Mercury 92-858058K01 Page 7 Manual Download

Page: 7 / 150

90-879172181

eng

FEBRUARY 2011

Page iii

Reference Electrode Wire of the MerCathode System. . .112

MerCathode Anode.........................................................113

Checking.....................................................................113

Replacing....................................................................113

MerCathode System Testing..........................................113

Trim Tab Anode..............................................................113

Checking.....................................................................113

Replacing....................................................................113

Continuity Circuits...........................................................114

Inhibiting Corrosion.........................................................115

Painting the Boat............................................................115

Propellers...............................................................................116

Propeller Removal..........................................................116

Propeller Repair..............................................................117

Propeller Installation.......................................................117

Section 6 - Storage

Storage Descriptions..............................................................122

Drive Storage.........................................................................122

Cold Weather (Freezing Temperature) Storage.............122

Seasonal and Extended Storage Instructions.................122

Engine Storage...............................................................123

Battery Storage......................................................................123

Recommissioning...................................................................124

Engine.............................................................................124

Drive...............................................................................124

Power Package...............................................................124

Section 7 - Troubleshooting

Diagnosing Electronically Controlled Fuel System Problems 126

Electrical Connections...........................................................126

Troubleshooting Engine Related Problems...........................126

Check VesselView First.........................................................126

VesselView Malfunction Fault Code List................................126

Troubleshooting Charts..........................................................127

Poor Performance...........................................................127

Standard Helm Joystick..................................................128

Auxiliary Joystick Station................................................128

Electronic Remote Controls............................................129

Steering System.............................................................130

Trim Tabs........................................................................130

Boat Response Changes................................................130

Battery Will Not Charge..................................................131

Gauges and Instrumentation..........................................131

Section 8 - Customer Assistance Information

Owner Service Assistance.....................................................134

Marine Repair Logistics..................................................134

Local Repair Service.......................................................134

Service Away From Home..............................................134

Stolen Power Package...................................................134

Attention Required After Submersion.............................134

Replacement Service Parts............................................134

Parts and Accessories Inquiries.....................................134

Resolving a Problem.......................................................135

Customer Service Literature..................................................135

English Language............................................................135

Other Languages..............................................................135

Andre sprog......................................................................135

Andere talen.....................................................................135

Muut kielet........................................................................135

Autres langues.................................................................135

Andere Sprachen.............................................................136

Altre lingue.......................................................................136

Andre språk......................................................................136

Outros Idiomas.................................................................136

Otros idiomas...................................................................136

Andra språk......................................................................136

Allej glþssej......................................................................136

Ordering Literature.................................................................136

United States and Canada...............................................136

Outside the United States and Canada............................136

Section 9 - Pre-Delivery Information

Pre‑Delivery Information........................................................140

Dealer Pre‑Delivery Checklist for Zeus Products (Before Delivery

to the Customer)....................................................................140

Skyhook (If Equipped)......................................................140

Before Starting—Key Off..................................................140

Before Starting—Key On..................................................141

Engines Running at the Dock...........................................141

Sea Trial...........................................................................141

After On Water Test.........................................................142

Skyhook (If Equipped)......................................................142

Summary of Contents for 92-858058K01

Page 1: ...fication decal a Decal b Gear ratio c Serial number d Model number e Location of drive in vessel f CMD part number Control system identification if applicable SmartCraft 3 0 versions of the Zeus elect...

Page 2: ...et Total Command Verado VesselView Zero Effort Zeus 1 On The Water M with Waves logo Mercury with Waves logo and SmartCraft logo are all registered trademarks of Brunswick Corporation Mercury Product...

Page 3: ...rious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or...

Page 4: ......

Page 5: ...SmartCraft 3 0 19 Overload Protection for the DC to DC Voltage System If Equipped 20 Overload Protection for Other Circuits 21 Section 3 On the Water Safe Boating Suggestions 24 Be Alert to Carbon Mo...

Page 6: ...ck Steering Control Valve 68 Procedure for a Stuck Trim Tab Control Valve 68 End of First Season Checkup 69 Section 4 Specifications Drive Gear Lubricant 72 Transmission 72 Steering Actuator and Trim...

Page 7: ...Station 128 Electronic Remote Controls 129 Steering System 130 Trim Tabs 130 Boat Response Changes 130 Battery Will Not Charge 131 Gauges and Instrumentation 131 Section 8 Customer Assistance Informa...

Page 8: ...Page iv 90 879172181 eng FEBRUARY 2011...

Page 9: ...age 1 Section 1 Limited Warranty Table of Contents Warranty Information 2 Warranty Registration United States and Canada 2 Warranty Registration Outside the United States and Canada 2 World Wide Limit...

Page 10: ...he United States and Canada 1 It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the Cummins MerCruiser Diesel Distributor or Cummins MerCruis...

Page 11: ...d the warranty Commercial use is defined as any work or employment related use of the product or any use of the product which generates income during any part of the warranty period even if the produc...

Page 12: ...pon proper re registration of the product Table 1 Warranty Coverage Coverage Duration Repair Charges Paid by CMD Used with Engine Rating of Months Hours Parts Labor Travel Removal and Installation Lab...

Page 13: ...ll parts and labor needed to repair the damage to the Product resulting from a Warrantable Failure All labor costs will be paid in accordance with CMD published Standard Repair Time guidelines When it...

Page 14: ...ts which cannot be affected or limited by the terms of this Warranty Nothing in this Warranty excludes or restricts any contractual rights the Owner may have against third parties Owner Responsibiliti...

Page 15: ...ained the product as a result of an insurance claim Conditions That Must Be Met to Obtain Warranty Coverage Corrosion prevention devices specified in the Operation Maintenance and Warranty manual must...

Page 16: ...or repair however the cost of such service or parts and subsequent failures resulting from such service or parts will not be covered under this emission control system warranty Failures except those...

Page 17: ...edometer and Tachometer Digital Gauges If Equipped 13 System Link Digital Gauges If Equipped 14 Mercury Gateway Electronic Accessory 14 Electronic Helm Steering 14 Dual Handle Electronic Remote Contro...

Page 18: ...on the VIP ELECTRONICS SERIAL NO 88 500 000 MADE IN USA www cmdmarine com 44343 Typical ESN data tag inside the VIP Smartcraft 3 0 models The serial number on the engine control system data tag identi...

Page 19: ...station installed All triple and quad systems some dual systems The vessel is equipped with three helm stations One single VIP for all engine systems 43913 Typical SmartCraft 3 0 VIP Features and Con...

Page 20: ...e the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We recommend instructing other occupants on proper starting and operating proced...

Page 21: ...ank levels Boat direction 27198 VesselView Applications may have more than one VesselView For more information refer to the VesselView Operators Manual SmartCraft Speedometer and Tachometer Digital Ga...

Page 22: ...rating temperature c Voltmeter Battery voltage d Fuel level Quantity of fuel in tank Mercury Gateway Electronic Accessory The Mercury Gateway is an electronic accessory used to convert SmartCraft data...

Page 23: ...e the ERC handles and to move the ERC handles through the detents is adjustable to help prevent unwanted motion of the handle in rough water To adjust the ERC handle detent tension 1 Remove the side c...

Page 24: ...everse port mounted handle The amount of force needed to move the ERC handle and to move the ERC handle through the detents is adjustable to help prevent unwanted motion of the handle in rough water A...

Page 25: ...n 8 To adjust ERC handle tension a Turn the adjustment screw clockwise to increase tension on the control handle and counter clockwise to decrease tension b Adjust to the desired tension Side cover re...

Page 26: ...raffic to learn how your boat responds to joystick inputs Further we recommend that you occasionally practice maneuvering in the traditional way to maintain your traditional drive docking skills in ca...

Page 27: ...s throughout the boat Have your dealer show you the location and identify the circuit that they protect After finding and correcting the cause of the overload reset the circuit breaker by pressing the...

Page 28: ...g 25 A Engine h 25 A Main i 25 A Ground Overload Protection for the DC to DC Voltage System If Equipped NOTE For additional information on the on off switch for the DC voltage regulator refer to Sect...

Page 29: ...egulators three or four in the set depending upon the application take the place of the jumper plugs to supply 12 volt power to the VIP and the other 12 volt circuits The power package manufacturer pr...

Page 30: ...will not operate resulting in a loss of corrosion protection Have your dealer show you the location of and service procedures for the fuse a 5 amp fuse or circuit breaker some models equipped with a 2...

Page 31: ...s If Equipped 42 Automatic Control 42 Manual Control 43 Trim Tab Offset 43 Special Digital Throttle and Shift DTS Features 44 Troll and Throttle Response 44 Dock 45 Throttle Only 46 Single Lever 1 Lev...

Page 32: ...at Prepare other boat operators Instruct at least one person aboard in the basics of starting and operating the engine and handling the boat in case the driver becomes disabled or falls overboard Do n...

Page 33: ...well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide Good Ventilation Ventilate the passenger area open the side curtains or forward hatches to remove fumes 1 Exa...

Page 34: ...cold weather equipment and precautions See Section 6 for cold weather or extended storage related information Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for wate...

Page 35: ...oat bottom 27301 IMPORTANT The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed Under these conditions red...

Page 36: ...boat does not respond as it should or if water is present in the gear lube monitor bottle have your boat inspected at the nearest Authorized Cummins MerCruiser Diesel Repair Facility Operating in rev...

Page 37: ...reach the engine Rated Speed RPM contact your boat builder boat dealer or an Authorized Cummins MerCruiser Diesel Repair Facility for assistance in propeller selection A list of propellers for the Ze...

Page 38: ...Start and When Refueling 2 Perform the engine checks and steps listed in the engine s operation and maintenance manual available for this package NOTE Some vessels are not equipped with a seawater re...

Page 39: ...put the vessel underway with a light throttle load until the engines reach normal operating temperature Normal Stopping 1 Move the ERC handles to the neutral position 2 Corresponding to the engine yo...

Page 40: ...ble for this package NOTE Some vessels are not equipped with a seawater return seacock 3 Open the seawater return seacock if equipped Rotate the handle in the direction indicated by the arrow Drive co...

Page 41: ...engines 11 Press and release the start stop switch or green SMARTSTART start stop switch on the VIP corresponding to the engine being started The control system automatically controls the starter to a...

Page 42: ...top an engine The engines can be stopped using the SMARTSTART stop start switch on the VIP for each engine 1 Move the ERC handles to the neutral position 2 Locate the VIP for each engine in the engine...

Page 43: ...Traditional Maneuvering with Steering and Thrust You can maneuver your Zeus equipped vessel much like a traditional inboard boat However the Zeus drive system expands the maneuvering capability of yo...

Page 44: ...o engines are operational on either side of hull centerline the starboard outer engine is keyed off or a critical fault has occurred NOTE The center engine in a triple is not utilized during joystick...

Page 45: ...age 37 Joystick Input and Boat Response Table Joystick Input Boat Response Movement shown from light gray to dark gray 24704 Boat at rest 25911 24705 Boat moves forward 25928 24706 Boat moves aft 2592...

Page 46: ...to port without rotating 25931 24709 Boat moves diagonally forward and to the starboard without rotating 25926 24715 NOTE In this maneuver move and twist the joystick for yaw correction if required B...

Page 47: ...at Response Movement shown from light gray to dark gray 24711 Boat moves diagonally aft and to the port without rotating 25923 24712 Boat moves diagonally forward and to the port without rotating 2592...

Page 48: ...24715 Boat moves diagonally forward and to the starboard while rotating clockwise 25916 24718 Boat moves diagonally forward and to the starboard while rotating counterclockwise 25918 24719 Boat moves...

Page 49: ...us indicator light e Center drive status indicator light f Starboard drive status indicator light g Transfer button and indicator light h Alarm button and fault indicator light Typical auxiliary joyst...

Page 50: ...the throttle only feature will remain engaged even after the transfer and until the operator disables the feature Stopping the Engines from an Auxiliary Joystick Station The only method to shutdown st...

Page 51: ...witch is cycled off and on or the AUTO switch is pressed In manual control the trim tabs do not move during acceleration unless the operator presses the individual trim tab switches NOTE In automatic...

Page 52: ...ler speed to lower than that of engine speed for the first 30 of lever travel c TRANSFER Allows boat control to be transferred to a different helm Refer to Helm Transfer d DOCK Reduces the throttle ca...

Page 53: ...levers are moved out of neutral 5 The RPM of the engines do not change for the first 30 of ERC lever travel while the transmissions allow some slippage at lower speeds Engine RPM rises through the rem...

Page 54: ...until the ERC lever is returned to neutral With both ERC levers in neutral the light will stop blinking and illuminate 4 Place either ERC lever into gear 5 The RPM of the engines can be raised while t...

Page 55: ...Synchronizing the Engines The system features an automatic engine synchronization feature called Sync Sync engages automatically at key up The synchronization feature monitors the position of both ER...

Page 56: ...e additional notes are exclusive to your package You can change or disengage Cruise through the VesselView screen at any time Cruise resets when the key is turned off If the cruise limit is changed wh...

Page 57: ...the neutral lights will flash Move all the ERC levers to neutral and the neutral light should then be on 2 With the TRANSFER button light blinking and neutral lights on press the TRANSFER button a sec...

Page 58: ...ne beep will sound at the requesting auxiliary joystick station and at the active station confirming the impending transfer TRANSFER button a Transfer button light b Transfer button NOTE Any movement...

Page 59: ...icon b Heading c Drive angle reference d Engine RPM Trackpad The Precision Pilot trackpad includes TURN buttons that provide a 10 course correction to the port or starboard each time the button is pre...

Page 60: ...he active mode to disengage it then press the button for the new mode If you press a button with the power icon when that button light is off the light turns on for that button a single beep sounds an...

Page 61: ...water near the boat Skyhook will not engage unless the joystick and control levers are in neutral When Skyhook is engaged the propellers turn but the rotation may not be obvious Ensure that no one is...

Page 62: ...death The operator must stay at the helm ready to evade hazards and warn others of course changes Track Waypoint allows the boat to automatically navigate to a specific waypoint or sequence of waypoin...

Page 63: ...nmental conditions and incorrect use Observe the following information when using the Track Waypoint and Waypoint Sequencing feature Waypoint data distance settings Between waypoints Greater than 1 0...

Page 64: ...splay in VesselView NOTE The displayed heading is based on magnetic North 31413 Track Waypoint screen dual engine application screen shown NOTE The Precision Pilot TURN buttons will not initiate turns...

Page 65: ...Turn During a Waypoint Arrival IMPORTANT Track Waypoint mode does not automatically turn the boat upon arrival at a plotted waypoint 1 When the boat enters an waypoint arrival zone as indicated by the...

Page 66: ...not taken at the end of the waypoint The system will continue to pilot the vessel in a straight line in Auto Heading until the operator takes control If adequate lookout is not maintained the boat may...

Page 67: ...otter Waypoint Sequence mode only informs Precision Pilot it is OK to proceed to next waypoint Waypoint Sequence mode acts as a waypoint acknowledge function and Precision Pilot sounds a horn beep whe...

Page 68: ...ng a waypoint arrival zone Inform passengers that the boat automatically turns so they can be prepared 9 Press WAYPOINT SEQUENCE button when not in a waypoint arrival zone to disable Auto Sequence mod...

Page 69: ...e conditions 3 3 Aggressive for severe conditions 3 The value setting for the current amount of response appears on the Auto Heading page in VesselView Auto Heading WARNING In some Precision Pilot mod...

Page 70: ...o apply sufficient force to overcome the electronic detent 7 Precision Pilot holds the compass heading the boat was following when the AUTO HEADING button was pressed and Auto Heading engaged 31409 Du...

Page 71: ...movement adjusts the chosen heading by 1 NOTE The joystick must move over 50 of its travel for the movement to be recognized as input 24707 Adjusting heading to starboard To Resume a Heading The RESU...

Page 72: ...all engines in neutral The AUTO HEADING button light turns off and the Standby light comes on Turn the steering wheel beyond the electronic detent The AUTO HEADING button light turns off and the Resu...

Page 73: ...joystick can be used as an alternative method of steering when operating the vessel in close vicinity of objects docks and other vessels Engine RPM is limited with joystick operation Loss of Engine O...

Page 74: ...b the reverse gear solenoid on the starboard side of the transmission the wire is tagged Reverse Gear 5 Using a 3 mm hex head wrench turn the solenoid screw in the center of the top of the forward gea...

Page 75: ...ult Drive Steering Control Fault Stuck in any position Fault code is seen on VesselView Drive is in reduced operation mode Engine throttle percentage is reduced The maximum boat speed that can be achi...

Page 76: ...does not clear using the above procedure then shift the transmission into neutral shut down the engine turn the key switch off and alternately push the port and starboard steering manual override but...

Page 77: ...ult or Tab Spool Stuck fault remains then shut down the engine and turn the key switch off on the unresponsive drive Operate on another engine and drive Refer to Port Engine Only Operation if the star...

Page 78: ...Section 3 On the Water Notes Page 70 90 879172181 eng FEBRUARY 2011...

Page 79: ...ecifications 90 879172181 eng FEBRUARY 2011 Page 71 Section 4 Specifications Table of Contents Drive Gear Lubricant 72 Transmission 72 Steering Actuator and Trim Oil 72 Approved Paints 72 Approved Lub...

Page 80: ...ynthetic Power Steering Fluid SAE 0W 30 92 858077K01 Transmission With Drop Box and Remote Engine Mounted Transmission Oil Cooler Description Fluid Capacity Fluid Type Fluid Part Number Transmission d...

Page 81: ...4 Filling 96 Changing 98 Seawater System 101 Draining the Seawater System 101 Boat Out of the Water 101 Boat In the Water 101 Checking the Seawater Pickup on the Drive 104 Seawater Strainer 105 Flushi...

Page 82: ...er the service manual for that model The service manual outlines the correct procedures to follow It is written for the trained mechanic so there may be procedures you do not understand Do not attempt...

Page 83: ...e to the hoses and other components as a result of mechanical hose abrasion during operation or damage to the hoses such as being stepped on during service or maintenance If equipped keep the drive co...

Page 84: ...t shield d Gear lube monitor fill e Hydraulic fluid filter f Trim tab and anode plates g Propeller shaft Top a Transmission dipstick b Gear lube monitor fill cap c Exhaust elbow d Driveshaft shield sc...

Page 85: ...luid level Every two months of operation Check the battery connections and fluid level Treat the power package components inside the boat with Corrosion Guard to protect the product from corrosion Ens...

Page 86: ...he hydraulic system fittings and hoses found on the drive for leaks or damage Check the hose fittings for tightness Check the bonding continuity circuit for loose or damaged connections Test the MerCa...

Page 87: ...Section 5 Maintenance 90 879172181 eng FEBRUARY 2011 Page 79 Date Maintenance Performed Engine Hours...

Page 88: ...ter section 4 Remove the two side covers 5 Remove the two top screws 6 Lift and remove the top of the drive cover Typical drive cover a Upper screw 6 b Lower screw 3 c Port side cover d Top of the dri...

Page 89: ...rews a Starboard cover b Screw 4 5 Align and insert the starboard cover into the groove of the H trim section on the port cover 6 Install the port side cover using five screws Typical port side cover...

Page 90: ...he monitor includes a switch that can detect a low level of gear lubricant and set an audio or visual alarm The Checking and Filling procedures as provided are for situations where the gear lubricant...

Page 91: ...is shut down NOTE It is normal to add a small amount of gear lube between change intervals IMPORTANT If the gear lube level is below the COLD FILL LEVEL line when checked especially after the first co...

Page 92: ...appears discolored contact your Cummins MerCruiser Diesel Authorized Repair Facility immediately These conditions may indicate a water leak in the drive 4 If the level is lower than the COLD FILL LEV...

Page 93: ...A click sound can be heard when the access cover snaps into final position 39514 Completing the access cover installation Filling If the gear lube level is below the COLD FILL LEVEL line add the speci...

Page 94: ...858064K01 3 Ensure that the rubber gasket is inside the cap for the gear lube monitor and install the cap Do not overtighten NOTE After the drive has been operated and the gear lube is hot the fluid...

Page 95: ...adapter 91 24789A1 4 Install a suitable double ended male adapter to the gear lube adapter Typical adapter a Double ended male adapter b Gear lube adapter and washer 5 Attach the crankcase oil pump o...

Page 96: ...ar lube pump or equivalent a Locate the adapter provided with the gear lube pump Description Part Number Quicksilver Gear Lube Pump 91 850730Q1 b Assemble the sealing washer spacer and sealing washer...

Page 97: ...o specification Description Nm lb in lb ft Steering actuator fill and drain screw 6 7 60 13 If the level is low fill the gear lube monitor to the COLD FILL LEVEL line Refer to Filling 14 Ensure that t...

Page 98: ...Authorized Repair Facility immediately 5 Allow the gear lube to drain completely Properly dispose of the gear lube IMPORTANT Use Mercury or Quicksilver High Performance Gear Lube in the drive 6 Instal...

Page 99: ...to the COLD FILL LEVEL line if the level is low Refer to Filling 10 Ensure that the rubber gasket is inside the cap for the gear lube monitor and install the cap Do not overtighten 11 Install the driv...

Page 100: ...the cap to open or close is imprinted on the top of the cap 2 Push down and turn the reservoir cap and dipstick about 1 3 turn in the open direction a Reservoir cap and dipstick b Open direction c Clo...

Page 101: ...the cap and dipstick Push down and turn the reservoir cap and dipstick about 1 3 turn in the open direction a Reservoir cap and dipstick b Open direction c Close direction IMPORTANT Always use the di...

Page 102: ...oil filter is dirty Change the oil and filter as soon as reasonably possible if not immediately Contact your local Authorized Cummins MerCruiser Diesel Repair Facility for additional information High...

Page 103: ...Power Steering Fluid SAE 0W 30 92 858077K01 NOTE If the transmission oil level is extremely low contact your local Cummins MerCruiser Diesel Authorized Repair Facility IMPORTANT For a more accurate me...

Page 104: ...ont of the access cover A click sound can be heard when the access cover snaps into final position 39514 Completing the access cover installation Filling You can fill the transmission with oil through...

Page 105: ...lter and oil coolers after changing the transmission oil Always use the dipstick to establish the correct oil level NOTICE The seawater pumps on vessels equipped with Zeus pod drives can be damaged by...

Page 106: ...damage this coating and the inner core causing water to leak into the boat Use caution when installing and working around the interface ring seal to prevent damage Do not use any lubricants or sealing...

Page 107: ...mbly b Assembly screw 8 Remove the filter cover assembly 9 Remove and discard the filter element and the O rings a Assembly screw b Washer c Cover d Filter cover assembly e O ring f O ring g Filter el...

Page 108: ...n drain plug with a new sealing washer Tighten the drain plug to specification a Drain plug and sealing washer b Transmission Description Nm lb in lb ft Transmission drain plug 90 66 NOTE The drop box...

Page 109: ...ed oil cooler 5 On models with a drop box and drive mounted transmission oil cooler as shown remove the drain plug Drain the seawater a Drain plug b Transmission oil cooler 6 On models equipped with a...

Page 110: ...closed position 3 Close the seawater discharge return seacock Rotate the handle in the direction indicated by the arrow Drive cover removed for clarity a Discharge seacock b Handle in closed position...

Page 111: ...drain the seawater a Drain plug b Transmission oil cooler 10 On models equipped with a seawater strainer refer to Seawater Strainer 11 Apply sealant to the drain plugs of the transmission oil coolers...

Page 112: ...ged 16 Place a tag at the helm and in the engine compartment stating that the seacocks are closed and must be opened after all drain plugs and hoses are installed prior to starting the engines Checkin...

Page 113: ...d ensure that all engines did start or shutdown where indicated in the table Station Task E stop to Activate Confirm E Stop Function Check Engine Status Finish Task Main helm station Start all engines...

Page 114: ...ling and exhaust system hose clamps for tightness Lubrication and Torque Maintenance Driveshaft Slip Joint The driveshaft has a slip joint that must be lubricated through a grease fitting Part of the...

Page 115: ...ad screws as shown Tighten the screws to specification a Top shield b Driveshaft shield to engine screw c Engine end Description Nm lb in lb ft Driveshaft shield screw engine end 36 27 Driveshaft U Jo...

Page 116: ...ntact your Cummins MerCruiser Diesel Repair Facility for additional information 4 Lubricate the driveshaft U joints through the grease fittings if equipped with approximately 3 4 pumps from a handheld...

Page 117: ...n Nm lb in lb ft Driveshaft shield retaining screw transmission end QSC and QSB models 36 27 QSM models 47 35 Driveshaft shield upper to lower retaining screw and nut transmission end 17 23 7 Install...

Page 118: ...sion input and driveshaft flanges 175 mm 6 88 in and use eight bolts and nuts Ensure the bolts and nuts are at least Grade 8 fasteners before tightening Typical four bolt flange shown eight bolt simil...

Page 119: ...re A Quicksilver Galvanic Isolator can be installed to block the passage of these currents while providing a path to ground for dangerous fault shock currents Refer to the Diesel Parts and Accessories...

Page 120: ...intenance manual provided by the boat manufacturer for additional information about vessel mounted anodes Other Anodes and Locations Description Location Figure Anode kit if equipped Mounted to the bo...

Page 121: ...a Quicksilver Reference Electrode and Test Meter Reference Electrode 91 76675T 1 9188 Senses the electrical current in the water when testing the MerCathode system Use to check hull potential Contact...

Page 122: ...o the threads of the trim tab anode screws Tube Ref No Description Where Used Part No Loctite 268 Trim tab anode screw threads when installed in the water Obtain Locally 8 Install the anodes on the tr...

Page 123: ...steps to inhibit corrosion 1 Paint your power package See Painting the Power Package 2 Spray power package components on the inside of the boat annually with Corrosion Guard to protect the finish from...

Page 124: ...d unpainted areas a Painted hull b Painted drive c Minimum unpainted 25 mm 1 in area If desired a non conductive anti fouling paint can be used to inhibit marine growth in the 25 mm 1 in minimum area...

Page 125: ...erCruiser Diesel Authorized Repair Facility Propeller Installation WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Befo...

Page 126: ...propeller shaft with the tapered side toward the propeller hub 3 Align the splines and place the front propeller on the propeller shaft The propeller must fit freely on the propeller shaft splines 4...

Page 127: ...until after the alignment of the drives Refer to Section 6 Initial Drive and Steering Wheel Alignment and Calibration 8 Slide the rear thrust hub onto the propeller shaft with the tapered side toward...

Page 128: ...Section 5 Maintenance Notes Page 120 90 879172181 eng FEBRUARY 2011...

Page 129: ...6 Storage Table of Contents Storage Descriptions 122 Drive Storage 122 Cold Weather Freezing Temperature Storage 122 Seasonal and Extended Storage Instructions 122 Engine Storage 123 Battery Storage...

Page 130: ...mmediately after operation Seasonal storage refers to when the boat is not being operated for one month or more The duration varies according to the geographic location Seasonal storage precautions an...

Page 131: ...e 8 Immediately close the seawater return seacock 9 Remove the temporary hose from the seawater pump 10 Connect the existing seawater inlet hose to the seawater pump Tighten the hose clamps securely 1...

Page 132: ...ause injury from electrical shock or can damage the electrical system Always disconnect the negative battery cable first and connect it last 1 Install a fully charged battery Clean the battery cable c...

Page 133: ...nnections 126 Troubleshooting Engine Related Problems 126 Check VesselView First 126 VesselView Malfunction Fault Code List 126 Troubleshooting Charts 127 Poor Performance 127 Standard Helm Joystick 1...

Page 134: ...ry before electric arc welding on the vessel Attach the welder ground cable no more than 0 61 m 2 ft from the part being welded Do not connect the ground cable of the welder to any ECM cooling plate o...

Page 135: ...ick Operation Disabled Joystick Operation Minimal Joystick Operation Reduced Joystick Station Configuration Fault Joystick Station Fault Joystick Station Faulted Joystick Station Lost Joystick Station...

Page 136: ...unction properly and a fault code is set Check VesselView for Guardian fault codes that cause engine power reduction If found have the system checked by your Authorized Cummins MerCruiser Diesel Repai...

Page 137: ...OCKING button on DTS track pad Place both ERC handles in neutral and push the dock button to disengage if light is on Check VesselView to see if cruise control is enabled Disable cruise control Consul...

Page 138: ...Section 5 Maintenance Contact your Authorized Cummins MerCruiser Diesel Repair Facility Steering wheel turned past end stop Key off and key on to restore steering wheel self centering Autopilot steeri...

Page 139: ...lty connections Repair or replace damaged wiring Ensure area around the ground connections is clean and making good metal to metal contact Alternator drive belt loose or in poor condition Replace or a...

Page 140: ...Section 7 Troubleshooting Notes Page 132 90 879172181 eng FEBRUARY 2011...

Page 141: ...on Required After Submersion 134 Replacement Service Parts 134 Parts and Accessories Inquiries 134 Resolving a Problem 135 Customer Service Literature 135 English Language 135 Other Languages 135 Andr...

Page 142: ...numbers and to whom the recovery is to be reported This information about the stolen motor is placed into a file at Cummins MerCruiser Diesel to aid authorities and dealers and distributors in the rec...

Page 143: ...s and Canada contact the nearest Mercury Marine or Marine Power International Service Center for further information When ordering be sure to List your product model year and serial numbers Check the...

Page 144: ...ne o Marine Power International para recibir informaci n Con su conjunto motriz se entrega una lista de los n meros de pieza para los otros idiomas Andra spr k F r att f Instruktions och underh llsb c...

Page 145: ...r form with payment to Mercury Marine Attn Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Ship To Please copy this form and print or type This is your shipping...

Page 146: ...Section 8 Customer Assistance Information Notes Page 138 90 879172181 eng FEBRUARY 2011...

Page 147: ...n Table of Contents Pre Delivery Information 140 Dealer Pre Delivery Checklist for Zeus Products Before Delivery to the Customer 140 Skyhook If Equipped 140 Before Starting Key Off 140 Before Starting...

Page 148: ...Operation Manual 90 8M0050668 VVM Captain s Briefing Information Brochure 3381956 Warranty Registration Card 90 842801002 Skyhook If Equipped Publication Name Publication Part Number Manual Code Skyho...

Page 149: ...d operational check ZIM Section 2 Exhaust leaks visual check Visual Inspection Fluid leaks visual check Visual Inspection Drive interface ring seal sealing grommet visual check for leaks Visual Inspec...

Page 150: ...the customer with the Zeus Operation Maintenance and Warranty Manual Supply the customer with the VesselView Operations manual Supply the customer with the Captain s Briefing Information brochure Sup...

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