft Drop ox drin cp Pge M eng OCTOBER 2013

107 15. Instll the trnsmission drin plug with new seling wsher. Tighten the drin plug to specifiction. Section 5 - Mintennce - Drin plug nd seling wsher - Trnsmission Description Nm l in. l ft Trnsmission drin plug NOTE: The drop ox fills with oil when the trnsmission is filled. The trnsmission my hve to e operted to fill the engine mounted cooler. Alwys use the dipstick to determine the quntity of oil required. 16. Fill the trnsmission, drop ox, nd engine mounted cooler, if equipped, to the proper level with the specified oil. Refer to Filling. 17. After first strt up, check for leks. If leks exist, stop opertion immeditely. Check the components nd repir s needed. 18. Instll the drive cover, if equipped. Refer to Instlling the Drive Cover. Sewter System Drining the Sewter System IMPORTANT: The vessel must e s level s possile to ensure complete drining of the cooling system. Drin the sewter system of the power pckge efore flushing or efore cold wether (freezing temperture), sesonl storge, or extended storge. IMPORTANT: The engine must not e operting during the drining procedure. Bot out of the Wter 1. Remove the ot from the wter. 2. Open the sewter inlet secock nd sewter return (overord) secock. 3. Drin the sewter. 4. On models with drop ox nd engine mounted trnsmission oil cooler, remove the two node plugs nd drin the sewter. - Anode (drin) plugs - Trnsmission oil cooler M eng OCTOBER 2013 Pge 101

108 Section 5 - Mintennce 5. On models with drop ox nd drive mounted trnsmission oil cooler, s shown, remove the drin plug. Drin the sewter. - Drin plug - Trnsmission oil cooler 6. On models equipped with sewter striner, refer to Sewter Striner. 7. Depending on equipment, pply selnt to the trnsmission oil cooler drin plug or node plugs efore instlltion. Tighten the drin plug securely or the node plugs to specifiction Tue Ref No. Description Where Used Prt No. 19 Perfect Sel Drin plug nd node plugs Q02 Description Nm l in. l ft Anode plugs Plce tg t the helm nd in the engine comprtment stting tht the secocks re open nd must e closed nd ll drin plugs nd hoses instlled, prior to plcing the ot in the wter. Bot in the wter! CAUTION Wter cn enter the ilge when drining the sewter system, dmging the engine or cusing the ot to sink. Remove the ot from the wter or close the sewter inlet nd dischrge secocks nd operte the ilge pump when drining. Do not operte the engine when drining the sewter system. 1. On models using through the hull sewter inlet, refer to your ot mnufcturer for instructions nd close the sewter inlet vlve or secock. 2. On models using the through the drive sewter inlet, close the sewter inlet secock. Rotte the hndle in the direction indicted y the rrow. Typicl port hndle - Inlet secock - Former position (open) c - Hndle in closed position c Pge M eng OCTOBER 2013

109 3. Close the sewter return (overord) secock. Rotte the hndle in the direction indicted y the rrow. Section 5 - Mintennce Drive cover removed for clrity - Return secock - Hndle in closed position Turn on the ilge pump. NOTE: In the following step, lower or end the hose s necessry to llow the sewter to drin completely. 5. Remove the hose from the sewter inlet secock. Drin the sewter. c Typicl connection - Inlet secock - Dul hose clmps c - Hose 6. Remove the sewter hose from the outlet end of the primry cooler for the hydrulic oil. Drin the sewter Remove the drin screw on the secock. Drin the sewter. c d - Dul hose clmps - Primry cooler c - Sewter hose d - Drin screw On models with drop ox nd engine mounted trnsmission oil cooler, remove the two node plugs nd drin the sewter. - Anode (drin) plugs - Oil cooler M eng OCTOBER 2013 Pge 103

110 Section 5 - Mintennce 9. On models with drop ox nd drive mounted trnsmission oil cooler, s shown, remove the drin plug nd drin the sewter. - Drin plug - Trnsmission oil cooler 10. On models equipped with sewter striner, refer to Sewter Striner. 11. On models with drop ox nd drive mounted trnsmission oil cooler:. Apply selnt to the threds of the drin plug for the trnsmission oil cooler Tue Ref No. Description Where Used Prt No. 19 Perfect Sel Drin plug Q02. Instll the drin plug. c. Tighten the drin plug securely. 12. On models with drop ox nd engine mounted trnsmission oil cooler:. Apply selnt to the threds of the node plugs. Tue Ref No. Description Where Used Prt No. 19 Perfect Sel Anode plugs Q02. Instll the node plugs. c. Tighten the node plugs to specifiction. - Anode (drin) plugs - Oil cooler Description Nm l in. l ft Anode plugs Reconnect the sewter hoses. Tighten the dul hose clmps securely. 14. Apply selnt to the threds of the drin screw for the return secock. Tue Ref No. Description Where Used Prt No. 19 Perfect Sel Threds of the drin screw for the return secock Q02 Pge M eng OCTOBER 2013

111 Section 5 - Mintennce 15. Instll the drin screw on the return secock. Tighten the screw securely. c d - Dul hose clmps - Primry cooler c - Sewter hose d - Drin screw NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or efore ny length of storge in freezing tempertures. If the ot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing ck into the cooling system. If the ot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. 16. Plce tg t the helm nd in the engine comprtment stting tht the secocks re closed nd must e opened fter ll drin plugs nd hoses re instlled, prior to strting the engines. Checking the Sewter Pickup on the Drive 1. Ensure tht the wter inlet openings for the sewter pickup re clen nd not ostructed. Crefully remove ny ostructions. Do not dmge the composite sewter pickup cover Inlet openings for sewter pickup (cvity not visile in this view) 2. Looking through the inlet openings, visully inspect the cvity etween the inlet cover nd the center section plte for mrine growth (shells, crustcens, etc.). If mrine growth is found in the cvity, contct your Mercury Diesel repir fcility. Shown with cover removed for clrity - Sewter inlet to secock - Cvity (shded re) c - Center section plte d - Cover c d M eng OCTOBER 2013 Pge 105

112 Section 5 - Mintennce Flushing the Sewter System Before sesonl or extended storge, we recommend flushing the sewter cooling system to void slt or silt uildup. Contct your Mercury Diesel uthorized repir fcility for dditionl informtion. Bttery All led cid tteries dischrge when not in use. Rechrge every 30 to 45 dys, or when specific grvity drops elow ttery mnufcturer's specifictions. Refer to specific instructions nd wrnings ccompnying your ttery. If this informtion is not ville, oserve the following:! WARNING An operting or chrging ttery produces gs tht cn ignite nd explode, sprying out sulfuric cid, which cn cuse severe urns. Ventilte the re round the ttery nd wer protective equipment when hndling or servicing tteries.! WARNING Rechrging wek ttery in the ot, or using jumper cles nd ooster ttery to strt the engine, cn cuse serious injury or product dmge from fire or explosion. Remove the ttery from the ot nd rechrge in ventilted re wy from sprks or flmes. Electricl System 1. Check for loose, dmged, or corroded fsteners. 2. Check for loose, dmged, or corroded wiring nd connectors. Cooling System nd Exhust System 1. Inspect the cooling nd exhust systems for dmge or leks. 2. Check the cooling nd exhust system hose clmps for tightness. Luriction Driveshft Slip Joint The driveshft hs slip joint tht must e luricted through grese fitting. Prt of the protective driveshft shield must e temporrily removed for ccess to the grese fitting. 1. Remove the driveshft shield on the engine end. Shield on engine end - Driveshft shield - Screw (two on ech side) c - Engine end c Luricte the driveshft slip joint through the grese fitting. - Driveshft - Grese fitting Pge M eng OCTOBER 2013

113 Section 5 - Mintennce Tue Ref No. Description Where Used Prt No. Extreme Grese Driveshft slip-joint 8M NOTE: A cp plug is instlled in the center of the nerest universl joint on the driveshft slip joint. The plug retins grese in the spline cvity. A hole in the center of the plug cts s pressure relief for grese in the spline cvity. 3. Pump grese into the grese fitting for the slip joint until grese is expelled from the pressure relief hole in the cp plug. c - Grese fitting - Cp plug c - Expelled grese Apply dhesive to the threds of the flnge hed screws for the driveshft shield on the engine end. Tue Ref No. Description Where Used Prt No. 10 Loctite 277 Driveshft shield retining screw threds Otin Loclly 5. Instll the driveshft shield on the engine end using the flnge hed screws s shown. Tighten the screws to the specified torque. - Driveshft shield - Screw (two on ech side) c - Engine end c Description Nm l in. l ft Driveshft shield screw engine end Driveshft U Joints NOTE: In ddition to the tsk nd intervl for inspecting nd luricting the driveshft U joints every 250 hours or one yer (whichever occurs first), you must replce the U joints every 1000 hours or two yers (whichever occurs first). Contct Mercury Diesel uthorized repir fcility for informtion on the nerest driveshft service loction. 90-8M eng OCTOBER 2013 Pge 107

114 Section 5 - Mintennce 1. Remove the driveshft shield on the engine end. - Driveshft shield - Screw (two on ech side) c - Engine end c Remove the top nd ottom driveshft shields on the trnsmission end s shown. c cd - Bottom shield - Driveshft shield upper to lower retining hrdwre (2) c - Top shield d - Driveshft shield retining screw (4) 3. Visully inspect ech U joint ering for:. Sel deteriortion or dmge.. The ppernce of rust or fretting round the yokes. c. If ny of these conditions exist, contct Mercury Diesel uthorized repir fcility for dditionl informtion. 4. Luricte the driveshft U joints through the grese fittings, if equipped, with pproximtely 3 4 pumps from hndheld mechnicl grese gun Driveshft U-joint with grese fittings Tue Ref No. Description Where Used Prt No. Extreme Grese Driveshft slip-joint nd U-joints 8M Apply dhesive to the screw nd olt threds tht re used to retin the driveshft shields. Tue Ref No. Description Where Used Prt No. 10 Loctite 277 Driveshft shield screw nd olt threds Otin Loclly Pge M eng OCTOBER 2013

115 Section 5 - Mintennce 6. Instll the top nd ottom driveshft shields on the trnsmission end s shown. Tighten the driveshft shield retining screws, nuts nd olts to the specified torque. c cd - Bottom shield - Driveshft shield upper to lower retining screw, nut, nd wsher (2) c - Top shield d - Driveshft shield retining screw nd wsher (4) Description Nm l in. l ft QSC nd QSB models Driveshft shield retining screw trnsmission end QSM models Driveshft shield upper to lower retining screw nd nut trnsmission end Instll the engine end driveshft shield. Tighten the screws to the specified torque. - Driveshft shield - Screw (two on ech side) c - Engine end c Description Nm l in. l ft Driveshft shield screw engine end Propeller Shft Remove the propellers. Refer to Propellers. 2. Apply lierl cot of one of the following luricnts to the propeller shft splines M eng OCTOBER 2013 Pge 109

116 Section 5 - Mintennce Tue Ref No. Description Where Used Prt No. Extreme Grese Propeller shft splines 8M C with PTFE Propeller shft splines A 1 3. Instll the propellers. Refer to Propellers. Corrosion nd Corrosion Protection The Cuses of Corrosion NOTICE Wshing the MerCthode ssemly cn dmge components nd led to rpid corrosion. Do not use ny clening equipment such s rushes or high pressure wshers to clen the MerCthode ssemly. Whenever two or more dissimilr metls (like those found on the drive) re sumerged in conductive solution, such s sltwter, polluted wter, or wter with high minerl content, chemicl rection tkes plce cusing electricl current to flow etween metls. The electricl current flow cuses the metl tht is most chemiclly ctive, or nodic, to erode. This is known s glvnic corrosion nd, if not controlled, it will in time cuse the need for replcement of power pckge components exposed to wter. Refer to the Mrine Corrosion Protection Guide ( ). Corrosion Protection These power pckges hve nodes s stndrd equipment to help protect them from glvnic corrosion under moderte conditions. The MerCthode system nd scrificil nodes will provide corrosion protection under norml usge. However, ots connected to AC shore power require dditionl protection to prevent destructive low voltge glvnic currents from pssing through the shore power ground wire. A Quicksilver Glvnic Isoltor cn e instlled to lock the pssge of these currents while providing pth to ground for dngerous fult (shock) currents. Refer to Diesel Prts nd Accessories Guide ( ) or the Mercury Accessories Guide (90 8M ) for prt numers. IMPORTANT: If AC shore power is not isolted from ot ground, the MerCthode System nd nodes my e unle to hndle the incresed glvnic corrosion potentil. Theory of Opertion The MerCthode system provides utomtic protection ginst glvnic corrosion. A solid stte device tht opertes off vessel's ttery, the MerCthode system provides protection y impressing reverse locking current tht stops the destructive flow of glvnic currents. The red MerCthode controller will regulte output to mintin 0.94 volts t the reference electrode. A solid green LED indictes tht the system is operting correctly. A flshing LED indictes tht fult hs occurred, or tht n norml condition exists. IMPORTANT: When ot or new drive is first put into service the LED my initilly indicte tht the protective current is not eing supplied through the MerCthode node. This condition is norml nd, in such cses, the LED my flsh for period of time. The green LED will ecome stedy fter the ot is moored for period of eight hours without opertion. Fult Codes LED Fult Codes 1 flsh every 0.5 seconds Reference volts elow flsh every 4 seconds Reference volts ove long nd 1 short flsh every 10 seconds Thermo shutdown 105 C (221 F) or higher 1 long flsh every 10 seconds Shorted or open reference terminl 2 long flshes every 10 seconds Shorted or open node terminl 1 long flsh every 60 seconds Open node nd reference terminls (dry docked) Anodes nd MerCthode System Anodes help protect ginst glvnic corrosion y scrificing their metl to e slowly eroded insted of the metl components on the drive or vessel. Corrosion protection for the drive is provided y scrificil nodes instlled on the trim ts. Other scrificil nodes my e mounted on the vessel to ensure ginst corrosion of vessel components. Fult Pge M eng OCTOBER 2013

117 H z OFF IG IP TEMP Section 5 - Mintennce IMPORTANT: Scrificil nodes must e inspected periodiclly. Replce the scrificil nodes if they re eroded 50 percent or more. Refer to Scheduled Mintennce. Anodes nd MerCthode System Loctions Description Loction Figure Trim t node pltes Mounted on the trim t The MerCthode system uses reference electrode nd n node ssemly to help protect ginst glvnic corrosion. The MerCthode controller is mounted on the trnsmission. The system should e tested to ensure dequte output. The test should e performed where the ot is moored, using the Quicksilver Reference Electrode nd DMT 2004 digitl multimeter. For testing, contct Mercury Diesel uthorized repir fcility or refer to the pproprite service mnul. Reference Electrode T 1 Senses nd electricl current in the wter when testing the MerCthode system. Use to check hull potentil DMT 2004 Digitl Multimeter A01 V mv H z TEMP m A A Mesures RPM on sprk ignition (SI) engines, ohms, mperes, AC nd DC voltges; records mximums nd minimums simultneously, nd ccurtely reds in high RFI environments. A m A C O M V H z 4516 Anodes nd MerCthode System Loctions Description Loction Figure MerCthode system The MerCthode reference electrode nd node re mounted to the composite cover on the underside of the drive. The MerCthode controller is mounted on the trnsmission. The controller hrness connects the components Other scrificil nodes, if equipped, my e mounted on the vessel to protect ginst glvnic corrosion. Refer to the opertion nd mintennce mnul provided y the ot mnufcturer for dditionl informtion out vessel mounted nodes. 90-8M eng OCTOBER 2013 Pge 111

118 Section 5 - Mintennce Other Anodes nd Loctions Description Loction Figure Anode kit (if equipped) Mounted to the ot trnsom Reference Electrode Wire MerCthode Assemly NOTICE Wshing the MerCthode ssemly cn dmge components nd led to rpid corrosion. Do not use ny clening equipment such s rushes or high pressure wshers to clen the MerCthode ssemly. Do not pressure wsh the reference electrode of the MerCthode ssemly. Doing so dmges the coting on the reference electrode wire nd decreses the corrosion protection. - Anode - Reference electrode wire MerCthode Anode Checking Inspect the MerCthode node nd replce the node if dmged. - Anode - Reference electrode (not visile in this view) Replcing Contct your Mercury Diesel uthorized repir fcility. MerCthode System Testing If the ot is equipped with Quicksilver MerCthode system, test the system to ensure tht it is providing dequte output to protect the underwter metl prts on the ot. The test should e mde where the ot is moored, using Quicksilver Reference Electrode nd Test Meter Pge M eng OCTOBER 2013

119 Section 5 - Mintennce Reference Electrode T 1 Senses the electricl current in the wter when testing the MerCthode system. Use to check hull potentil Contct Mercury Diesel uthorized repir fcility for testing or refer to the pproprite service mnul. Trim T Anode Checking 1. Inspect the trim t nodes. 2. Replce the node if eroded 50 percent or more. Trim t nodes Replcing IMPORTANT: The trim t cylinder is equipped with check vlve to void the lowering of the trim t fter shut down. When service is required lower the trim t efore shutting the engine down. 1. Completely lower the trim t. 2. Remove the five trim t node ttching screws on ech node from the ottom of the trim t Removing the strord node - Screw (5) - Anode Inspect nd replce ny trim t node mounting screws dmged y corrosion. 4. Remove nd discrd the trim t node. 5. Clen the trim t node mounting surfces to re metl. 6. Apply dhesive to the threds of the five trim t node screws. Tue Ref No. Description Where Used Prt No. 7 Loctite 271 Thredlocker Trim t node screw M eng OCTOBER 2013 Pge 113

120 Section 5 - Mintennce 7. Instll the nodes on the trim t. Tighten the screws to specifiction. c - Port node - Strord node c - Screws (5) c Description Nm l in. l ft Trim t node screw (M8 x 20 mm long) Continuity Circuits NOTE: Refer to the opertion nd mintennce mnul provided y the ot mnufcturer for mintennce informtion out vessel mounted nodes nd relted continuity circuits. The drive system is equipped with ground circuit wires to ensure good electricl continuity etween the drive components. Good continuity to ground ( ) is essentil for the node nd MerCthode system to function most effectively. 1. Remove the drive cover. Refer to Removing the Drive Cover in this section. 2. Inspect the MerCthode controller nd wires for loose connections, roken connectors, or fryed wiring. e f - Anode wire - Bttery positive (+) terminl wire c - Bttery negtive ( ) terminl wire d - Reference electrode wire e - MerCthode controller LED f - Bullet connector c d Pge M eng OCTOBER 2013

121 Section 5 - Mintennce 3. Inspect the onding stud, nut, nd continuity wire ( ) on the center section for corrosion, loose connections, roken connectors, or fryed wiring. - Blck/green continuity wire - Nut c - Bonding stud c At the specified intervl, with the ot out of the wter, lower the trim ts nd inspect the continuity wire ( ) locted etween the trim t nd the hinge lock. - Hinge lock - Trim t c - Screw d - Continuity wire d c Inhiiting Corrosion In ddition to the corrosion protection devices, follow these steps to inhiit corrosion: 1. Pint your power pckge. Refer to Pinting the Bot. 2. Spry power pckge components on the inside of the ot nnully with Corrosion Gurd to protect the finish from dulling nd corrosion. 3. Keep ll luriction points well luricted. Pinting the Bot IMPORTANT: The limited wrrnty does not cover corrosion dmge s result of improper pint ppliction. IMPORTANT: Pint on the nodes or reference electrode renders the MerCthode system ineffective. The underwter portion of the drive cn e pinted in order to inhiit mrine growth. Conventionl ntifouling cotings (ottom pint) cn e used, s well s more specilized foul relese cotings (like PropSpeed ). If ottom pint is used, est results will e seen using pint contining copper oxide plus n lgecide dditive. NOTE: PropSpeed is registered U.S. trdemrk of Ocenmx Interntionl, Limited. When pinting drive or ot hull with ntifouling pint, oserve the following: Follow the pint mnufcturer s recommendtions regrding preprtion nd ppliction. Use high qulity, ntifouling pint designed for mrine use. If using copper sed or tin sed pints is necessry, ensure tht you oserve ll locl nd federl lws regulting or prohiiting their use. Do not pint drin holes or items s specified y the ot mnufcturer. Do not pint ny nodes or the MerCthode system components M eng OCTOBER 2013 Pge 115

122 Section 5 - Mintennce Avoid ny electricl interconnection etween the pinted hull nd the drive, nodic locks, trim t nodes, or the MerCthode system. Allow minimum of 25 mm (1 in.) of unpinted re on the hull of the ot round the interfce ring sel (grommet) on models with molded in tunnel opening or round the olt on interfce ring ssemly (if equipped), s shown. If this guideline is not followed, the MerCthode corrosion protection system will e rendered ineffective. Pinted nd unpinted res - Pinted hull - Pinted drive c - Minimum unpinted 25 mm (1 in.) re c If desired, nonconductive ntifouling pint cn e used to inhiit mrine growth in the 25 mm (1 in.) minimum re etween conductive hull nd pinted drive. The propellers cn e coted with foul relese coting (like PropSpeed ) or my remin uncoted. IMPORTANT: The ppliction of ntifouling pint my ffect ot speed nd engine RPM. Wter testing must e performed to ensure tht engines still chieve the minimum rted RPM fter the ppliction of ottom pint. Propellers Propeller Removl! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, remove the key from the key switch, plce the drive in neutrl, nd engge the E stop switch to prevent the engine from strting. 1. Plce lock of wood etween the rer propeller lde nd the trim t. 2. Turn the rer propeller nut counterclockwise to remove the nut Block of wood - Trim t Slide the propeller nd thrust hu off of the propeller shft. Pge M eng OCTOBER 2013

123 Section 5 - Mintennce 4. Using the propeller nut tool, turn the front propeller nut counterclockwise nd remove the nut. - Block of wood - Trim t c - Propeller nut tool c Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Slide the front propeller nd the front thrust hu off the propeller shft. - Front thrust hu - Front propeller c - Front propeller nut c Propeller Repir Some dmged propellers cn e repired. Contct your Mercury Diesel uthorized repir fcility. Propeller Instlltion 28265! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, remove the key from the key switch, plce the drive in neutrl, nd engge the E stop switch to prevent the engine from strting. 1. Lierlly cot the propeller shft splines with one of the following Quicksilver luricnts. Tue Ref No. Description Where Used Prt No C with PTFE Propeller shft splines A M eng OCTOBER 2013 Pge 117

124 Section 5 - Mintennce Extreme Grese Propeller shft splines 8M Luricting the propeller shft splines 2. Slide the front thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 3. Align the splines nd plce the front propeller on the propeller shft. The propeller must fit freely on the propeller shft splines. 4. Instll the front propeller nut. - Front propeller - Nut Plce lock of wood etween the trim t nd the propeller. 6. Tighten the front propeller nut to the specified torque with the propeller nut tool. - Block of wood - Trim t c - Propeller nut tool c Pge M eng OCTOBER 2013

125 Section 5 - Mintennce Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Description Nm l in. l ft Front propeller nut Check the propeller rottion. The propeller must not contct the lower drive housing. 8. Slide the rer thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 9. Align the splines nd plce the rer propeller on the propeller shft. The propeller must fit freely on the propeller shft splines. 10. Instll the rer propeller nut. 11. Plce lock of wood etween the trim t nd the propeller. 12. Tighten the rer propeller nut to the specified torque. - Block of wood - Trim t f Zeus drive propeller ssemly - Front thrust hu - Front propeller c - Front propeller nut d - Rer thrust hu e - Rer propeller f - Rer propeller nut e d c Description Nm l in. l ft Rer propeller nut M eng OCTOBER 2013 Pge 119