Identification Record

Transcription

1 Identifiction Record Plese record the following informtion: The seril numers re the mnufcturer s keys to numerous engineering detils tht pply to your Cummins MerCruiser Diesel product. When contcting Cummins MerCruiser Diesel (CMD) out service, lwys specify model nd seril numers. Drive seril numer loctions - Trnsmission seril numer plte Drive seril numer decl nd stmping Refer to the engine opertion nd mintennce mnul ville from the engine mnufcturer for the loction of the engine dt tg, which contins the engine seril numer nd model numer. Drive Seril Numers Port Strord Engine Model nd Horsepower / Plese record the following informtion: Zeus Drive Seril Numer Trnsmission Seril Numer Port Strord Engine Seril Numer 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) / The description nd specifictions contined herein were in effect t the time this guide ws pproved for printing. CMD, whose policies re sed on 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, U.S.A. Printed in U.S.A. / 2007 Mercury Mrine Cummins QSB nd QSC Zeus Drive Models CMD /

2 2007, Mercury Mrine Mercury, Mercury Mrine, MerCruiser, Mercury MerCruiser, Mercury Rcing, Mercury Precision Prts, Mercury Propellers, Mriner, Quicksilver, #1 On The Wter, Alph, Brvo, Pro Mx, OptiMx, Sport Jet, K Plnes, MerCthode, RideGuide, SmrtCrft, Zero Effort, M with Wves logo, Mercury with Wves logo, nd SmrtCrft logo re ll registered trdemrks of Brunswick Corportion. Mercury Product Protection logo is registered service mrk of Brunswick Corportion. 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. 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 Cummins MerCruiser Diesel products. We sincerely hope your oting will e plesnt. Cummins MerCruiser Diesel Wrrnty Messge The product you hve purchsed comes with limited wrrnty from Cummins MerCruiser 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. 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. These sfety lerts follow ANSI stndrd Z for product sfety informtion in product mnuls, instructions, nd other collterl mterils. Oserve them crefully. These Sfety Alerts lone cnnot eliminte the hzrds tht they signl. Strict complince with these specil instructions while performing the service, plus common sense opertion, re mjor ccident prevention mesures.! 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.

3 ! 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.! 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.

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5 TABLE OF CONTENTS Section 1 - Limited Wrrnty Wrrnty Informtion...2 Wrrnty Registrtion United Sttes nd Cnd...2 Wrrnty Registrtion Outside the United Sttes nd Cnd...2 Limited Wrrnty Coverge...3 Zeus Drive Limited Wrrnty Aginst Corrosion (Worldwide)...7 Emission Wrrnty...8 Trnsfer Of Wrrnty...8 Section 2 - Getting to Know Your Power Pckge Generl Informtion...12 Models Covered...12 Drive Seril Numer nd Decl Plcement...12 Fetures nd Controls...12 Emergency Stop (E Stop) Switch...12 Instrumenttion...13 VesselView...13 Digitl Guges (If Equipped)...13 Anlog Guges (If Equipped)...14 Electronic Helm Steering...15 Dul Hndle Electronic Remote Control (ERC) with DTS Trckpd Fetures nd Opertion..15 Opertion...15 Bsic Joystick Opertion...17 Electricl System Overlod Protection...17 Vessel Interfce Pnel (VIP) Overlod Protection...18 Overlod Protection for Other Circuits...18 Zeus Drive Alignment...18 Section 3 - On The Wter Sfe Boting Suggestions...20 Be Alert To Cron Monoxide Poisoning...21 Good Ventiltion...21 Poor Ventiltion...22 Bsic Bot Opertion...22 Freezing Temperture nd Cold Wether Opertion...22 Drin Plug nd Bilge Pump...23 Protecting People in the Wter...23 While the Bot is Moving...23 While the Bot is Sttionry...23 Wve nd Wke Jumping...24 Impct with Underwter Hzrds...24 Zeus Drive Impct Protection...25 Conditions Affecting Bot Opertion...25 Weight Distriution (Pssengers nd Ger) Inside the Bot...25 Bottom Of Bot...26 Cvittion...26 Ventiltion...26 Propeller Selection...26 Getting Strted...27 Brek In Period (New or With Replcement Gers)...27 CMD / AUGUST 2007 Strting nd Stopping the Engines...27 Norml Strting...27 Norml Stopping...28 Strting the Engines Mnul Override...28 Stopping the Engines Mnul Override...30 Trditionl Mneuvering with Steering nd Thrust...30 To Mneuver the Bot in Forwrd...31 To Steer the Bot in Tight Turns t Low Speeds...31 To Spin the Bot on its Axis t Low Speeds 31 Mneuvering with the Joystick...31 Trim T Override...35 Mnul Adjustment...35 Trim T Override Use...36 Getting on Plne...36 Smoothing the Ride...36 Correcting List...36 Low Speed Trim...36 Pge i

6 Specil Digitl Throttle nd Shift (DTS) Fetures...37 Troll nd Throttle Response...38 Dock...39 Throttle Only (One) Lever...40 Sync...40 Cruise Control Precision Pilot Trck Pd Fetures...41 Generl Informtion Stndy...42 Stndy nd Active Lights Power Icon...43 Skyhook Skyhook Screen Notes...45 Engging Skyhook...46 Disengging Skyhook...46 Turn Buttons Auto Heding...48 Disengge Auto Heding...49 To Resume to Heding...50 Trck Wypoint...51 Engging Trck Wypoint Mode...52 Disengging Trck Wypoint Mode...53 Turn Button or Joystick in Trck Mode Auto Heding Button in Trck Mode...53 Acknowledging Turn During Wypoint Arrivl...54 Wypoint Sequence...55 Wypoint Acknowledge...56 Response Button Chnging VesselView Mode Disply Times End of First Seson Checkup Contingent Opertions Bckup Steering System...59 Port Engine Only Opertion Ger Enggement Emergency Procedure. 59 Section 4 - Specifictions Drive Ger Luricnt Trnsmission...62 Steering Actutor nd Trim Fluid...62 Approved Pints...62 Approved Luricnts Section 5 - Mintennce Product Responsiilities...66 Owner nd Opertor Responsiilities Deler Responsiilities...66 Do It Yourself Mintennce Suggestions Inspection...67 Drive Cover Removing the Drive Cover...67 Clening nd Inspecting the Drive Cover Instlling the Drive Cover...68 Mintennce Schedules...69 Appliction...69 Routine Mintennce Scheduled Mintennce...69 Mintennce Log...70 Drive Ger Lue...72 Checking Filling...73 Chnging...74 With the Bot in the Wter...74 With the Bot Out of the Wter...77 Steering Actutor nd Trim Fluid...79 Checking Filling...80 Chnging...80 Trnsmission Fluid Checking Filling...82 Chnging...83 Sewter Striner...86 Bttery...87 Guges...87 Checking Guges...87 Clening Guges Electricl System...87 Cooling System nd Exhust System Luriction...88 Driveshft Slip Joint Secock Sewter Return (Overord) Propeller Shft Corrosion Protection...90 Anodes nd MerCthode System Reference Electrode Wire of the MerCthode System MerCthode Anode...92 Checking...92 Replcing...92 Pge ii CMD / AUGUST 2007

7 MerCthode System Testing...92 Trim T Anodes...93 Checking...93 Replcing...93 Continuity Circuits...93 Inhiiting Corrosion...94 Pinting the Bot...94 Propellers...95 Propeller Removl...95 Propeller Repir...97 Propeller Instlltion...97 Section 6 - Storge Cold Wether (Freezing Temperture) Storge nd Sesonl Storge Storge Descriptions Prepring the Power Pckge for Storge Drive Storge Engine Storge Bttery Storge Recommissioning Engine Drive Power Pckge Section 7 - Trouleshooting Dignosing Electroniclly Controlled Fuel System Prolems Electricl Connections Trouleshooting Chrts Trouleshooting Engine Relted Prolems..106 Check VesselView First Poor Performnce Joystick Electronic Remote Controls Steering System Trim Ts Bot Response Chnges Bttery Will Not Chrge Guges nd Instrumenttion 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 Customer Service Literture English Lnguge Other Lnguges Andre sprog Andere tlen Muut kielet Autres lngues Andere Sprchen Altre lingue Andre språk Outros Idioms Otros idioms Andr språk Allej glþssej Ordering Literture United Sttes nd Cnd Outside The United Sttes nd Cnd CMD / AUGUST 2007 Pge iii

8 Pge iv CMD / AUGUST 2007

9 Tle of Contents Section 1 - Limited Wrrnty Section 1 - Limited Wrrnty 1 Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd...2 Wrrnty Registrtion Outside the United Sttes nd Cnd...2 Limited Wrrnty Coverge...3 Zeus Drive Limited Wrrnty Aginst Corrosion (Worldwide)...7 Emission Wrrnty...8 Trnsfer Of Wrrnty...8 CMD / AUGUST 2007 Pge 1

10 Section 1 - Limited Wrrnty Wrrnty Informtion Wrrnty Registrtion United Sttes nd Cnd The CMD wrrnty registrtion center will coordinte wrrnty registrtion for oth CMD/Cummins nd Mercury Mrine products, only one Wrrnty Registrtion Form is required to e filed for ech engine/drive system. 1. To ensure tht your wrrnty coverge egins promptly, your selling deler should fill out the Wrrnty Registrtion Crd completely nd mil it to the fctory immeditely upon sle of the new product. 2. The Wrrnty Registrtion Crd identifies the nme nd ddress of the originl purchser, product model nd seril numer(s), dte of sle, type of use nd selling deler s code, nme, nd ddress. The deler lso certifies tht you re the originl purchser nd user of the product. A temporry Owner Wrrnty Registrtion Crd will e presented to you when you purchse the product. 3. Upon receipt of the Wrrnty Registrtion Crd t the fctory, you will e sent n owner resource guide tht includes your wrrnty registrtion confirmtion. If you do not receive your owner resource guide within 60 dys from dte of new product sle, plese contct your selling deler. 4. Becuse of your selling deler s ongoing interest in your stisfction, the product should e returned to him for wrrnty service. 5. The product wrrnty is not effective until the product is registered t the fctory. NOTE: Registrtion lists must e mintined y the fctory nd deler on mrine products sold in the United Sttes in the event tht sfety recll notifiction under the Federl Bot Sfety Act is required. 6. You my chnge your registrtion ddress t ny time, including t time of wrrnty clim, y clling CMD or sending letter or fx with your nme, old ddress, new ddress, nd engine seril numer to CMD's wrrnty registrtion deprtment. Your deler cn lso process this chnge of informtion. United Sttes customers or delers my contct: Cummins MerCruiser Diesel LLC, Inc. Attn: Wrrnty Registrtion Deprtment 4500 Leeds Avenue - Suite 301 Chrleston, South Crolin Fx Fx 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 Cummins MerCruiser Diesel Distriutor or Cummins MerCruiser Diesel Authorized Deler 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. Pge 2 CMD / AUGUST 2007

11 Section 1 - Limited Wrrnty 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 Cummins MerCruiser Diesel Distriutor or Cummins MerCruiser Diesel Authorized Deler will receive 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. Center will issue you permnent (plstic) Wrrnty Registrtion Crd within 30 dys fter 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 Cummins MerCruiser Diesel Distriutor or Cummins MerCruiser Diesel Authorized Deler fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re. Limited Wrrnty Coverge Engines nd Drive Systems Included in this Coverge Products Wrrnted High Output Rting Mrine Propulsion Zeus 3500 Zeus 3800 Bse Engine nd Drive Limited Wrrnty This limited wrrnty pplies to new Engines nd Drive Systems sold y Cummins MerCruiser Diesel LLC. Inc., herein fter "CMD", tht re rnded s Cummins MerCruiser Diesel products nd used in Mrine pplictions nywhere in the world where CMD pproved service is ville 1. nd delivered to the first user on or fter Septemer 1, This limited wrrnty excludes ll Engines rnded nd sold s Cummins Mrine Diesel products. The Product consists of new CMD Engine nd Drive System, s well s ccessories, which re pproved nd supplied y CMD nd Cummins, nd which re either instlled y CMD or CMD uthorized distriutor. These Products hve the following designtion: Intended for use in vrile lod pplictions where full power is limited to one hour out of every eight hours of opertion. Reduced power must e t or elow 200 RPM of the mximum RPM. This power rting is for plesure crft pplictions tht operte less thn 500 hours per yer. This limited wrrnty covers ny filures of the Product, under norml use nd service, which result from defect in CMD mteril or fctory workmnship (Wrrntle Filure) Underwter impct dmge is not wrrntle filure. Coverge egins with the retil sle of the Engine nd Drive y CMD nd continues for the Durtion stted in the following tle. The Durtion commences on either the dte of delivery of the Product to the first user, or the dte the unit is first lesed, rented or loned, or when the Product hs een operted for 125 hours, whichever occurs first. Commercil use of this 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, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. 1. Loctions in the United Sttes nd Cnd re listed in the Cummins United Sttes nd Cnd Sles nd Service Directory; other loctions re listed in the Cummins Interntionl Sles nd Service Directory. CMD / AUGUST 2007 Pge 3

12 Section 1 - Limited Wrrnty Two Yer Limited Wrrnty Limited Wrrnty Coverge Coverge Durtion (whichever occurs first) Coverge Ctegory Months Hours Prts Lor Repir Chrge Pid y CMD Removl nd Instlltion Lor Bse Engine Wrrnty Yes Yes Yes Yes Extended Mjor Components Yes Yes Yes Yes Extended Mjor Components Limited Wrrnty Trvel The Extended Mjor Components Limited Wrrnty provision is concurrent with the Bse Engine nd Drive Limited Wrrnty nd continues eyond the expirtion of the Bse Engine nd Drive Limited Wrrnty for n dditionl four yers or 2000 hours whichever occurs first. The Extended Mjor Components Limited Wrrnty covers Wrrntle Filures of the following Engine nd Drive prts or cstings (Covered prts): Engine: Engine Cylinder Block nd Hed Csting Engine Cmshft nd Crnkshft Forging Engine Connecting Rod Forging Engine Ger Trin Gers: Crnkshft Ger Cmshft nd Cmshft Idler Ger Accessory Drive Ger Fuel Pump Ger Engine Ger Cover Csting Flywheel Housing Csting Bushing nd ering filures re NOT covered. Drive: Mrine Ger Housing Mrine Ger Drop Box Housing Steering Actutor Housing Csting Drive Mid section Csting Lower Ger Housing Csting (Underwter Impct Dmge Excluded) Trim T Csting (Underwter Impct Dmge Excluded) Bering Crrier Csting (Underwter Impct Dmge Excluded) Drive Shft (Less U joints) Intermedite Shft (Underwter Impct Dmge Excluded) Clmp Rings Steering nd Trim Oil Tnk Skeg (Underwter Impct Dmge Excluded) Consumer Products Pge 4 CMD / AUGUST 2007

13 Section 1 - Limited Wrrnty The wrrnty on Consumer Products in the United Sttes is limited wrrnty. CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied wrrnties pplicle to Consumer Products terminte concurrently with the expirtion of the express wrrnties pplicle to the Product. In the United Sttes, some sttes do not llow the exclusion of incidentl or consequentil dmges, or limittions on how long n implied wrrnty lsts, so the limittions or exclusions herein my not pply to you. These wrrnties re mde to ll Owners in the chin of distriution nd Coverge continues to ll susequent Owners until the end of the periods of Coverge. CMD Responsiilities During the Bse Engine Limited Wrrnty CMD will py for ll prts nd lor needed to repir the dmge to the Product resulting from Wrrntle Filure when performed during norml usiness hours. All lor costs will e pid in ccordnce with Cummins nd Mercury Mrine's pulished Stndrd Repir Time guidelines. When it is necessry for mechnics to mke on site wrrnty repirs, CMD will py resonle trvel expenses, including mels, milege nd lodging, for mechnics to trvel to nd from the repir dock. CMD will py for the luricting oil, ntifreeze, filter elements, nd other mintennce items tht re not reusle due to the Wrrntle Filure. CMD will py for resonle lor costs for Engine nd Drive System removl nd reinstlltion when necessry to repir Wrrntle Filure. During the Extended Mjor Components Limited Wrrnty CMD will py for prts nd lor for the repir or, t its option, the replcement of the defective covered prt nd ny covered prt dmged y wrrntle filure of the defective covered prt. Owner Responsiilities During Both the Bse Engine nd Drive System nd the Extended Mjor Components Limited Wrrnties Owner is responsile for the cost of luricting oil, ntifreeze, filter elements, nd other mintennce items replced during wrrnty repirs unless such items re not reusle due to the Wrrntle Filure. During the Extended Mjor Components Limited Wrrnties Owner is responsile for the cost of ll prts nd lor required for the repir except for the defective Covered Prt nd ny Covered Prt dmged y Wrrntle Filure of the defective Covered Prt. Owner is responsile for the opertion nd mintennce of the Product s specified in the pplicle Cummins, MerCruiser, or CMD Opertion nd Mintennce Mnul. Owner is lso responsile for providing proof tht ll recommended mintennce hs een performed. Exceeding the opertionl prmeters of the HO rting will void this wrrnty. The owner of the ot is ultimtely responsile for ensuring the engine nd drive system is properly operted nd mintined. The wrrnty will e void on ny Engines nd Drives tht re mispplied, not mintined properly or misused. Before the expirtion of the pplicle wrrnty, Owner must notify CMD distriutor, uthorized deler, or other repir loction pproved y CMD of ny Wrrntle Filure nd mke the Engine nd Drive System ville for repir y such fcility. Loctions in the United Sttes nd Cnd re listed in the Cummins U.S. nd Cnd Sles nd Service Directory; other loctions re listed in the Cummins Interntionl Sles nd Service Directory. In the event of ny Product filure, Owner is responsile for the cost of towing the ot to the repir dock nd for ll ssocited docking, storge, nd hror chrges. Owner is responsile for communiction expenses, mels, lodging, nd similr costs incurred s result of Wrrntle Filure. Owner is responsile for mintining the Engine hour meter in good working order t ll times nd to ensure tht the hour meter ccurtely reflects the totl hours of opertion of the Product. Owner is responsile for the costs to investigte complints, unless the prolem is cused y defect in CMD mteril or fctory workmnship. Owner is responsile for non Engine nd non Drive System repirs, "downtime" expenses, crgo dmge, fines, ll pplicle txes, ll usiness costs, nd other losses resulting from Wrrntle Filure. Limittions CMD / AUGUST 2007 Pge 5

14 Section 1 - Limited Wrrnty CMD is not responsile for filures or dmge resulting from wht CMD determines to e use or neglect, including, ut not limited to: opertion without dequte coolnts or luricnts; over fueling; over speed; lck of system mintennce to the engine nd drive: improper storge, strting, wrm up, run in or shutdown prctices, corrosion of Engine or Drive due to lck of mintennce; unuthorized modifictions to the Engine or Drive. CMD is lso not responsile for filures cused y incorrect oil or fuel or y wter, dirt or other contminnts in the fuel or oil. CMD is not responsile for filure resulting from: 1. Use or ppliction of the Product inconsistent with its rting designtion set forth ove. 2. Incorrect instlltion. 3. Engines tht do not rech rted RPM ecuse of issues unrelted to the engine (for exmple, overloding the vessel, selecting n engine with insufficient horsepower for the vessel, improper ger nd/or propeller selection, indequte hull mintennce, etc.). 4. Use of improper propellers. 5. The lck of completing pulished mintennce procedures. Before clim for excessive oil consumption will e considered, Owner must sumit dequte documenttion to show tht oil consumption exceeds CMD pulished stndrds. CMD does not wrrnt ccessories or prts tht re not supplied y Cummins/Mercury Mrine Fctory. CMD is not responsile for filures of mintennce Components supplied y Cummins/Mercury Mrine eyond 90 dys After the coverge durtion strt dte. Mintennce Components include, ut re not limited to: se wter pump impellers; zinc plugs; oil filters; fuel filters; ir filters; wter filters; nd fuel/wter seprtor filters. Except for the ccessories noted previously, CMD does not wrrnt ccessories which er the nme of nother compny. Prts used in wrrnty repirs my e new Cummins/Mercury Mrine prts, or Cummins / Mercury Mrine pproved reuilt or repired prts. CMD is Not responsile for filures resulting from the use of Prts not supplied y Cummins/Mercury Mrine. A new Cummins/Mercury Mrine prt or Cummins / Mercury Mrine pproved reuilt prt used to replce Wrrnted Prt ssumes the identity of the Wrrnted Prt it replced nd is entitled to the remining coverge hereunder. CMD DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS. CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. THESE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CMD IN REGARD TO THESE ENGINES. CMD MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. In the United Sttes 2. nd Cnd, this wrrnty gives you specific legl rights, nd you my lso hve other rights which vry from stte to stte. Outside the United Sttes 3. nd Cnd, in cse of consumer sles, in some countries the Owner hs sttutory rights which cnnot e ffected or limited y the terms of this wrrnty. Nothing in this wrrnty excludes or restricts ny contrctul rights the Owner my hve ginst third prties. 2. United Sttes includes Americn Smo, the Commonwelth of Northern Mrin Islnd, Gum, Puerto Rico nd the U.S. Virgin Islnds. 3. United Sttes includes Americn Smo, the Commonwelth of Northern Mrin Islnd, Gum, Puerto Rico nd the U.S. Virgin Islnds. Pge 6 CMD / AUGUST 2007

15 Section 1 - Limited Wrrnty Zeus Drive Limited Wrrnty Aginst Corrosion (Worldwide) Wht Is Covered Durtion of Coverge Cummins MerCruiser Diesel wrrnts the Zeus Drive (Product) will not e rendered inopertive s direct result of corrosion for the period of time descried elow. This limited corrosion wrrnty provides coverge for three (3) yers / 1500 Hours 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 reregistrtion of the product. Wrrnty coverge is terminted for used product repossessed from retil customer, purchsed t uction, from slvge yrd, or from n insurnce compny tht otined the product s result of n insurnce clim. Conditions Tht Must Be Met to Otin Wrrnty Coverge Wht Cummins MerCruiser Diesel Will Do How to Otin Wrrnty Coverge Wht Is Not Covered 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. Cummins MerCruiser Diesel reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. Cummins MerCruiser Diesel nd Mercury'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 CMD / Mercury Mrine certified, remnufctured prts, or refunding the purchse price of the CMD / Mercury product. CMD / Mercury reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. The customer must provide Cummins MerCruiser Diesel with resonle ccess to the product for wrrnty service nd resonle opportunity to repir the product. Cummins MerCruiser Diesel deler will rrnge for the inspection nd ny covered repir. 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. Purchser shll not, unless requested y Cummins MerCruiser Diesel, ship the product or prts of the product directly to Cummins MerCruiser Diesel. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge. This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge; corrosion tht cuses purely cosmetic dmge; use or improper service; corrosion to ccessories, instruments, or steering systems; dmge due to mrine growth; replcement prts (prts purchsed y the customer); products used in commercil ppliction. 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 wrrnty period, even if the product is only occsionlly used for such purposes. CMD / AUGUST 2007 Pge 7

16 Section 1 - Limited Wrrnty Emission Wrrnty Product Wrrnted Coverge Limittions This Emission Wrrnty pplies to new Engines certified to United Sttes EPA 40 CFR 94 sold y CMD tht re instlled in vessels flgged or registered in the Unites Sttes CMD wrrnts to the first user nd ech susequent purchser tht the Engine is designed, uilt, nd equipped so s to conform t the time of sle y CMD with ll U.S. Federl emission regultions pplicle t the time of mnufcture nd tht it is free from defects in workmnship or mteril which would cuse it not to meet these regultions within the longer of the following periods: 1. Five yers or 500 hours of opertion, whichever occurs first, The Emissions Wrrnty strts from the dte of delivery of the Engine to the first user, or the dte the unit is first lesed, rented, or loned, or when the Engine hs een operted for 50 hours, whichever occurs first, or 2. The Bse Engine Wrrnty. The owner my elect to hve mintennce, replcement, or repir of the emission control prts performed y fcility other thn CMD distriutor, n uthorized deler or repir loction pproved y CMD, nd my elect to use prts other thn new genuine Cummins/Mercury Mrine or Cummins / Mercury Mrine pproved reuilt prts nd ssemlies for such mintennce, replcement or repir; however, the cost of such service or prts nd susequent filures resulting from such service or prts will not e covered under this emission control system wrrnty. Filures, except those resulting from defect in mterils, or fctory workmnship, re not covered y the WARRANTY. CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. In the United Sttes 3. nd Cnd, this wrrnty gives you specific legl rights, nd you my lso hve other rights which vry from stte to stte. Outside the United Sttes 4. nd Cnd, in cse of consumer sles, in some countries the Owner hs sttutory rights which cnnot e ffected or limited y the terms of this wrrnty. Nothing in this wrrnty excludes or restricts ny contrctul rights the Owner my hve ginst third prties 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 CMD's wrrnty registrtion deprtment. In the United Sttes mil to: Cummins MerCruiser Diesel LLC, Inc. Attn: Wrrnty Registrtion Deprtment 4500 Leeds Avenue - Suite 301 Chrleston, South Crolin Fx Fx Upon processing the trnsfer of wrrnty, CMD will send registrtion verifiction to the new owner of the product y mil. There is no chrge for this service. 1. Loctions in the United Sttes nd Cnd re listed in the Cummins United Sttes nd Cnd Sles nd Service Directory; other loctions re listed in the Cummins Interntionl Sles nd Service Directory. 2. United Sttes includes Americn Smo, the Commonwelth of Northern Mrin Islnds, Gum, Puerto Rico, nd the U.S. Virgin Islnds. 3. United Sttes includes Americn Smo, the Commonwelth of Northern Mrin Islnds, Gum, Puerto Rico, nd the U.S. Virgin Islnds. 4. United Sttes includes Americn Smo, the Commonwelth of Northern Mrin Islnds, Gum, Puerto Rico, nd the U.S. Virgin Islnds. Pge 8 CMD / AUGUST 2007

17 Section 1 - Limited Wrrnty For products purchsed outside the United Sttes nd Cnd, contct the Cummins MerCruiser Diesel Distriutor or Cummins MerCruiser Diesel distriutor in your country. CMD / AUGUST 2007 Pge 9

18 Section 1 - Limited Wrrnty Notes: Pge 10 CMD / AUGUST 2007

19 Section 2 - Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tle of Contents Generl Informtion Models Covered...12 Drive Seril Numer nd Decl Plcement...12 Fetures nd Controls Emergency Stop (E-Stop) Switch...12 Instrumenttion...13 VesselView Digitl Guges (If Equipped)...13 Anlog Guges (If Equipped)...14 Electronic Helm Steering...15 Dul-Hndle Electronic Remote Control (ERC) with DTS Trckpd Fetures nd Opertion...15 Opertion Bsic Joystick Opertion...17 Electricl System Overlod Protection...17 Vessel Interfce Pnel (VIP) Overlod Protection Overlod Protection for Other Circuits Zeus Drive Alignment CMD / AUGUST 2007 Pge 11

20 Section 2 - Getting to Know Your Power Pckge Generl Informtion Models Covered Models Covered Engine Model nd Rting Seril Numer Or Yer Zeus 3500 QSB (High Output) QSB Intermittent QSB (HO) QSB (HO) QSB (HO) Informtion not ville t time of printing Zeus 3800 QSC (HO) Informtion not ville t time of printing Drive Seril Numer nd Decl Plcement Seril numers re the mnufcturer's key to numerous engineering detils tht pply to your drive. Drive seril numer loctions - Trnsmission seril numer plte - Drive seril numer decl nd stmping Fetures nd Controls 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. Emergency Stop (E Stop) Switch The emergency stop (E stop) switch turns off the engines in n emergency sitution, such s person overord or tngled propeller. When ctivted, the E stop switch interrupts the power supply to the min power rely, including power to the guges, steering, nd ccessories. Activtion of the E stop switch stops the engines immeditely, ut the ot continues to cost for some distnce depending upon the velocity nd degree of ny turn t shutdown. However, the ot does 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 recommend instructing other occupnts on proper strting nd operting procedures should they need to operte the engine in n emergency. Pge 12 CMD / AUGUST 2007

21 Section 2 - Getting to Know Your Power Pckge 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, 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. Opertor cn lose power nd directionl control in hevy ses, strong current, or high winds. Opertor cn lose control when docking. Instrumenttion VESSELVIEW VesselView is the primry informtion source for the Zeus drive, ll engine informtion, fult codes, tnk levels, ot direction, nd clirtions. Refer to the VesselView Opertors Mnul for more informtion. VesselView DIGITAL GAUGES (IF EQUIPPED) The Cummins MerCruiser Diesel SmrtCrft instrument pckge ugments the informtion provided y VesselView. A few of the functions the instrument pckge cn disply re: Engine RPM Bot speed Coolnt temperture Oil pressure Bttery voltge Fuel consumption CMD / AUGUST 2007 Pge 13

22 Section 2 - Getting to Know Your Power Pckge Engine operting hours c Typicl SmrtCrft guges - Tchometer - Speedometer c - LCD System View disply The SmrtCrft instrument pckge lso ids in identifying the fult codes ssocited with the sounding of the engine udio wrning system. The SmrtCrft instrument pckge displys criticl engine lrm dt nd other potentil prolem res on its LCD disply. Refer to the mnul provided with your guge pckge for sic opertion informtion on the SmrtCrft Instrument pckge nd for detils on the wrning functions monitored y the system. ANALOG GAUGES (IF EQUIPPED) Other instrumenttion pckges hve guges tht ugment the informtion provided y VesselView. The owner nd opertor should e fmilir with ll the instruments nd their functions on the ot. Becuse of the lrge vriety of instrumenttion nd mnufcturers, hve your ot deler explin the guges nd norml redings tht pper on your ot. The following types of guges my e included with your power pckge KPH MPH X R P M L OIL H BATT C TEMP H c d e FUEL CRUISELOG f g h i Pge 14 CMD / AUGUST 2007

23 Electronic Helm Steering Item Guge Function Speedometer Indictes ot speed. Tchometer Indictes engine RPM. c Oil pressure guge Indictes engine oil pressure. d Voltmeter Indictes ttery voltge. Section 2 - Getting to Know Your Power Pckge e Wter temperture guge Indictes engine operting temperture. f Fuel guge Indictes quntity of fuel in tnk. g Hour meter Records engine operting time. h Bilge lower switch Opertes ilge lower. i Ignition switch Allows opertor to strt nd stop engine. The Electronic Helm Steering is true drive y wire system tht controls the steering through electronic signls. The feel of the steering is creted y computer designted resistnce. We recommend tht you drive crefully until you hve chnce to explore the Zeus system's hndling chrcteristics in n open re without ostructions or other ot trffic, nd you re fmilir with the ot's responses. The steering is two turns lock to lock, providing fst steering response. The first few mneuvers t speed cn e more rupt thn expected. The numer of turns lock to lock is djustle y the distriutor, if desired. Dul Hndle Electronic Remote Control (ERC) with DTS Trckpd Fetures nd Opertion OPERATION The electronic remote control (ERC) hndle controls the opertion of shift nd throttle. 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. CMD / AUGUST 2007 Pge 15

24 Section 2 - Getting to Know Your Power Pckge NOTE: In certin modes, ger position is determined y the position of the shift vlves on the trnsmission, not the position of the ERC levers. When using the joystick or while in Skyhook, the computer moves the trnsmission in nd out of ger even though the hndles re in neutrl. c d - Neutrl - Forwrd c - Reverse d - Bow of ot The mount of force needed to move the ERC hndles nd to move the ERC hndles through the detents is djustle to help prevent unwnted motion of the hndle in rough wter. To djust ERC hndle tension: 1. Remove the side cover. 2. Turn the screw clockwise to increse tension on the control hndle nd counter clockwise to decrese tension. 3. Adjust to tension desired. To djust ERC hndle detent tension: 1. Remove the side cover. 2. Turn the screw clockwise to increse tension on the control hndle nd counter clockwise to decrese tension. Pge 16 CMD / AUGUST 2007

25 Section 2 - Getting to Know Your Power Pckge 3. Adjust to tension desired Bsic Joystick Opertion Strord side with side cover removed. - ERC hndle tension screw - ERC hndle detent tension screw 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. 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 high current drw, turn off or disconnect ll the ccessories connected to the engine nd instrumenttion wiring. Reset the circuit reker. If the reker remins open, the electricl overlod hs not een eliminted. Contct your Cummins MerCruiser Diesel Authorized Repir Fcility to check the electricl system. Circuit rekers nd fuses provide protection for the electricl system s indicted. The circuit rekers 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. CMD / AUGUST 2007 Pge 17

26 Section 2 - Getting to Know Your Power Pckge VESSEL INTERFACE PANEL (VIP) OVERLOAD PROTECTION The Vessel Interfce Pnel (VIP) contins six circuit rekers tht help protect the trnsmission hrness, engine hrness, vessel sensor hrness, nd helm hrness. c d e f Port shown, strord similr Item Circuit Breker Rting Protection Loction on VIP 15 Ger Upper left 10 SIM/Vessel Middle left c 10 Helm Lower left d 5 Engine Dignostics Upper right e 5 VIP Dignostics Middle right f 25 Min Lower right The VIP itself is protected y 30 mp in line fuse etween the ttery nk nd the VIP. The in line fuse is often locted on the fuse pnel. Ask your deler for the loction. OVERLOAD 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. Ask your deler for the loction nd opertion instructions of ll overlod protection devices. Circuit rekers re used to protect the ckup hydrulic system. The 30 mp rekers, one for ech drive, re instlled y the ot mnufcturer nd my vry in ppernce nd loction. Ask your deler for the loction nd operting instructions. 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. Zeus Drive Alignment The Zeus Drives re ligned y the ot mnufcturer, nd must not e djusted y nyone other thn your Cummins MerCruiser Diesel Authorized Service nd Repir Fcility. The Zeus drives utomticlly reclirte to this setting t ech strtup. The drives do not need to e re ligned under norml use. Pge 18 CMD / AUGUST 2007

27 Tle of Contents Section 3 - On The Wter Section 3 - On The Wter Sfe Boting Suggestions Be Alert To Cron Monoxide Poisoning...21 Good Ventiltion Poor Ventiltion Bsic Bot Opertion Freezing Temperture nd Cold Wether Opertion...22 Drin Plug nd Bilge Pump...23 Protecting People in the Wter...23 While the Bot is Moving While the Bot is Sttionry Wve nd Wke Jumping...24 Impct with Underwter Hzrds...24 Zeus Drive Impct Protection...25 Conditions Affecting Bot Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot...25 Bottom Of Bot...26 Cvittion...26 Ventiltion...26 Propeller Selection...26 Getting Strted Brek-In Period (New or With Replcement Gers)...27 Strting nd Stopping the Engines...27 Norml Strting Norml Stopping Strting the Engines Mnul Override Stopping the Engines Mnul Override Trditionl Mneuvering with Steering nd Thrust...30 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...31 Trim T Override...35 Mnul Adjustment Trim T Override Use Getting on Plne Smoothing the Ride Correcting List Low Speed Trim Specil Digitl Throttle nd Shift (DTS) Fetures...37 Troll nd Throttle Response Dock Throttle Only (One) Lever Sync Cruise Control...41 Precision Pilot Trck Pd Fetures...41 Generl Informtion Stndy Stndy nd Active Lights Power Icon Skyhook Skyhook Screen Notes Engging Skyhook Disengging Skyhook Turn Buttons Auto Heding Disengge Auto Heding To Resume to Heding Trck Wypoint Engging Trck Wypoint Mode Disengging Trck Wypoint Mode Turn Button or Joystick in Trck Mode Auto Heding Button in Trck Mode Acknowledging Turn During Wypoint Arrivl Wypoint Sequence Wypoint Acknowledge Response Button Chnging VesselView Mode Disply Times End of First Seson Checkup...58 Contingent Opertions Bckup Steering System...59 Port Engine Only Opertion...59 Ger Enggement Emergency Procedure CMD / AUGUST 2007 Pge 19

28 Section 3 - On The Wter Sfe Boting Suggestions In order to sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl oting regultions nd restrictions, nd lso consider the following suggestions. Know nd oey ll nuticl rules nd lws of the wterwys. Cummins MerCruiser Diesel strongly recommends tht ll powerot opertors complete oting sfety course. Courses re offered in the U.S.A. y the U.S. Cost Gurd Auxiliry, the Power Squdron, the Red Cross, nd your stte or provincil oting lw enforcement gency. Inquiries my e mde to the Boting Hotline t or the Bot U.S. Foundtion t BOAT. Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Check sfety equipment on ord. Here re some suggestions of the types of sfety equipment to crry when oting: Approved fire extinguishers Pddle or or Signl devices: flshlight, rockets or flres, flg, nd whistle or horn Trnsistor rdio Tools necessry for minor repirs First id kit nd instructions Anchor nd extr nchor line Wterproof storge continers Mnul ilge pump nd extr drin plugs Spre operting equipment, tteries, uls, nd fuses Drinking wter Compss nd mp or chrt of the re 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, werle type life jcket (personl flottion device), correctly sized nd redily ccessile for every person ord, 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 ord in the sics of strting nd operting the engine nd hndling the ot 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 cpcity plte). Know your ot s operting nd loding limittions. Know if your ot will flot if full of wter. When in dout, contct your uthorized Cummins MerCruiser Diesel deler/distriutor or the ot mnufcturer. Pge 20 CMD / AUGUST 2007

29 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; 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 e under the influence of lcohol or drugs while oting (it is the lw). Alcohol or drugs impirs 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 operting the ot ove idle or plning trnsition speed. Wtch out for others, keep your eyes on the the wter, nd e wre of your wke. Never drive your ot directly ehind wter skier in cse the skier flls. As n exmple, your ot trveling t 40 km/h (25 MPH) will overtke fllen skier who ws 61 m (200 ft.) in front of you in five seconds. Wtch fllen skiers. When using your ot for wter skiing 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 Boting Accident 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 US $ or 4) there is complete loss of the ot. Seek further ssistnce from locl lw enforcement. Be Alert To Cron Monoxide Poisoning GOOD VENTILATION Cron monoxide is present in the exhust fumes of ll internl comustion engines including the outords, sterndrives nd inord engines tht propel ots, s well s the genertors tht power vrious ot ccessories. Cron monoxide is dedly gs tht is odorless, colorless nd tsteless. Erly symptoms of cron monoxide poisoning, which should not e confused with sesickness or intoxiction, include hedche, dizziness, drowsiness nd nuse.! WARNING Cron monoxide poisoning cn led to unconsciousness, rin dmge, or deth. Keep the ot well ventilted while t rest or underwy nd void prolonged exposure to cron monoxide. Ventilte the pssenger re, open the side curtins or forwrd htches to remove fumes. 1. Exmple of desired ir flow through the ot. mc CMD / AUGUST 2007 Pge 21

30 Section 3 - On The Wter POOR VENTILATION Under certin 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 n operting engine my e exposed to hzrdous level of cron monoxide. 1. Exmples of poor ventiltion while ot is sttionry: - Operting the engine when the ot is moored in confined spce mc Mooring close to nother ot with its engine operting 2. Exmples of poor ventiltion while ot is moving: - Operting the ot with the trim ngle of the ow too high mc Operting the ot with no forwrd htches open (sttion wgon effect) Bsic Bot Opertion Freezing Temperture nd Cold Wether Opertion IMPORTANT: If the ot is operted during periods of freezing temperture, tke precutions to prevent freezing dmge to the power pckge. Dmge cused y freezing is not covered y Cummins MerCruiser Diesel 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 cold wether. 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. In order to operte the engine in tempertures of 0 C (32 F) or lower, oserve the following instructions: At the end of ech dily opertion, completely drin the sewter section of the cooling system to protect ginst dmge y freezing. At the end of ech dily opertion, drin the wter from the wter seprtor, if equipped. Fill the fuel tnk t end of dily opertion to prevent condenstion. Pge 22 CMD / AUGUST 2007

31 Drin Plug nd Bilge Pump Section 3 - On The Wter Use the required permnent type ntifreeze solution to protect components ginst dmge y freezing. Use proper cold wether luriction oil; ensure tht the crnkcse contins sufficient mount. Mke certin tht the ttery is of sufficient size nd is fully chrged. Check tht ll other electricl equipment is in optimum condition. At tempertures of 20 C ( 4 F) nd elow, use coolnt heter to improve cold strting. If operting in rctic tempertures of 29 C ( 20 F) or lower, consult your Cummins MerCruiser Diesel Authorized Repir Fcility for informtion out specil cold wether equipment nd precutions. See Section 6 for cold wether or extended storge relted informtion. 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 Cummins MerCruiser Diesel Limited Wrrnty. Protecting People in the Wter WHILE THE BOAT 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 BOAT IS STATIONARY 21604! 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. CMD / AUGUST 2007 Pge 23

32 Section 3 - On The Wter 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. 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. Pge 24 CMD / AUGUST 2007

33 Impct dmge to the underwter drive components, skeg, or ot. Section 3 - On The Wter 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 n Authorized Cummins MerCruiser Diesel 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 with impct dmge cn result in product dmge, serious injury, or deth. If the ot experiences n impct, hve n Authorized Cummins MerCruiser Diesel Repir Fcility inspect the vessel nd power pckge nd perform repirs s necessry. 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 Authorized Cummins MerCruiser 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 Authorized Cummins MerCruiser Diesel Repir Fcility. 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. 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. CMD / AUGUST 2007 Pge 25

34 Section 3 - On The Wter Improves rough wter ride. Cn cuse the ot to veer ck nd forth (ow steer) t extremes. Bottom Of Bot Cvittion Ventiltion 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 occurs when wter flow cnnot follow the contour of fst moving underwter oject, such s ger housing or propeller. Cvittion permits the propeller to speed up, ut the ot speed to reduce. 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 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 propeller must llow the engine to operte t the Engine Rted RPM (revolutions per minute). Use n ccurte service tchometer to verify engine operting RPM. It is the responsiility of the ot mnufcturer or the selling deler to equip the power pckge with the correct propeller. Refer to the Diesel Prts And Accessories Guide nd red Everything You Need To Know Aout Propellers. Refer to the Mrine Recretionl High Output Propulsion Units QSB nd QSC Opertion nd Mintennce Mnul for the specified Engine Rted RPM. Select propeller tht will llow the engine power pckge to operte t the Engine Rted RPM with full lod on ord. If full throttle opertion is elow the recommended rnge, chnge the propellers to prevent loss of performnce nd possile engine dmge. On the other hnd, operting n engine ove the recommended Engine Rted RPM cuses higher thn norml wer or dmge. After initil propeller selection, the following common prolems my require lower pitch propeller: Wrmer wether nd greter humidity cn cuse loss of RPM (not s significnt on these models). Operting in higher elevtion cuses loss of RPM (not s significnt on these models). Operting with dirty ot ottom cuses loss of RPM. Pge 26 CMD / AUGUST 2007

35 Getting Strted Section 3 - On The Wter Operting with incresed lod (dditionl pssengers or ger) cuses loss of RPM. Becuse of the mny vriles of ot design, only testing will determine the est propeller for prticulr ppliction. Aville propellers re listed in the Diesel Prts And Accessories Guide. Contct your Authorized Cummins MerCruiser Diesel Repir Fcility for ssistnce on propeller selection. 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 5 hours. During the next 5 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. Strting nd Stopping the Engines NORMAL STARTING Your Zeus power pckge is equipped with "SmrtStrt" system, s well s ckup, mnul override engine strt nd stop system. Strt nd stop the engine from the helm using the "SmrtStrt" system, in norml circumstnces. 1. Perform the drive checks listed in Section 5-Routine Mintennce, Ech Dy Strt nd When Refueling. 2. Perform the checks nd steps listed in the engine's opertion nd mintennce mnul ville for this pckge. 3. Open the sewter return secock, if not lredy in the open position. c - Sewter return (overord) secock - Secock hndle c - Hndle in closed position d - Hndle in open position d CMD / AUGUST 2007 Pge 27

36 Section 3 - On The Wter 4. Open the secock for the engine sewter inlet nd the secock (if equipped) for ny ccessory equipment. c d Typicl Secock hndle (in closed position) - Direction to move hndle to open c - Secock for engine sewter inlet d - Secock (if equipped) for ccessory sewter inlet 5. Move the ERC hndles to the neutrl position. 6. Turn the key switch to the on position for ech engine eing strted. 7. Verify tht the engines re sfe to strt. 8. Press nd relese the "START/STOP" utton corresponding to the engine eing strted. The onord computers utomticlly control the strter to chieve successful strt. NORMAL STOPPING Typicl SmrtStrt switch 1. Move the ERC hndles to the neutrl position. 2. When the engines re running, press nd relese the "START/STOP" utton corresponding to the engine to e stopped. 3. Turn the key switch to the off position. STARTING THE ENGINES MANUAL OVERRIDE Under certin circumstnces, the engine control systems my not e le to utomticlly strt n engine. If this is the cse, strt the engine with mnul override switch in the engine room. 1. Perform the drive checks listed in Section 5-Routine Mintennce, Ech Dy Strt nd When Refueling Pge 28 CMD / AUGUST 2007

37 Section 3 - On The Wter 2. Perform the checks nd steps listed in the engine's opertion nd mintennce mnul ville for this pckge. 3. Open the sewter return secock, if not lredy in the open position. c - Sewter return (overord) secock - Secock hndle c - Hndle in closed position d - Hndle in open position d Open the secock for the engine sewter inlet nd the secock (if equipped) for ny ccessory equipment. c d Typicl Secock hndle (in closed position) - Direction to move hndle to open c - Secock for engine sewter inlet d - Secock (if equipped) for ccessory sewter inlet NOTE: The neutrl LED lmps flsh on nd off if the ERC hndles re not in the neutrl position when the key switch is turned to the on position. Also, the propellers do not spin nd the throttles re not ctive until the ERC hndles re first returned to the neutrl position if the engines re strted with the ERC hndles in ger position. Returning the ERC hndles to neutrl stops the neutrl LED lmps from flshing, restoring propeller nd throttle control. 5. Move the ERC hndles to the neutrl position. 6. Turn the key switch to the on position for ech engine to e strted. 7. Verify tht the engines re sfe to strt. 8. Locte the Vessel Interfce Pnel (VIP) in the engine room for ech engine. CMD / AUGUST 2007 Pge 29

38 Section 3 - On The Wter 9. Press nd hold the green "START" utton on the respective VIP until the engine strts. Do not hold the utton for more thn 30 seconds if the engine fils to strt. Allow the strter to cool efore ttempting to strt gin Strord VIP shown - Red mnul "STOP" switch - Green mnul "START" switch STOPPING THE ENGINES MANUAL OVERRIDE Under certin circumstnces, the engine control systems my not e le to utomticlly stop n engine. If this is the cse, stop the engines with the mnul override switch in the engine room. 1. Move the ERC hndles to the neutrl position. 2. Locte the Vessel Interfce Pnel (VIP) for ech engine in the engine room. 3. When the engines re running, press nd hold the respective red "STOP" utton until the desired engine comes to complete stop Strord VIP shown, port similr - Red mnul "STOP" switch - Green mnul "START" switch 4. Turn the key switch to the "OFF" position for ech engine stopped. Trditionl Mneuvering with Steering nd Thrust 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 30 CMD / AUGUST 2007

39 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 MANEUVER THE BOAT IN FORWARD Plce one or oth engines in forwrd ger nd steer with the steering wheel s you would ny comprle ot. TO STEER THE BOAT IN TIGHT TURNS AT LOW SPEEDS To turn the ot in tight turns t low speeds, turn the wheel in the direction of the turn. 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 BOAT ON ITS AXIS AT LOW SPEEDS To spin to the right, plce the strord engine in reverse nd the port engine in forwrd. To spin to the left, plce the port engine in reverse nd the strord engine in forwrd. To increse the rte of turn, simultneously djust ech ERC lever for more throttle. Mneuvering with the Joystick The joystick provides n intuitive driver 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 computer control system to utomticlly clculte the steering ngle of ech drive, the throttle level, nd the proper shift nd clutch slip percentge to push or rotte the ot in direction corresponding to the joystick movement or twist. For exmple, if you move the joystick sidewys, the computer control system pplies thrust to the ot in the sidewys direction. You cn move the joystick in ny direction, nd the ot moves in tht direction without turning. For exmple, moving the joystick to port cuses the ot to move sidewys to port. Rotting the joystick cretes forces tht cuse 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 computer control system utomticlly ttempts to dmpen ow swinging during joystick opertion. If the joystick is not twisted, the computer mesures the yw rte of the ot nd ctively countercts the yw motion of the ot. 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. Mneuvering with the Joystick CMD / AUGUST 2007 Pge 31

40 Section 3 - On The Wter Joystick Input Bot Response Movement (shown from light gry to drk gry) Bot t rest Bot moves forwrd Bot moves ft Bot moves to strord without rotting Pge 32 CMD / AUGUST 2007

41 Joystick Input Bot Response Section 3 - On The Wter Movement (shown from light gry to drk gry) Bot moves to port without rotting Bot moves digonlly forwrd nd to the strord without rotting Bot moves digonlly ft nd to the strord without rotting Bot moves digonlly ft nd to the port without rotting CMD / AUGUST 2007 Pge 33

42 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 counter clockwise Bot moves digonlly forwrd nd to the strord while rotting clockwise Pge 34 CMD / AUGUST 2007

43 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 T Override MANUAL ADJUSTMENT The Zeus drive comes equipped with utomtic trim ts tht operte vi computer control to provide sic performnce control nd efficiency improvements. However, trim override llows mnul djustments for nturl conditions tht ffect the ttitude of the ot. You cn mnully djust the utomtic ts for conditions y using the individul t switches s needed. The trim ts continue to operte normlly with the dditionl djustments until clered or djusted gin, or until chnge in the speed of the ot cuses the ts to utomticlly redjust. CMD / AUGUST 2007 Pge 35

44 Section 3 - On The Wter Activting the override switch turns off the utomtic ts. With the utomtic ts turned off, the port ("PORT") nd strord ("STBD") switches provide totl control of the ts. While this is possile, we do not recommend overriding the utomtic ts, s it is difficult for the opertor to djust the ts s efficiently s the utomtic control. TRIM TAB OVERRIDE USE GETTING ON PLANE SMOOTHING THE RIDE CORRECTING A LIST LOW SPEED TRIM Typicl trim t switches with uto override The utomtic trim t system provided with your Zeus drive does good jo of trimming the vessel under norml conditions. However, conditions re not lwys norml, nd dditionl minor djustments re often desired to fine tune the ot's ttitude for the most comfortle nd efficient opertion. Achieving trim is otining the desired operting ttitude when operting in less thn idel conditions. The following re conditions where dditionl minor djustments to the trim ts might e eneficil. During initil ccelertion, the ts utomticlly drop (ow down) to ring the ot on plne fster, to improve forwrd visiility, nd use less power. As the ot comes on plne, the ts re rought up so the ow not plow. The ts cn e mnully djusted for the est performnce when the ot conditions re temporrily outside the norml operting conditions, s when the ot is fully loded. A hed se cn crete n uncomfortle, jrring ride. Put the ts to mid position. As the wve throws the ow up, ts dmpen the ot's rection, leveling nd smoothing the ride. In following se, put the ts up. This llows the ow to lift, offsetting the wves, which lift the stern. In milder wter, some ots gently porpoise. Drop the ts, little t time, until the lope disppers. Listing my e cused y n unlnced lod. A little down t on the side of the hevy lod levels the ride. List my lso occur in qurter following se. Wves lift the stern unevenly, cusing the ot to pitch forwrd nd roll opposite the lift. If the strord trnsom is lifting, drop the port t little. This removes the listing nd produce dryer, more level ride. In controlled speed zones, mny ots strt to fll off plne s the speed decreses, therey reducing visiility. Lowering oth trim ts keeps ot on plne longer t legl, lower speeds, while mintining level ot ttitude. At idle speed, ow steering (wndering side to side) requires constnt correction to mintin heding. Dropping oth ts cretes stern drg, which improves trcking. Pge 36 CMD / AUGUST 2007

45 Section 3 - On The Wter Ts cn lso help reduce roll. When ot is t rest, wve which normlly cuses rolling must first move wter out of the wy, from ove one t nd elow the other. This dmpens rolling. Specil Digitl Throttle nd Shift (DTS) Fetures The DTS system fetures severl lternte opertionl modes for the Electronic Remote Control (ERC) levers. Any of the listed fetures cn e operted simultneously nd cn help you with: Wrming the engines. Synchronizing the engines. Trolling the vessel for docking opertions. Allowing ccess to the slow speed trolling fetures of the integrted trnsmission system. h g c f e d Item Control c "NEUTRAL" lights "TROLL" "TRANSFER" ERC Levers with DTS Trckpd Function Illuminte when the trnsmission is in the neutrl ger position. The lights flsh when the engine is in throttle only mode. "TROLL" sets the ot speed for slow speed cruising or mneuvering. Allows ot control to e trnsferred to different helm. Refer to Helm Trnsfer d "DOCK" Reduces 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 port lever. Turns off or on the uto synchroniztion feture. Refer to Synchronizing Engines Increses nd decreses settings for vrious functions, like speed of cruise control. CMD / AUGUST 2007 Pge 37

46 Section 3 - On The Wter TROLL AND 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 is commnded etween idle speed nd mximum rted engine speed. To engge Troll mode: "TROLL" utton 1. Plce oth ERC levers in neutrl. 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 Press the "TROLL" utton. The "TROLL" utton light turns off. Pge 38 CMD / AUGUST 2007

47 Section 3 - On The Wter DOCK The Dock mode reduces the RPM throughout the rnge y 50%. This llows etter control of engine power in close qurter situtions THROTTLE ONLY To engge Dock mode: "DOCK" utton 1. Plce oth ERC levers in neutrl. 2. Press the "DOCK" utton locted on the DTS Trckpd ttched to the ERC levers. 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 ny detent. 2. Press the "DOCK" utton. The "DOCK" utton light turns off "THROTTLE ONLY" utton To engge Throttle Only mode: 1. Plce oth ERC levers in neutrl. 2. Press the "THROTTLE ONLY" utton, locted on the DTS Trckpd. CMD / AUGUST 2007 Pge 39

48 Section 3 - On The Wter 1 (ONE) LEVER 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 remins 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. The neutrl lights remins on. The Zeus system fetures the ility to commnd oth engines with single lever. This feture simplifies engine mngement during rough se conditions y llowing you to grsp single lever to commnd oth engines simultneously "1 LEVER" utton SYNC To engge 1 Lever mode: 1. Plce oth ERC levers in neutrl. 2. Press the "1 LEVER" utton locted on the DTS Trckpd ttched to the ERC levers. 3. The "1 LEVER" utton lights. 4. Plce the strord ERC lever into ger. 5. The engine RPM rises nd lowers simultneously while the trnsmissions remin in the sme ger. To disengge 1 Lever mode: 1. Plce oth ERC levers in neutrl. 2. Press the "1 LEVER" utton. The "1 LEVER" utton light turns off. The Zeus system fetures n utomtic engine synchroniztion, or Sync, feture, which engges utomticlly t key up. The synchroniztion feture monitors the position of oth levers. If oth levers re within 10% of one nother, the port engine synchronizes to the strord engine's RPM. Pge 40 CMD / AUGUST 2007

49 Section 3 - On The Wter 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: "SYNC" utton 1. Plce the ERC levers in ny detent. 2. Press the "SYNC" utton To re engge Sync mode, press the "SYNC" utton. Cruise Control The VesselView system fetures integrted throttle cruise control (Cruise), which llows the opertor to limit the pek RPM of choice elow Wide Open Throttle (WOT). VesselView is required for this feture. Refer to the owners nd opertors mnul provided with your VesselView for opertion instructions. These dditionl notes re exclusive to your pckge: You cn chnge or disengge Cruise through the screen t ny time. Cruise resets when the key is turned off. Skyhook does not function if Skyhook is in effect. 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 to disengge. Precision Pilot Trck Pd Fetures GENERAL INFORMATION Precision Pilot (Pilot) functions re controlled through the Pilot trck pd only. Pilot screens, when ccessed y the trckpd, pper on the VesselView for three seconds unless clirted otherwise. Pressing ny utton on VesselView dismisses the utopilot screen from the VesselView screen, unless the screen ws chosen from the VesselView environment menu. The "TURN" uttons provide 10 course correction for ech press to the port or strord. The joystick provides 1 course correction for ech press to the port or strord. CMD / AUGUST 2007 Pge 41

50 Section 3 - On The Wter STANDBY The steering wheel feels locked into detent when "AUTO" or "TRACK" re engged. Approximtely kg (8 10 l.) of force re required to overcome this detent. Mnully overcoming the steering wheel's detent force utomticlly puts Pilot into stndy mode. c d Stndy screen on VesselView - "OFF" icon - Heding c - Drive ngle reference d - Engine RPM In stndy mode, the disply shows digitl compss vlue nd the ngle of the drives when engged. The compss vlue is the ctul current heding from the AutoPilot. On the right side of the screen, n icon leled "OFF" indictes tht Pilot is not engged. NOTE: Not ll of the functions of Precision Pilot work when DTS functions re engged. Disengge the DTS functions to use the functions of Precision Pilot. The following informtion shows the loction nd explins the function of the Precision Pilot trck pd lights nd uttons. For more informtion, refer to the Precision Pilot Owner's Mnul provided with the product. Pge 42 CMD / AUGUST 2007

51 Section 3 - On The Wter STANDBY AND ACTIVE LIGHTS "STANDBY" light - "ACTIVE" light POWER ICON Precision Pilot is disengged (off) when the "STANDBY" light is illuminted. You must press utton to engge mode. When the "ACTIVE" light is illuminted one mode of Precision Pilot is engged (on). c Buttons with Power Icons - "SKYHOOK" utton - "AUTO HEADING" utton c - TRACK WAYPOINT" utton The power icon indictes tht these uttons hve the ility to engge or disengge the Precision Pilot function they perform. If you press utton tht hs the power icon when tht utton light is on, the light turns off for tht utton nd the "STANDBY" light illumintes. CMD / AUGUST 2007 Pge 43

52 Section 3 - On The Wter If you press utton tht hs the power icon when tht utton light is off, the light turns on for tht utton, single eep sounds, nd the "ACTIVE" light illumintes, unless nother mode is currently ctive. If nother mode is currently ctive, press the utton on the ctive mode to disengge it, then press the utton for the new mode. SKYHOOK If you press utton with the power icon when tht utton light is off, the light turns on for tht utton, single eep sounds, nd the "ACTIVE" light illumintes.! WARNING A rotting propeller, moving ot, or device ttched to moving ot cn cuse serious injury to people in the wter. When the Skyhook electronic nchor 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. Your Zeus vessel is equipped with the Skyhook electronic nchor, or Skyhook, which llows the ot to utomticlly mintin its position nd heding. The computer control system mneuvers the drives utomticlly to keep the ot in one position. Skyhook keeps the ot stedy without hving to use nchors or lines when no people re present in the wter ner the ot. The cpility of most vessels limits the ility of Skyhook electronic nchor to counterct currents of up to 2 knots (2.3 MPH) when the ot is sidewys to the current. If you notice your ot drifting sidewys while Skyhook electronic nchor is engged, move the ow or stern more directly into the current to help reduce the effects of this sitution. The Skyhook electronic nchor system relies on n opertionl GPS receiver nd opertionl heding sensor. Occsionlly, due to stellite geometry or ostructions, GPS my e temporrily unville. Skyhook continues to operte through GPS outge for up to 10 seconds, ut utomticlly disengges if the GPS outge persists. If disenggement occurs, horn sounds nd the light on the Precision Pilot keypd "SKYHOOK" utton turns off. The Skyhook electronic nchor performnce is lrgely dictted y the performnce of the onord GPS system. The Zeus GPS system is ccurte within 3 meters (10 feet) when receiving Wide Are Augmenttion System (WAAS) correction. WAAS is system of stellites nd ground sttions tht provide GPS signl corrections, llowing for more ccurte positioning of your GPS. When WAAS is not ville, the performnce of the system mintins the ot within 20 meters ( 60 feet ) of the desired position. We do not recommend Skyhook for close qurter or docking opertions. Pge 44 CMD / AUGUST 2007

53 Section 3 - On The Wter SKYHOOK SCREEN NOTES c d Skyhook screen on VesselView - Loction where Skyhook is set - Loction where ot is reltive to set loction c - 5 meter grdtion d - Engine RPM In Skyhook mode the "ON" light illumintes, single eep sounds, nd the disply shows engine speed, trget with cross hirs, nd ot icon. The rottion ngle of the ot shows the yw error. Zero yw error shows the ot pointing upwrd. Positive yw error cuses the ot to rotte counter clockwise. Negtive yw error cuses the ot to rotte clockwise. The horizontl nd verticl displcement of the vessel from the cross hirs is proportionl to the position error reported y the GPS. Ech grdtion of color in the circulr trget on the VesselView screen is equivlent to 5 meters of error. If the ot exceeds 20 meters of error, then the ot is locted t the edge of the circle. The ot continues to try to correct until Skyhook is disengged. During Skyhook electronic nchor opertions, the computer control system shifts the engines nd drives utomticlly. Do not llow people in the wter round the ot while Skyhook is engged. Activities in the wter ner the vessel while Skyhook is engged my result in injury. A single eep sounds when the Skyhook is disengged or the GPS signl is lost. CMD / AUGUST 2007 Pge 45

54 Section 3 - On The Wter ENGAGING SKYHOOK "SKYHOOK" utton 1. Move the levers to neutrl nd ring the ot to stop. Skyhook does not engge until the ot is in neutrl nd t speed slow enough for sfe enggement. The Skyhook light links while the mode is witing for the ot to decelerte enough to engge. The ot my reverse utomticlly if it hs pssed the position where the "SKYHOOK" utton ws pressed in order to get ck to the point it ws sked to hold.! WARNING When the Skyhook electronic nchor is engged, the ot stys in preset position; however, Skyhook cn disengge unexpectedly. When Skyhook disengges, the ot does not hold the preset position nd my drift, cusing the potentil of dmge or personl injury. The helm opertor must e le to tke control of the ot when using Skyhook. 2. Press the "SKYHOOK" utton to turn on Skyhook mode nd single eep sounds. A wrning screen ppers on VesselView while Skyhook mintins the ot's current position nd heding.. Press the check to cknowledge. The light stops linking nd remins on constntly once Skyhook is engged. 3. Move the joystick, move the ERC levers, or press the "SKYHOOK" utton when illuminted to turn off Skyhook. A single eep sounds when the function turns off. 4. The VesselView "SKYHOOK" screen displys on VesselView for one second fter the "SKYHOOK" utton is pressed nd the screen displys green circle with "SH" when Skyhook engges. The screen must e turned on in VesselView clirtion. See Mode Disply in VesselView. 5. Press the "SKYHOOK" utton second time to put Precision Pilot in stndy. All lights other thn "STANDBY" turn off. DISENGAGING SKYHOOK IMPORTANT: Under most circumstnces, oth engines nd drives must e opertionl to chieve cceptle Skyhook electronic nchor performnce. If the necessry reference signls from n engine or drive ecome unville, Skyhook utomticlly disengges. To disengge the Skyhook Electronic Anchor, you cn choose one of the following methods: Press the "SKYHOOK" utton on the Precision Pilot keypd. Move ny lever out of neutrl. Pge 46 CMD / AUGUST 2007

55 TURN BUTTONS Operte the ot with the joystick. NOTE: In ech of the methods, the light on the "SKYHOOK" utton turns off. Section 3 - On The Wter While in "AUTO HEADING" mode, these uttons respectively chnge the set heding y defult of 10. While in the "HEADING" mode, tpping the joystick left or right lso djusts your course y 1 per tp. 1. Press the "TURN" utton in the direction of the desired heding chnge. Ech press of the utton chnges the desired heding y Port "TURN" utton - Strord "TURN" utton 2. Move (press) the joystick in the desired direction to mke smll djustments in the chosen heding. The joystick must move over 50% of its trvel for the movement to e recognized s input. Ech recognized movement djusts the chosen heding y Adjusting heding to strord CMD / AUGUST 2007 Pge 47

56 Section 3 - On The Wter AUTO HEADING c "TURN" uttons - "RESUME" utton c - "AUTO HEADING" utton 1. At lest one engine must e running for Auto Heding to function. 2. Press the "AUTO HEADING" utton to engge Precision Pilot. The utton illumintes nd single eep sounds. A doule eep sounds if Auto Heding does not engge. Precision Pilot holds the compss heding the ot following when the "AUTO HEADING" utton is engged. 3. To mke djustments in the defult heding while the "AUTO HEADING" is ctive nd the utton light is on, press the respective "TURN" utton on the trckpd or tp (quickly move) the joystick. 4. To mke turn: Press one of the "TURN" uttons in the direction you wnt the turn. Tp the joystick in the direction you wnt the turn. Tpping the joystick left or right djusts your course y 1 for ech movement. Pge 48 CMD / AUGUST 2007

57 Section 3 - On The Wter 5. Turn the wheel or press the "AUTO HEADING" utton to disengge the Auto Heding nd single eep sounds. If the steering wheel is used to disengge Auto Heding, the resume utton LED turns on nd single eep sounds. While the LED is lit, you cn press the "RESUME" utton to resume the course in Auto Heding. 6. If the ERC Hndles re moved to neutrl, Auto Heding turns off, single eep sounds, nd the "STANDBY" light turns on. You re not le to resume your course y pressing the "RESUME" utton. c d - "OFF" utton - Current heding c - Drive positions d - Engine RPM DISENGAGE AUTO HEADING Pressing the "AUTO HEADING" utton cuses VesselView to displys the "AUTO HEADING" screen for three seconds. If the VesselView "AUTO HEADING" screen does not pper, the "AUTO HEADING" screen needs to e ctivted in VesselView clirtion. Precision Pilot still engges whether the screen ppers or not. NOTE: If you press the "AUTO HEADING" utton second time, the pilot goes to Stndy mode nd ll lights other thn "STANDBY" turn off. 1. Disengge the AutoPilot mode y ny of the following ctions. Plce the ERC levers for oth engines in neutrl. Turn the steering wheel eyond the electronic detent. CMD / AUGUST 2007 Pge 49

58 Section 3 - On The Wter Press the "AUTO HEADING" utton on the Precision Pilot keypd. The "AUTO HEADING" utton light turns off. c TO RESUME TO A HEADING - "TURN" utton - "RESUME" utton c - "AUTO HEADING" utton The "RESUME" utton light turns on if the previous course heding is ville to resume. The previous heding cn only e resumed within one minute of the AutoPilot eing disengged or if the ot hs not turned more thn 180. These numers cn e djusted. If you disengge the AutoPilot y turning the steering wheel, or if you press one of the "TURN" uttons with AutoPilot still engged, press the "RESUME" utton to resume the previous heding. 1. Plce t lest one engine in forwrd ger. 2. Mnully steer the ot to the desired heding nd hold the ot stedy. Pge 50 CMD / AUGUST 2007

59 Section 3 - On The Wter 3. Press the "AUTO HEADING" utton on the Precision Pilot keypd. The light on "AUTO HEADING" utton illumintes nd the system utomticlly keeps the vessel steering towrds the desired course. Press either of the "TURN" uttons or use the joystick to chnge or djust the course. TRACK WAYPOINT - "AUTO HEADING" utton - "TURN" uttons! WARNING In some Precision Pilot modes "Auto Heding," "Trck Wypoint," nd "Wypoint Sequence" the ot nvigtes preset course. The ot does not utomticlly respond to hzrds such s other wtercrft, ostcles, swimmers, or underwter terrin. Collision with these hzrds could cuse ot dmge, serious injury, or deth. The opertor must sty t the helm, redy to evde hzrds nd wrn others of course chnges "TRACK WAYPOINT" utton 1. Move the ERC levers pst the forwrd detent. Trck Wypoint does not function if the levers re in neutrl or reverse. 2. Turn on the chrt plotter nd select wypoint. Wypoint dt needs to e provided y third prty chrt plotter CMD / AUGUST 2007 Pge 51

60 Section 3 - On The Wter 3. Press the "TRACK WAYPOINT" utton. The "TRACK WAYPOINT" utton light turns on, single eep sounds, nd Precision Pilot engges. Pilot egins trcking to wypoint. Two eeps sounds if Trck Wypoint does not engge. 4. The VesselView "TRACK WAYPOINT" screen displys on VesselView for one second fter pressing the "TRACK WAYPOINT" utton. The screen is ctivted during VesselView clirtion. See Mode Disply in VesselView. Trck Wypoint screen NOTE: Pilot does not turn in wypoint mode. Turn fetures re only ville in Auto Heding mode. The disply shows the digitl heding tht the ot is trveling, the ngles of the drives, nd engine speed in RPM. The GPS system genertes the heding, nd is represented from mgnetic North. 5. Turn the steering wheel, put the ERC levers in neutrl, or press the "TRACK WAYPOINT" utton second time to put Pilot in Stndy mode. A single eep sounds, the "TRACK WAYPOINT" light turns off, nd the "STANDBY" light turns on. 6. You cn resume the heding within the time limit, if the vessel hs not turned too fr nd the "RESUME" light is still on or flshing. ENGAGING TRACK WAYPOINT MODE To engge Trck Wypoint mode of Precision Pilot: 1. Crete nd use route from the chrt plotter. Refer to your chrt plotter user mnul for detils. 2. Plce t lest one ERC lever in forwrd ger nd estlish sfe operting speed. Pge 52 CMD / AUGUST 2007

61 Section 3 - On The Wter 3. Press the "TRACK WAYPOINT" utton on the Precision Pilot keypd. The "TRACK WAYPOINT" utton turns on, indicting tht Pilot is trcking to the chrt plotter s desired course. "TRACK WAYPOINT" utton 4. A eep sounds, nd wrning ppers on VesselView. Press the check to cknowledge the wrning. DISENGAGING TRACK WAYPOINT MODE Disengge the Trck Wypoint mode y ny one of the following methods: Press the "TRACK WAYPOINT" utton on the precision pilot keypd. The utton light goes off nd Pilot goes to Stndy. Turn the steering wheel hrd enough to overcome the force feedck nd Pilot goes to Stndy. Move oth ERC levers ck to neutrl nd Pilot goes to Stndy. Press either "TURN" utton nd Pilot goes to Auto mode. Press the "AUTO HEADING" utton nd Pilot goes to Auto mode. Turn off the chrt plotter nd Pilot goes to Stndy. TURN BUTTON OR JOYSTICK IN TRACK MODE While in "TRACK WAYPOINT" the left nd right "TURN" uttons on the keypd or joystick inputs chnges the mode to "AUTO HEADING." AUTO HEADING BUTTON IN TRACK MODE While in "TRACK WAYPOINT", the "AUTO HEADING" utton cuses the AutoPilot to chnge to "AUTO HEADING." CMD / AUGUST 2007 Pge 53

62 Section 3 - On The Wter ACKNOWLEDGING A TURN DURING A WAYPOINT ARRIVAL 1. When the ot enters the wypoint rrivl zone of the chrt plotter, the AutoPilot sounds short horn lrm nd links the "WAYPOINT SEQUENCING" utton light, informing the opertor to mke turn. "WAYPOINT SEQUENCE" utton 2. The opertor must determine it is sfe to turn the ot. If so, press the "WAYPOINT SEQUENCE" utton to cknowledge tht it is sfe for the Pilot to turn the ot nd mneuver to the new course. If the wypoint is not cknowledged, the ot continues on its current heding. 3. At the end of the Trck Wypoint course, input new route or tke control of the ot. Otherwise, the ot reverts to Auto Heding mode nd continues on its lst course heding Pge 54 CMD / AUGUST 2007

63 Section 3 - On The Wter WAYPOINT SEQUENCE! WARNING In some Precision Pilot modes "Auto Heding," "Trck Wypoint," nd "Wypoint Sequence" the ot nvigtes preset course. The ot does not utomticlly respond to hzrds such s other wtercrft, ostcles, swimmers, or underwter terrin. Collision with these hzrds could cuse ot dmge, serious injury, or deth. The opertor must sty t the helm, redy to evde hzrds nd wrn others of course chnges. "WAYPOINT SEQUENCE" utton 1. Plce the ERC lever or levers into forwrd. "WAYPOINT SEQUENCE" does not engge if the levers re in neutrl or reverse. 2. If not lredy ccomplished, press the "TRACK WAYPOINT" utton nd note tht the utton light is on. 3. Press the "WAYPOINT SEQUENCE" utton: IMPORTANT: Sty lert. The ot turns utomticlly in this mode. The opertor must e wre if the ot is in sfe re to turn when the vessel is entering wypoint rrivl zone nd inform pssengers tht the ot utomticlly turns so they cn e prepred CMD / AUGUST 2007 Pge 55

64 Section 3 - On The Wter If you re in the wypoint rrivl zone set y the chrt plotter, "WAYPOINT SEQUENCE" only informs Pilot it is OK to proceed to next wypoint. It cts s wypoint cknowledge function nd Pilot eeps when in the zone. The opertor must cknowledge tht it is OK to turn y pressing the Wypoint Acknowledge utton on the VesselView screen. Once cknowledged, Pilot trcks to the next wypoint in the route. If you re not in the wypoint rrivl zone, set y third prty chrt plotter interfced to Pilot, "WAYPOINT SEQUENCE" engges uto sequencing to the wypoints in the route. You must cknowledge the wrning screen y pressing the check utton WAYPOINT ACKNOWLEDGE 4. Press the "TRACK WAYPOINT" utton, nd the VesselView Trck screen displys for three seconds, the "WAYPOINT SEQUENCE" utton light turns on, nd single eep sounds. 5. The Trck Screen does not pper unless the screen is ctivted (turned on) during VesselView clirtion. Pilot engges whether the screen is on or not. See Mode Disply in VesselView. 6. Press the "TRACK WAYPOINT" utton second time to put the Pilot in Stndy mode. All lights other thn "STANDBY" turn off. The Trck Wypoint mode does not utomticlly turn the ot upon the rrivl t wypoint. Turns re controlled in the Auto Heding mode Pge 56 CMD / AUGUST 2007

65 Section 3 - On The Wter Pressing the "WAYPOINT SEQUENCE" utton during Trck Wypoint mode, ut not t the rrivl wypoint, cuses the AutoPilot to continue to the next wypoint. The "WAYPOINT SEQUENCE" light continuously illumintes. The VesselView icon is shown when in AutoPilot mode. Wypoint cknowledge screen In Trck Wypoint mode, if the Wypoint Sequence mode hs not een engged, the "WAYPOINT SEQUENCE" light links t the rrivl lrm, the AutoPilot controls the vessel to the most recent heding setpoint, nd VesselView displys pop up screen Pop up screen wrning CMD / AUGUST 2007 Pge 57

66 Section 3 - On The Wter RESPONSE BUTTON Response utton 1. Press the "RESPONSE" utton to chnge the gin for Auto Pilot or Wypoint modes. 2. Press the "RESPONSE" utton gin to chnge the gin further. Ech time you press the "RESPONSE" utton, the utton light links to show you the gin setting for tht mode. The initil utton press shows the current setting vlue. Additionl utton presses increse the gin in steps up to three nd then return to one. Numer of links Response setting shown Aggressiveness of correction 1 1 Mild (for gentle or clm conditions) 2 2 Medium (for moderte conditions) 3 3 Aggressive (for severe conditions) 3. The screen of the mode you re in is displyed, s well s the response popup dedicted to tht mode on the VesselView for 3 seconds, once the utton is pressed. The screen needs to e turned on in VesselView clirtion. See Mode Disply in VesselView. CHANGING VESSELVIEW MODE DISPLAY TIMES All modes (Auto Heding, Trck Wypoint, nd Skyhook) disply screen on VesselView for three seconds y defult. The length of time tht screen is visile in VesselView cn e chnged from no disply t ll, disply up to 10 seconds, or disply the screen until chnged. To chnge the disply time: 1. Open VesselView. 2. Select Setting. 3. Select Screen Options. 4. Select the mode you wnt to chnge. 5. Select the time option. 6. Press to exit. End of First Seson Checkup At the end of the first seson of opertion, contct n Authorized Cummins MerCruiser Diesel Repir Fcility to discuss or perform scheduled mintennce items. See Section 5 if you re in n re where the product is operted continuously, yer round, contct your Authorized Cummins MerCruiser Diesel Repir Fcility t the end of the first 500 hours of opertion or once yerly, whichever occurs first. Pge 58 CMD / AUGUST 2007

67 Section 3 - On The Wter Contingent Opertions Bckup Steering System If the electronic steering wheel ceses to operte, the control system utomticlly monitors the joystick for steering commnds. When in ger, left nd right movement of the joystick corresponds to left nd right steering of the wheel. When in neutrl, the joystick returns to norml 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 in 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 Section 5 The Drive Cover. CMD / AUGUST 2007 Pge 59

68 Section 3 - On The Wter 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. 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 n Authorized Cummins MerCruiser Diesel Repir Fcility nd inform them tht the drive ger hs een mnully engged. Pge 60 CMD / AUGUST 2007

69 Tle of Contents Section 4 - Specifictions Section 4 - Specifictions Drive Ger Luricnt Trnsmission Steering Actutor nd Trim Fluid Approved Pints Approved Luricnts CMD / AUGUST 2007 Pge 61

70 Section 4 - Specifictions Drive Ger Luricnt Model Fluid Cpcity (includes the drive nd the ger lue monitor) Fluid Type Fluid Prt Numer Zeus 5 1/4 liters (5 1/2 qurts) High Performnce Ger Lue Q01 Trnsmission Trnsmission With Drop Box IMPORTANT: Alwys use the dipstick to determine the exct quntity of luricnt or fluid required. Description Fluid Cpcity Fluid Type Fluid Prt Numer Trnsmission nd drop ox 5 1/4 liters (5 1/2 qurts) Synthetic Power Steering Fluid SAE 0W K01 Trnsmission Without Drop Box Description Fluid Cpcity Fluid Type Fluid Prt Numer Trnsmission only 4 liters (4 1/4 qurts) Synthetic Power Steering Fluid SAE 0W K01 Steering Actutor nd Trim Fluid Description Fluid Cpcity Fluid Type Fluid Prt Numer Steering ctutor nd trim system 5 3/4 to 6 liters (6 to 6 1/3 qurts) Synthetic Power Steering Fluid SAE 0W K01 Approved Pints Approved Luricnts Description Prt Numer Mrine Cloud White (CMD prt numer: ) Otin loclly Mercury Light Gry Primer Mercury Phntom Blck Q1 Tue Ref No. Description Where Used Prt No. 120 Corrosion Gurd Drive exterior surfces Tue Ref No. Description Where Used Prt No. 42 U-joint nd Giml Bering Grese Driveshft slip-joint A1 Tue Ref No. Description Where Used Prt No. 91 Engine Coupler Spline Grese Driveshft slip-joint A1 Pge 62 CMD / AUGUST 2007

71 Section 4 - Specifictions Tue Ref No. Description Where Used Prt No. 94 Anti-Corrosion Grese Secock nd propeller shfts Q 1 CMD / AUGUST 2007 Pge 63

72 Section 4 - Specifictions Notes: Pge 64 CMD / AUGUST 2007

73 Tle of Contents Section 5 - Mintennce Section 5 - Mintennce Product Responsiilities Owner nd Opertor Responsiilities...66 Deler Responsiilities...66 Do-It-Yourself Mintennce Suggestions...66 Inspection...67 Drive Cover Removing the Drive Cover...67 Clening nd Inspecting the Drive Cover...68 Instlling the Drive Cover...68 Mintennce Schedules Appliction...69 Routine Mintennce...69 Scheduled Mintennce...69 Mintennce Log...70 Drive Ger Lue Checking...72 Filling...73 Chnging...74 With the Bot in the Wter With the Bot Out of the Wter Steering Actutor nd Trim Fluid Checking...79 Filling...80 Chnging...80 Trnsmission Fluid Checking...81 Filling...82 Chnging...83 Sewter Striner Bttery Guges Checking Guges...87 Clening Guges...87 Electricl System Cooling System nd Exhust System Luriction Driveshft Slip-Joint...88 Secock Sewter Return (Overord)...89 Propeller Shft...90 Corrosion Protection Anodes nd MerCthode System...90 Reference Electrode Wire of the MerCthode System...91 MerCthode Anode...92 Checking Replcing MerCthode System Testing...92 Trim T Anodes...93 Checking Replcing Continuity Circuits...93 Inhiiting Corrosion...94 Pinting the Bot...94 Propellers Propeller Removl...95 Propeller Repir...97 Propeller Instlltion CMD / AUGUST 2007 Pge 65

74 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 Cummins MerCruiser Diesel Authorized 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 Cummins MerCruiser Diesel Authorized 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 Present dy mrine equipment, such s your Cummins MerCruiser Diesel power pckge, re highly technicl pieces of mchinery. Specil fuel delivery systems provide greter fuel economies, ut lso re more complex for the untrined mechnic. If you re one of those persons who likes to do it yourself, here re some suggestions for you. Do not ttempt ny repirs unless you re wre of the Cutions, Wrnings, nd procedures required. Your sfety is our concern. If you ttempt to service the product yourself, we suggest you order the service mnul for tht model. The service mnul outlines the correct procedures to follow. It is written for the trined mechnic, so there my e procedures you do not understnd. Do not ttempt repirs if you do not understnd the procedures. There re specil tools nd equipment tht re required to perform some repirs. Do not ttempt these repirs unless you hve these specil tools nd equipment. You cn cuse dmge to the product in excess of the cost deler would chrge you. Also, if you prtilly disssemle n engine or drive ssemly nd re unle to repir it, the deler's mechnic must ressemle the components nd test to determine the prolem. This will cost you more thn tking it to the deler immeditely upon hving prolem. It my e very simple djustment to correct the prolem. Do not telephone the deler, service office, or the fctory to ttempt for them to dignose prolem or to request the repir procedure. It is difficult for them to dignose prolem over the telephone. Your locl Cummins MerCruiser Diesel Authorized Repir Fcility is there to service your power pckge. They hve qulified fctory trined mechnics. Pge 66 CMD / AUGUST 2007

75 Section 5 - Mintennce Inspection It is recommended you hve the Cummins MerCruiser Diesel Authorized Repir Fcility do periodic mintennce checks on your power pckge. Hve them winterize it in the fll nd service it efore the oting seson. This will reduce the possiility of ny prolems occurring during your oting seson when you wnt troule free oting plesure. Inspect your power pckge often nd t regulr intervls to help mintin top operting performnce nd correct 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 Mrine Recretionl High Output Propulsion Units QSB nd QSC Opertion nd Mintennce Mnul pproprite for your engine. 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 Cummins MerCruiser Diesel Authorized Repir Fcility. 4. Repir nicks nd corrosion dmge on the power pckge exterior finish. Contct your Cummins MerCruiser Diesel Authorized Repir Fcility. 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 t ll times, unless removl is necessry during some mintennce inspections nd procedures. c Rer view of typicl drive cover - Top cover - Strord side cover c - Port side cover When it is necessry to remove the drive cover, see Drive Cover. Drive Cover 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. CMD / AUGUST 2007 Pge 67

76 Section 5 - Mintennce 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 - Upper screw (6) - Lower screw (4) c - Port side cover d - Top of the drive cover e - Strord side cover f - Top screw (2) Typicl drive cover 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. Remove nd retin the two lifting rings, if instlled. 2. Crefully instll the top of the drive cover. Align the top with the two threded holes in the trnsmission where lifting rings were removed. 3. Instll the two upper screws. 4. Instll the strord side cover nd the three upper screws nd one lower screw. 5. Instll the port side cover nd the three upper nd two lower screws. Pge 68 CMD / AUGUST 2007

77 Section 5 - Mintennce 6. Tighten ll screws securely. f e d c Typicl drive cover - Upper screw port shown - Lower screw port shown c - Port side cover d - Top of the drive cover e - Strord side cover f - Top screw Mintennce Schedules Appliction The following schedules pply to the Zeus drive nd driveshft connection, not to the Cummins engine. For the engine mintennce schedule nd procedures, refer to the Mrine Recretionl High Output Propulsion Units QSB nd QSC 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 fluid level. Check the ger lue level in the ger lue monitor. Check the trnsmission 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). Scheduled Mintennce Tsk Intervl After the First 25 Hours nd not to Exceed 30 Hours Mintennce to e Performed Chnge the trnsmission fluid nd filter, including the trnsmission fluid in the drop ox, if equipped. CMD / AUGUST 2007 Pge 69

78 Section 5 - Mintennce Tsk Intervl Every 250 hours of Opertion or Once Yer (Whichever Occurs First) Every 500 Hours or Once Yer (Whichever Occurs First) Mintennce to e Performed Torque the driveshft connecting olts nd nuts. Inspect nd luricte the driveshft slip joint. Chnge the ger lue in the drive gercse. Chnge the trnsmission fluid nd filter, including the trnsmission fluid in the drop ox, if equipped. Luricte nd inspect the secock for engine sewter return (sewter overord). Ensure tht the secock opens nd closes freely. Chnge the steering ctutor fluid nd filter. Luricte the propeller shft splines nd torque the propeller nuts. 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 lose, 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. 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. Mintennce Log Record ll mintennce performed on your power pckge here. Be sure to sve ll work orders nd receipts. Pge 70 CMD / AUGUST 2007

79 Section 5 - Mintennce Dte Mintennce Performed Engine Hours CMD / AUGUST 2007 Pge 71

80 Section 5 - Mintennce Drive Ger Lue 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. Checking IMPORTANT: The ger lue level in the ger lue monitor rises nd flls during drive opertion. Check the ger lue level when the drive is cool nd the engine is off. 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). To check the drive ger lue with the drive cover instlled: 1. Remove the ccess cover from the drive cover. 2. Remove the cp from the ger lue monitor. c - Access cover - Cp c - Ger lue monitor Inspect the ger lue level in the ger lue monitor. The ger lue level should e t the "COLD FILL LEVEL" (cold full line). c Shown with drive cover removed - Cp - "COLD FILL LEVEL" line c - "MAX OPERATING LEVEL" line Pge 72 CMD / AUGUST 2007

81 4. If the level is low, see Filling. 5. If the level is correct, instll the ccess cover. To check the drive ger lue with the drive cover removed: 1. Remove the drive cover. See Removing the Drive Cover. Section 5 - Mintennce 2. Inspect the ger lue level in the ger lue monitor. The ger lue level should e t the "COLD FILL LEVEL" (cold full line) when the drive nd fluid re cold. - "COLD FILL LEVEL" line - Ger lue level Filling IMPORTANT: If ny wter is visile t the ottom of the ger lue monitor or ppers t the fill nd drin plug hole, or if the ger lue ppers discolored, contct your Cummins MerCruiser Diesel Authorized Repir Fcility immeditely. Both conditions my indicte wter lek in the drive. 3. If the level is low, see Filling. 4. If the level is correct, instll the drive cover. See Instlling the Drive Cover. IMPORTANT: If more thn 59 ml (2 fl. oz.) of High Performnce Ger Lue is required to fill the ger lue monitor, sel my e leking. Lck of luriction will dmge the drive. Contct your Cummins MerCruiser Diesel Authorized Repir Fcility. 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. 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. Shown with drive cover removed - "COLD FILL LEVEL" line - Ger lue level CMD / AUGUST 2007 Pge 73

82 Section 5 - Mintennce Tue Ref No. Description Where Used Prt No. 87 High Performnce Ger Lue Ger lue monitor K01 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). c - Cp - "COLD FILL LEVEL" line c - "MAX OPERATING LEVEL" line Ensure tht the ruer gsket is inside the cp for the ger lue monitor nd instll the cp. Do not overtighten. - Ger lue monitor - Cp Chnging WITH THE BOAT IN THE WATER NOTE: Chnge the drive ger luricnt when the drive is t operting temperture. Wrmer luricnt flows more freely, crrying wy more impurities nd is esier to remove from the drive. 1. Plce oil sorent wipes or mteril round the re to contin ny spilled luricnt. Pge 74 CMD / AUGUST 2007

83 Section 5 - Mintennce 2. Remove the fill nd drin screw from the steering ctutor. - Steering ctutor - Fill nd drin screw Quickly instll n dptor or suitle threded fitting into the threded hole of the drin nd fill screw nd ttch crnkcse oil pump. Crnkcse Oil Pump A 5 Aids in the removl of drive oil without drining the drive Remove the ger lue monitor cp. - Ger lue monitor - Cp Remove the ger lue y pumping the crnkcse oil pump from the drive 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 Cummins MerCruiser Diesel Authorized Repir Fcility immeditely. 6. Remove the crnkcse oil pump. CMD / AUGUST 2007 Pge 75

84 Section 5 - Mintennce 7. Ensure tht the ruer gsket is inside the cp for the ger lue monitor nd instll the cp. Do not overtighten. - Ger lue monitor - Cp Instll suitle ger lue pump into the fill nd drin hole of the steering ctutor nd egin to fill the drive with the specified ger lue. IMPORTANT: Use only Mercury or Quicksilver High Performnce Ger Lue in the drive. 9. 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 - Ger lue level Drive Model Fluid Cpcity includes the Sterndrive nd the Ger lue Monitor Fluid Type Fluid Prt Numer Zeus 5.2 liters (5.5 qurts) High Performnce Ger Lue Q Remove the ger lue pump nd quickly reinstll the steering ctutor fill nd drin wsher nd screw. Torque the fill nd drin screw. Description Nm l. in. l. ft. Steering ctutor fill nd drin screw See Filling nd fill the ger lue monitor to the "COLD FILL LEVEL" line, if the level is low. 12. Recheck the ger lue level t the ger lue monitor fter the first use. See 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. Pge 76 CMD / AUGUST 2007

85 Section 5 - Mintennce WITH THE BOAT OUT OF THE WATER 1. Remove the drive propellers. See Propellers. 2. Remove the gercse fill nd drin screw nd seling wsher. - Gercse - Fill drin screw nd seling wsher 3. Remove the ger lue monitor cp Ger lue monitor - Cp Drin the ger lue into suitle continer. 5. Allow the ger lue to drin completely. IMPORTANT: If ny wter exits the fill nd drin hole, or if the ger lue ppers milky, the drive is leking. Contct your Cummins MerCruiser Diesel Authorized Repir Fcility immeditely. IMPORTANT: Use only Mercury or Quicksilver High Performnce Ger Lue in the drive. CMD / AUGUST 2007 Pge 77

86 Section 5 - Mintennce 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 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 - Ger lue level Drive Model Fluid Cpcity includes the Sterndrive nd the Ger lue Monitor Fluid Type Fluid Prt Numer Zeus 5.2 liters (5.5 qurts) High Performnce Ger Lue Q01 Pge 78 CMD / AUGUST 2007

87 Section 5 - Mintennce 8. Ensure tht the ruer gsket is inside the cp for the ger lue monitor nd instll the cp. Do not overtighten. - Ger lue monitor - Cp Remove the ger lue pump nd quickly reinstll the ger cse fill nd drin screw nd wsher. Description Nm l. in. l. ft. Ger cse fill nd drin screw See Filling nd fill the ger lue monitor to the "COLD FILL LEVEL" line, if the level is low. 11. Instll the drive propellers. See Propellers. 12. Check the ger lue level t the ger lue monitor fter the first use. See Checking. NOTE: After the drive hs een operted nd the ger lue is hot, the fluid will expnd nd my e up to the "MAX OPERATING LEVEL" line (hot full line). Steering Actutor nd Trim Fluid Checking The steering ctutor nd trim system use common hydrulic pump nd fluid storge reservoir for the comined luriction nd hydrulic fluid. 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. Remove the cp. CMD / AUGUST 2007 Pge 79

88 Section 5 - Mintennce 3. Inspect the fluid level, which should e 25 mm (1 in.) elow the ottom of the filler neck of the reservoir. c d - Correct fluid level - Reservoir c - Bottom of filler neck d - Cp Filling 4. If the level is low, see 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. 2. Remove the cp. 3. Fill the reservoir with the specified fluid until the fluid is 25 mm (1 in.) elow the ottom of the filler neck of the reservoir. Do not overfill. 4. Instll the cp. c d - Correct fluid level - Reservoir c - Bottom of filler neck d - Cp Description Fluid Cpcity Fluid Type Fluid Prt Numer Chnging Steering ctutor nd trim system (pproximte totl cpcity) 5 3/4 to 6 liters (6 to 6 1/3 qurts) Synthetic Power Steering Fluid SAE 0W 30 Contct your locl Cummins MerCruiser Diesel Authorized Repir Fcility K01 Pge 80 CMD / AUGUST 2007

89 Trnsmission Fluid Checking Section 5 - Mintennce You cn check the trnsmission fluid level through the ccess cover on the drive cover or with the drive cover removed. 1. If the drive cover is removed, go to step If the drive cover is instlled, remove the ccess cover from the drive cover; then, go to step 3. c - Access cover - Trnsmission c - Trnsmission dipstick Remove the dipstick. Wipe the dipstick with clen, lint free cloth. 4. Insert the dipstick, resting it on the top of the threded hole. 5. Remove the dipstick nd check the fluid level indicted. The fluid level should e etween the mximum nd minimum mrks on the dipstick. NOTE: Fluid from the trnsmission fluid cooler nd hoses my drin into the trnsmission, cusing fluid level slightly ove the mximum mrk. d c Checking dipstick rested on top of threded hole - Mximum mrk - Minimum mrk c - Top of threded hole d - Dipstick 6. If the level is correct, instll the dipstick CMD / AUGUST 2007 Pge 81

90 Section 5 - Mintennce 7. If the fluid level is low, dd the specified trnsmission fluid 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 Filling NOTE: If the trnsmission fluid level is extremely low, see your locl Cummins MerCruiser Diesel Authorized Repir Fcility. IMPORTANT: For more ccurte mesurement, operte the engine t 1500 RPM for three minutes immeditely efore checking the fluid level. 8. Strt the engine nd operte t 1500 RPM for three minutes to fill ll the hydrulic circuits. 9. Stop the engine nd quickly check the fluid level. 10. If the fluid level is low, dd the specified trnsmission fluid to ring the level up to the mximum mrk on the dipstick. 11. Instll the dipstick. 12. Instll the ccess cover onto the drive cover if it ws removed. 13. Instll the drive cover if it ws removed. See Instlling the Drive Cover. You cn fill the trnsmission with fluid through the ccess cover on the drive cover or with the drive cover removed. 1. Remove the drive cover to fill the trnsmission with the drive cover removed. See Removing the Drive Cover, then go to step Remove the ccess cover from the drive cover, if filling with the drive cover instlled. Go to step Remove the dipstick. Wipe the dipstick with clen, lint free cloth. Check the fluid level s outlined in Checking. c - Access cover - Trnsmission c - Trnsmission dipstick Add the specified trnsmission fluid through the dipstick threded hole to ring the level up to the mximum mrk on the dipstick. Pge 82 CMD / AUGUST 2007

91 Section 5 - Mintennce Description Fluid Cpcity Fluid Type Fluid Prt Numer Trnsmission nd drop ox Trnsmission only 5 ¼ liters (5 ½ qurts) Synthetic Power Steering Fluid SAE 4 liters (4 ¼ qurts) 0W K01 IMPORTANT: For more ccurte mesurement, operte the engine t 1500 RPM for three minutes immeditely efore checking the fluid level. 5. Strt the engine nd operte t 1500 RPM for three minutes to fill ll the hydrulic circuits. 6. Stop the engine. Quickly unscrew nd remove the dipstick. 7. Check the fluid level s outlined in Checking. d c - Mximum mrk - Minimum mrk c - Top of threded hole d - Dipstick Chnging 8. If the fluid level is low, dd the specified trnsmission fluid to ring the level up to the mximum mrk on the dipstick. 9. Instll the dipstick. 10. Instll the ccess cover onto the drive cover if it ws removed. 11. Instll the drive cover if it ws removed. See Instlling the Drive Cover. 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. See Removing the Drive Cover. 2. Ly down oil soring wipes or mteril to ctch excess trnsmission fluid. CMD / AUGUST 2007 Pge 83

92 Section 5 - Mintennce 3. Remove the M drin plug nd seling wsher from the ft, strord end of the trnsmission nd drin the trnsmission fluid into suitle continer. - Drin plug nd seling wsher - Trnsmission On models with drop ox, remove the M drin plug nd seling wsher from the lower, port side of the drop ox nd drin the trnsmission fluid into suitle continer. - Drin plug nd seling wsher - Drop ox Dispose of the fluid properly. 6. Clen the exterior of the trnsmission round the fluid filter ssemly. 7. Use 6 mm Allen wrench nd remove the fluid filter ssemly screw. - Fluid filter ssemly - Assemly screw Pge 84 CMD / AUGUST 2007

93 Section 5 - Mintennce 8. Remove the filter cover ssemly. 9. Remove nd discrd the filter element nd the O rings. c d - Assemly screw - Wsher c - Cover d - Filter cover ssemly e - O ring e f g h i f - O ring g - Filter element h - Sel i - Oil pipe 10. Cot the new O rings with trnsmission fluid. 11. Instll the new O rings nd filter element. 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 fluid filter ssemly in the trnsmission cvity y turning the ssemly clockwise during instlltion. 13. Using 6 mm Allen wrench, tighten the filter ssemly screw to specifiction. - Assemly screw - Fluid filter ssemly Description Nm l. in. l. ft. Filter ssemly screw IMPORTANT: Use new seling wshers to void leks. CMD / AUGUST 2007 Pge 85

94 Section 5 - Mintennce 14. On models with drop ox, instll the drop ox drin plug with new seling wsher. Tighten the drop ox drin plug to specifiction. - Drin plug nd seling wsher - Drop ox Description Nm l. in. l. ft. Drop ox drin plug Instll the trnsmission drin plug with new seling wsher. Tighten the trnsmission drin plug to specifiction. - Drin plug nd seling wsher - Trnsmission Sewter Striner Description Nm l. in. l. ft. Trnsmission drin plug NOTE: The drop ox fills with fluid when the trnsmission is filled. 16. Fill the trnsmission to the proper level with the specified fluid. See Filling. 17. Instll the drive cover. See Instlling the Drive Cover. Refer to the pproprite Cummins Opertion nd Mintennce Mnul Mrine Engine for sewter striner mintennce instructions. Pge 86 CMD / AUGUST 2007

95 Section 5 - Mintennce 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. Guges Checking Guges 1. Check tht ll guges re securely mounted. 2. Check tht ny viewing systems such s VesselView, if equipped, re securely mounted. 3. Check for loose, dmged, or corroded wiring nd connectors. 4. Contct your Cummins MerCruiser Diesel Authorized Repir Fcility for correction or repir if necessry. Clening Guges Electricl System Clen guge y wshing with fresh wter to remove snd nd slt deposits. Wipe off with soft cloth moistened with wter. The guge my e scored or dmged if wiped with rsive mteril (snd, sline or detergent compounds, etc.) or wshed with solvents such s trichlorethylene, turpentine etc. 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. CMD / AUGUST 2007 Pge 87

96 Section 5 - Mintennce Luriction Driveshft Slip Joint 1. Remove the top nd ottom driveshft shields on the trnsmission end s shown. c d Top shield nd ottom shield t trnsmission end - Top shield - Bottom shield c - Socket hed driveshft shield to trnsmission retining hrdwre d - Driveshft shield upper to lower retining hrdwre 2. Luricte the driveshft slip joint through the grese fitting y pplying pproximtely 3 6 pumps of specified grese from typicl hnd operted grese gun Driveshft slip joint - Grese fitting Tue Ref No. 42 Tue Ref No. 91 Description Where Used Prt No. Driveshft slip-joint A1 Description Where Used Prt No. Engine Coupler Spline Grese Driveshft slip-joint A1 U-joint nd Giml Bering Grese 3. Apply dhesive to the threds of the screws nd olts of the shield on the trnsmission end. Pge 88 CMD / AUGUST 2007

97 Section 5 - Mintennce Tue Ref No. Description Where Used Prt No. 10 Loctite 277 Driveshft shield retining screw nd nut Otin Loclly 4. Instll the top nd ottom driveshft shields on the trnsmission end s shown. Tighten the driveshft shield retining screws nd nuts on the trnsmission end to specifictions. c d Top shield nd ottom shield t trnsmission end Top shield - Bottom shield c - Socket hed driveshft shield to trnsmission retining screw (M mm [1 in.]long) nd wsher d - Driveshft shield upper to lower retining screw (M mm [1/2 in.] long), nut, nd wsher Description Nm l. in. l. ft. Driveshft shield retining screw nd nut trnsmission end Driveshft shield upper to lower retining screw nd nut Secock Sewter Return (Overord) 1. Luricte the secock through the grese fitting y pplying pproximtely 3 6 pumps of specified grese from typicl hnd operted grese gun. Typicl drive (with cover removed for visul clrity) - Grese fitting - Secock (sewter return [overord]) CMD / AUGUST 2007 Pge 89

98 Section 5 - Mintennce Tue Ref No. Description Where Used Prt No. 94 Anti-Corrosion Grese Secock Q 1 Propeller Shft 1. Remove the propellers. Refer to Propellers. 2. Apply lierl cot of one of the following luricnts to the propeller shfts Tue Ref No. Description Where Used Prt No. 94 Anti-Corrosion Grese Propeller shfts Q 1 34 Specil Luricnt 101 Propeller shft Q C Mrine Luricnt with Teflon Propeller shft A1 Corrosion Protection 3. Instll the propellers. Refer to Propellers. 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 ( ). 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. IMPORTANT: Replce the scrificil nodes if they re eroded 50 percent or more. Pge 90 CMD / AUGUST 2007

99 Section 5 - Mintennce The MerCthode system uses n electrode controller nd node ssemly to protect ginst glvnic corrosion. 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 Test Meter. For testing, contct Cummins MerCruiser Diesel Authorized Repir Fcility or refer to the pproprite Cummins MerCruiser Drive Service Mnul. Anodes nd MerCthode System Loctions Description Loction Figure Trim t node plte Mounted on the trim t 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. Other Anodes nd Loctions Description Loction Figure Anode kit (if equipped) Mounted to the ot trnsom Reference Electrode Wire of the MerCthode System 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. CMD / AUGUST 2007 Pge 91

100 Section 5 - Mintennce Do not pressure wsh the reference electrode of the MerCthode ssemly. Doing so dmges the coting on the reference electrode wire nd decrese the corrosion protection. - Anode - Reference electrode (not visile in this view) MerCthode Anode CHECKING 1. Inspect the MerCthode node nd replce the node if dmged. REPLACING - Anode Contct your Cummins MerCruiser Diesel Authorized 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 92 CMD / AUGUST 2007

101 Reference Electrode T 1 Section 5 - Mintennce Senses the electricl current in the wter when testing the MerCthode system. Use to check hull potentil Trim T Anodes CHECKING Contct Cummins MerCruiser Diesel Authorized Repir Fcility for testing or refer to the pproprite Cummins MerCruiser Diesel Drive Service Mnul for testing procedures. 1. Inspect the trim t nodes. 2. Replce the nodes if they re eroded 50 percent or more. REPLACING Trim t node Contct your Cummins MerCruiser Diesel Authorized Repir Fcility. 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. d e f MerCthode controller - Reference electrode wire c - Bttery negtive ( ) terminl wire c d - Anode wire e - Bttery positive (+) terminl wire f - Blck/green continuity wire ( ) to onding stud CMD / AUGUST 2007 Pge 93

102 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. c c Bonding stud - Nut c - Blck/green continuity wire 4. 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. d c cd- Hinge lock Trim t Screw Continuity wire Inhiiting Corrosion In ddition to the corrosion protection devices, follow these steps to inhiit corrosion: 1. Pint your power pckge. See Pinting the Power Pckge. 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 renders nodes nd the MerCthode system ineffective s inhiitors of glvnic corrosion. When pinting the ot hull with nti fouling pint, oserve the following: Use high qulity, nti fouling pint designed for mrine use. Pge 94 CMD / AUGUST 2007

103 Section 5 - Mintennce Avoid using nti fouling pint tht contins copper mteril, which could conduct electricl current. If using copper sed or tin sed pints is necessry, ensure tht you comply with ll locl nd federl lws 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. Avoid ny electricl interconnection etween the pint nd drive, nodic locks, trim t nodes, or MerCthode system y llowing minimum of 40 mm (1 1/2 in.) unpinted re on the hull of the ot round these items nd s shown in the following figure. Unpinted re Minimum unpinted 40 mm (1 1/2 in.) re round the interfce ring sel (grommet) on models with molded in tunnel opening or round the olt on interfce ring ssemly (if equipped) 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. CMD / AUGUST 2007 Pge 95

104 Section 5 - Mintennce 2. Turn the rer propeller nut counter clockwise to remove the nut. - Block of wood - Trim t Slide the propeller nd thrust hu off of the propeller shft. 4. Using the propeller nut tool, turn the front propeller nut counter clockwise 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 Pge 96 CMD / AUGUST 2007

105 5. Slide the front propeller nd the front thrust hu off the propeller shft. Section 5 - Mintennce c - Front thrust hu - Front propeller c - Front propeller nut Propeller Repir Some dmged propellers cn e repired. Contct your Cummins MerCruiser Diesel Authorized Repir Fcility. Propeller Instlltion! 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, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. 1. Lierlly cot the propeller shft spline with one of the following Quicksilver luricnts. NOTE: Anti corrosion grese is for sltwter pplictions only. Tue Ref No. Description Where Used Prt No. 34 Specil Luricnt 101 Propeller shft splines Q C Mrine Luricnt with Teflon Propeller shft splines A1 94 Anti-Corrosion Grese Propeller shft splines Q 1 Luricting the propeller shft splines CMD / AUGUST 2007 Pge 97

106 Section 5 - Mintennce IMPORTANT: Check tht oth the front nd ft propeller prt numers mtch for port nd strord drives. 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 specifiction using the propeller nut tool. - 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 Pge 98 CMD / AUGUST 2007

107 Section 5 - Mintennce Description Nm l. in. l. ft. Front propeller nut Check the propeller for 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 specifiction. - Block of wood - Trim t f e d c - Front thrust hu - Front propeller c - Front propeller nut Zeus drive propeller ssemly d - Rer thrust hu e - Rer propeller f - Rer propeller nut Description Nm l. in. l. ft. Rer propeller nut CMD / AUGUST 2007 Pge 99