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Mercury Zeus 3000 Series, User Manual

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Mercury Zeus 3000 Series User Manual Download Page 7

90-866938081   MAY  2009

Page  iii

Filling............................................................104

Changing......................................................106

Seawater System................................................110

Draining the Seawater System.....................110

Boat out of the Water.................................110

Boat in the water........................................112

Checking the Seawater Pickup on the Drive 115

Seawater Strainer.........................................116

Flushing the Seawater System.....................116

Battery.................................................................116

Gauges................................................................116

Checking Gauges.........................................116

Cleaning Gauges..........................................117

Electrical System.................................................117

Cooling System and Exhaust System.................117

Lubrication...........................................................117

Driveshaft Slip‑Joint ....................................117

Driveshaft U‑Joints ......................................119

Propeller Shaft..............................................121

Corrosion and Corrosion Protection....................122

The Causes of Corrosion.............................122

Corrosion Protection.....................................122

Anodes and MerCathode System ...............123

Reference Electrode Wire of the MerCathode

System.........................................................124

MerCathode Anode......................................124

Checking....................................................124

Replacing...................................................124

MerCathode System Testing........................124

Trim Tab Anode............................................125

Checking....................................................125

Replacing...................................................125

Continuity Circuits........................................126

Inhibiting Corrosion......................................127

Painting the Boat..........................................127

Propellers............................................................128

Propeller Removal........................................128

Propeller Repair...........................................129

Propeller Installation.....................................130

Section 6 - Storage

Storage Descriptions...........................................134

Drive Storage.......................................................134

Cold Weather (Freezing Temperature)

Storage.........................................................134

Seasonal and Extended Storage

Instructions...................................................135

Engine Storage.............................................135

Battery Storage....................................................135

Recommissioning................................................135

Engine..........................................................135

Drive.............................................................136

Power Package............................................136

Section 7 - Troubleshooting

Diagnosing Electronically Controlled Fuel System

Problems.............................................................138

Electrical Connections.........................................138

Troubleshooting Charts.......................................138

Troubleshooting Engine Related Problems. .138

Check VesselView First................................138

Poor Performance........................................139

Joystick.........................................................139

Electronic Remote Controls..........................139

Steering System...........................................140

Trim Tabs.....................................................141

Boat Response Changes.............................141

Battery Will Not Charge................................141

Gauges and Instrumentation........................142

Galvanic Isolator...........................................142

Section 8 - Customer Assistance Information

Owner Service Assistance...................................144

Marine Repair Logistics................................144

Local Repair Service....................................144

Service Away From Home............................144

Stolen Power Package.................................144

Attention Required After Submersion...........144

Replacement Service Parts..........................144

Parts and Accessories Inquiries...................145

Resolving a Problem....................................145

Summary of Contents for Zeus 3000 Series

Page 1: ...ntains the engine serial number and model number Please record the following information Drive Serial Numbers Zeus Drive Serial Number Transmission Serial Number Port Starboard Engine Model and Horsep...

Page 2: ...age The product you have purchased comes with a limited warranty from Cummins MerCruiser Diesel the terms of the warranty are set forth in the Warranty Sections of this manual The warranty statement c...

Page 3: ...particular step or action WARNING The operator driver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend th...

Page 4: ......

Page 5: ...ge Regulator System If Equipped 19 Overload Protection for Other Circuits 20 Galvanic Isolator and Monitor 20 Section 3 On the Water Safe Boating Suggestions 25 Be Alert to Carbon Monoxide Poisoning 2...

Page 6: ...rival 64 Waypoint Sequence 66 Contingent Operations 68 Steering Emergency Alternative Method 68 Port Engine Only Operation 69 Gear Engagement Emergency Procedure 69 Steering and Trim Manual Override 7...

Page 7: ...128 Propeller Removal 128 Propeller Repair 129 Propeller Installation 130 Section 6 Storage Storage Descriptions 134 Drive Storage 134 Cold Weather Freezing Temperature Storage 134 Seasonal and Exten...

Page 8: ...s 147 Andra spr k 147 Allej gl ssej 147 Ordering Literature 147 United States and Canada 147 Outside the United States and Canada 147 Section 9 Pre Delivery Information Pre Delivery Information 150 De...

Page 9: ...anty Registration United States and Canada 2 Warranty Registration Outside the United States and Canada 2 High Output Recreational Use World Wide Limited Warranty 3 Intermittent Commercial Use World W...

Page 10: ...d be returned to him for warranty service 5 The product warranty is not effective until the product is registered at the factory NOTE Registration lists must be maintained by the factory and dealer on...

Page 11: ...ibutor or Cummins MerCruiser Diesel Authorized Dealer fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area Hig...

Page 12: ...tion Labor Travel Base Engine Warranty 24 1000 Yes Yes Yes Yes Extended Major Components 72 3000 Yes Yes Yes Yes Extended Major Components Limited Warranty The Extended Major Components Limited Warran...

Page 13: ...ts and other maintenance items replaced during warranty repairs unless such items are not reusable due to the Warrantable Failure During the Extended Major Components Limited Warranties Owner is respo...

Page 14: ...90 days After the coverage duration start date Maintenance Components include but are not limited to sea water pump impellers sacrificial anodes oil filters fuel filters air filters water filters and...

Page 15: ...lure Underwater impact damage is not a warrantable failure Coverage begins with the retail sale of the Engine and Drive by CMD and continues for the Duration stated in the following table The Duration...

Page 16: ...e event of any Product failure Owner is responsible for the cost of towing the boat to the repair dock and for all associated docking and harbor charges Owner is responsible for maintaining the Engine...

Page 17: ...or failures resulting from 1 Use or application of the Product inconsistent with its rating designation set forth above 2 Incorrect installation Before a claim for excessive oil consumption will be co...

Page 18: ...rCruiser Diesel Will Do Cummins MerCruiser Diesel and Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing a corroded part replacing such part or parts wit...

Page 19: ...resulting from a defect in materials or factory workmanship are not covered by the WARRANTY CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES In the United States2 and Canada this warran...

Page 20: ...Section 1 Limited Warranty Notes Page 12 90 866938081 MAY 2009...

Page 21: ...n 15 VesselView 15 SmartCraft Speedometer and Tachometer Digital Gauges If Equipped 15 System Link Digital Gauges If Equipped 16 Electronic Helm Steering 17 Dual Handle Electronic Remote Control ERC F...

Page 22: ...engine for the location of the engine data tag that contains the engine serial number and model number Features and Controls E Stop Emergency Stop Switch If Equipped An E stop emergency stop switch t...

Page 23: ...ower and directional control in heavy seas strong current or high winds The operator can lose control when docking Restarting an engine using the key switch or start button after an E stop shutdown wi...

Page 24: ...ation on the SmartCraft Instrument package and for details on the warning functions monitored by the system refer to the manual provided with your gauge package SYSTEM LINK DIGITAL GAUGES IF EQUIPPED...

Page 25: ...rol ERC handle controls the operation of shift and throttle Push the control handle forward from neutral to the first detent for forward gear Continue pushing the handle forward to increase speed Pull...

Page 26: ...learn we recommend that you drive the boat in the traditional way until you can spend time in an open area free of obstructions and traffic to learn how your boat responds to inputs Further we recomm...

Page 27: ...NOTE A VIP for each engine is located in the engine room 33923 a b c d e f All similar Item Circuit Breaker Rating Protection Location on VIP a 15 A Gear Upper left b 10 A SIM Vessel Middle left c 10...

Page 28: ...o the positive terminal on the controller If the fuse is defective open the system will not operate resulting in a loss of corrosion protection Have your dealer show you the location of and service pr...

Page 29: ...rder to provide a path for fault current and to assist the MerCathode in preventing galvanic corrosion on drive components Install a galvanic isolator or similar isolation device in the AC shore power...

Page 30: ...Section 2 Getting to Know Your Power Package Notes Page 22 90 866938081 MAY 2009...

Page 31: ...in the Boat on its Axis at Low Speeds 39 Maneuvering with the Joystick 39 Trim Tabs 43 Automatic Control 43 Manual Control 44 Using Trim Tab Offset 44 Special Digital Throttle and Shift DTS Features 4...

Page 32: ...Section 3 On the Water Page 24 90 866938081 MAY 2009 Procedure for a Stuck Trim Tab Control Valve 73 End of First Season Checkup 73...

Page 33: ...ne Waterproof storage containers Manual bilge pump and extra drain plugs Spare operating equipment batteries bulbs and fuses Drinking water Compass and map or chart of the area Watch for signs of weat...

Page 34: ...llen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to the skier The operator should...

Page 35: ...ches open station wagon effect Basic Boat Operation Freezing Temperature and Cold Weather Operation IMPORTANT If the boat is operated during periods of freezing temperature take precautions to prevent...

Page 36: ...ther or extended storage related information Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect For this reason boats are normally equipped with a dr...

Page 37: ...use serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible mc79680 1 Operating recreational boats over waves and wakes is a natural...

Page 38: ...drive components or boat bottom could cause additional damage to other parts of the power package or could affect control of the boat If continued operation is necessary do so at greatly reduced spee...

Page 39: ...g the engine to overheat Cavitation Cavitation occurs when water flow cannot follow the contour of a fast moving underwater object such as a gear housing or a propeller Cavitation increases propeller...

Page 40: ...manual Refer to the Zeus drive Mercury Parts Manual 90 879150112 Getting Started Break In Period New or With Replacement Gears Always perform these procedures on new drive units This break in procedu...

Page 41: ...cumstances start and stop the engine from the helm using the start stop button of the SmartStart system Refer to Section 2 Getting to Know Your Power Package for additional information on the E stop s...

Page 42: ...e starting the engines the ERC handles must be in neutral position as indicated by the neutral indicator lights on continuously 6 Move the ERC handles to the neutral position NOTE Ask your dealer for...

Page 43: ...s a b 41199 Drive cover removed for clarity a Seacock for seawater return b Handle in closed position a c b 41196 Typical inlet seacock port orientation a Seacock for seawater inlet b Former position...

Page 44: ...closed 5 Open the seacock if equipped for any accessory equipment NOTE When the key switch is turned to the on position the neutral LED lights on the ERC trackpad flash on and off if the ERC handles...

Page 45: ...an engine from the engine room or under certain circumstances the engine control system may not be able to automatically stop an engine The engines can be stopped using the SMARTSTART stop start swit...

Page 46: ...peeds the drive system is capable of directing the thrust to produce more responsive turning of the vessel The Zeus drive system features counter rotating propellers that do not produce any sideways m...

Page 47: ...ing for very intricate movements for maneuvering in tight quarters The control system automatically attempts to dampen bow and stern swinging referred to as yaw during joystick operation An on board s...

Page 48: ...1 MAY 2009 Joystick Input Boat Response Movement shown from light gray to dark gray 24705 Boat moves forward 25928 24706 Boat moves aft 25927 24707 Boat moves to starboard without rotating 25929 24708...

Page 49: ...ard and to the starboard without rotating 25926 24715 NOTE In this maneuver move and twist the joystick for yaw correction if required Boat moves diagonally forward and rotates starboard for yaw corre...

Page 50: ...ovement shown from light gray to dark gray 24712 Boat moves diagonally forward and to the port without rotating 25925 24713 Boat rotates clockwise 25921 24714 Boat rotates counter clockwise 25920 2471...

Page 51: ...system to provide basic performance and efficiency improvements under normal conditions The automatic trim tab control feature can be engaged turned on or disengaged turned off To engage the feature...

Page 52: ...ng initial acceleration the trim tabs are automatically adjusted automatic control or must be manually adjusted manual control to bring the boat on plane faster bow down to improve forward visibility...

Page 53: ...l Function a NEUTRAL lights Illuminate when the transmission is in the neutral gear position The lights flash when the engine is in throttle only mode b TROLL Troll reduces the propeller speed to lowe...

Page 54: ...ed and maximum rated engine speed 31463 TROLL button To engage Troll mode 1 Place both ERC levers in neutral 2 Press the TROLL button located on the DTS trackpad attached to the ERC levers 3 Place eit...

Page 55: ...tached to the ERC levers 3 The DOCK button light turns on 4 Place either ERC lever into gear 5 The engines raise the RPM at a proportionally lower RPM for the ERC lever position and with half the powe...

Page 56: ...remains in Throttle Only mode until you place the levers in neutral 1 Bring both ERC levers to neutral Throttle Only will not disengage unless the ERC levers are in neutral 2 Press the THROTTLE ONLY...

Page 57: ...urns green when they synchronize The icon turns grey when Sync mode is off To disengage Sync mode 1 Place the ERC levers in any detent 2 Press the SYNC button 31467 SYNC button To re engage Sync mode...

Page 58: ...or navigation functions are attempted after the helm transfer procedure is started To remove the fault codes it may be necessary to cycle the key switch off and on and then restart the helm transfer...

Page 59: ...gage when the TRANSFER button is pressed the second time You must engage Skyhook at the the newly active helm The Resume feature for Auto Heading does not transfer automatically After engaging the pre...

Page 60: ...ions to use the functions of Precision Pilot 31408 b c a d Standby screen on VesselView a OFF icon b Heading c Drive angle reference d Engine RPM STANDBY AND ACTIVE LIGHTS Precision Pilot is disengage...

Page 61: ...ngage 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 and the ACTIVE light ill...

Page 62: ...operates to stay out of the water and off the swim platform and to be alert for any sudden shifts in the boats position Check to see no one is on the swim platform or in the water anywhere near the bo...

Page 63: ...d passengers should read and observe the warning labels on the boat before Skyhook is engaged 33798 8M0034159 Label adjacent to the Precision Pilot trackpad 33824 Label in the vicinity of the transom...

Page 64: ...w to close the safety pop up NOTE Pressing the SKYHOOK button will also close the safety pop up and then disengage Skyhook 7 The Skyhook system engages and a one second solid horn beep sounds one time...

Page 65: ...sselView screen is equivalent to 5 meters of error If the boat exceeds 20 meters of error then the boat is located at the edge of the circle The boat continues to try to correct until Skyhook is disen...

Page 66: ...at least one running engine in forward gear NOTE Auto Heading does not function with the ERC levers in neutral or reverse 2 Steer the boat to the desired compass heading 3 Press the AUTO HEADING butt...

Page 67: ...TMENT USING THE TURN BUTTONS OR JOYSTICK While in AUTO HEADING mode the TURN buttons course adjust buttons change the set course heading each time they are pressed Tapping the joystick left or right a...

Page 68: ...turned more than 180 Press the RESUME button to resume the previous heading if you Turned the steering wheel and disengaged Auto Heading Pressed one of the TURN course adjust buttons with Auto Heading...

Page 69: ...Auto Heading See To Resume a Heading If you do not wish to resume the course press the AUTO HEADING button once to engage Standby and press it again to turn the Auto Heading mode off 31408 b c a d a M...

Page 70: ...ions 2 2 Medium for moderate 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 Track Waypoint WARNIN...

Page 71: ...ecision Pilot 1 Turn on the chart plotter and select a single waypoint or waypoint route to be tracked 2 Place at least one ERC handle in forward gear Track Waypoint does not function if both handles...

Page 72: ...t goes to Standby Move both ERC levers back to neutral and Pilot goes to Standby Press either TURN button and Pilot goes to Auto Heading mode Press the AUTO HEADING button and Pilot goes to Auto Headi...

Page 73: ...the chart plotter a short horn beep sounds and the WAYPOINT SEQUENCING button light starts blinking to inform the operator to make a turn 27703 WAYPOINT SEQUENCE button 2 If the Waypoint Sequence mode...

Page 74: ...cknowledged the boat continues on its current heading 5 At the end of the Track Waypoint course input a new route or take control of the boat Otherwise the boat reverts to Auto Heading mode and contin...

Page 75: ...ion Pilot sounds a horn beep when in the zone WARNING In some Precision Pilot modes Auto Heading Track Waypoint and Waypoint Sequence the boat navigates a preset course The boat does not automatically...

Page 76: ...pop up screen warning and press the enter button the button with a check mark symbol 31412 Pop up screen warning 9 Press the TRACK WAYPOINT button The WAYPOINT SEQUENCE button light turns on and a si...

Page 77: ...s a single engine vessel Note that joystick and station keeping are not available in this condition However Zeus features redundant AutoPilot systems so Auto Heading and Track Waypoint mode are still...

Page 78: ...art with the ERC lever in gear even though the drive is manually engaged in a gear 8 When you are ready to start the engine position the ERC lever in neutral gear before turning the key switch to the...

Page 79: ...achieved on a single engine with one engine shut down or with one drive that is not steerable will vary on different models Except in an emergency normal operation on a single engine should not excee...

Page 80: ...Wait at least 30 seconds if possible 3 Restart the engine Confirm the steering fault has cleared 4 If the steering fault did not clear repeat the start stop routine up to three times 5 If the steering...

Page 81: ...ve cover if equipped for additional information 6 Restart the engine At the helm trim the tab up and down to confirm the fault has cleared If the Tab_Spool_Stuck fault remains then shut down the engin...

Page 82: ...Section 3 On the Water Notes Page 74 90 866938081 MAY 2009...

Page 83: ...4 Specifications 90 866938081 MAY 2009 Page 75 Section 4 Specifications Table of Contents Drive Gear Lubricant 76 Transmission 76 Steering Actuator and Trim Oil 76 Approved Paints 76 Approved Lubrican...

Page 84: ...art Number Transmission and drop box 5 1 4 L 5 1 2 US qt Synthetic Power Steering Fluid SAE 0W 30 92 858077K01 Transmission With Drop Box and Remote Engine Mounted Transmission Oil Cooler Description...

Page 85: ...8081 MAY 2009 Page 77 Tube Ref No Description Where Used Part No 42 U joint and Gimbal Bearing Grease Driveshaft slip joint 92 802870A1 Tube Ref No Description Where Used Part No 94 Anti Corrosion Gre...

Page 86: ...Section 4 Specifications Notes Page 78 90 866938081 MAY 2009...

Page 87: ...Changing 102 Transmission Oil Fluid and Filter 102 Checking 102 Filling 104 Changing 106 Seawater System 110 Draining the Seawater System 110 Boat out of the Water 110 Boat in the water 112 Checking...

Page 88: ...elf Maintenance Suggestions Present day marine equipment such as your Cummins MerCruiser Diesel power package are highly technical pieces of machinery Special fuel delivery systems provide greater fue...

Page 89: ...amage 3 Remove and inspect the propellers If nicked bent or cracked contact your Cummins MerCruiser Diesel Authorized Repair Facility 4 Repair nicks and corrosion damage on the power package exterior...

Page 90: ...l cooler d Exhaust outlet connection e Engine seawater return outlet f Muffler seawater bypass g Seawater inlet seacock h Hydraulic oil drain plug i Gearcase drain plug j Hydraulic oil reservoir Port...

Page 91: ...or cap Maintenance Schedules Application The following schedules apply to the Zeus drive and driveshaft connection not to the Cummins engine For the engine maintenance schedule and procedures refer to...

Page 92: ...corrosion Ensure that the gauges and the wiring connections are secure Clean the gauges every two months or every 50 hours whichever occurs first If operating in saltwater the interval is reduced to e...

Page 93: ...the 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 MerC...

Page 94: ...Section 5 Maintenance Page 86 90 866938081 MAY 2009 Date Maintenance Performed Engine Hours...

Page 95: ...er screws holding the port side cover to the center section 3 Remove the one lower screw holding the starboard side cover to the center section 4 Remove the two side covers 5 Remove the two top screws...

Page 96: ...Top cover b Threaded holes 2 Install one large washer on each of the top cover screws 3 Install the two screws Tighten the screws to specification c a b 39498 a Top cover screw b Washer c Torque wrenc...

Page 97: ...040 d 41329 Typical port side cover a Screw 5 b Port cover c H trim d Information decal 7 Tighten the three lower and six upper cover screws to specification Description Nm lb in lb ft Cover upper scr...

Page 98: ...is still visible in the monitor is correct In some events such as a seal leaking the gear lubricant level may have dropped low enough that no lubricant is visible in the monitor In these situations th...

Page 99: ...MPORTANT If the gear lube level is below the COLD FILL LEVEL line when checked especially after the first couple of times the boat is operated for a long period or if gear lube must be added frequentl...

Page 100: ...ears 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 LEVEL c...

Page 101: ...cover 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 th...

Page 102: ...ar housing and gear lube monitor after break in after the first 25 30 hours of operation 92 858064K01 3 Ensure that the rubber gasket is inside the cap for the gear lube monitor and install the cap Do...

Page 103: ...into the threaded hole for the drain and fill screw c b a 38298 a Coupling nut and washer b Adapter fitting c Threads into steering actuator 3 8 in 16 UNC Description Part Number Gear lube adapter fit...

Page 104: ...Pump the gear lube pump and begin to fill the drive with the specified gear lube IMPORTANT Use only Mercury or Quicksilver High Performance Gear Lube in the drive 10 Continue to pump gear lube into t...

Page 105: ...drive is cool and the engine is shut down WITH THE BOAT OUT OF THE WATER 1 Remove the drive propellers See Propellers 2 Remove the gearcase fill and drain screw and sealing washer 27852 a b a Gearcase...

Page 106: ...nitor Fluid Type Fluid Part Number Zeus 5 1 4 L 5 1 2 US qt High Performance Gear Lube 92 858064K01 1 L 1 US qt 92 858065Q01 9 5 L 2 5 US gal 8 Remove the gear lube pump and quickly reinstall the gear...

Page 107: ...rication and pressure The pump filter and storage system are the same on all models For specific procedures refer to Checking Filling and Changing Checking 1 Using a clean lint free cloth wipe the dir...

Page 108: ...vel is correct insert the cap and dipstick into the neck of the reservoir Push down and turn the reservoir cap in the close direction b c a 40235 a Cap and dipstick b Open direction c Close direction...

Page 109: ...ick to determine the exact quantity of oil required 3 Fill the hydraulic reservoir with the specified oil to bring the level up to the full cold mark Do not overfill b c a 40243 d a Cap and dipstick b...

Page 110: ...37306 High pressure filter system a Filter head b Filter housing with filter element Transmission Oil Fluid and Filter Checking If the drive is equipped with a drive cover you can check the transmiss...

Page 111: ...level is correct install the dipstick 6 If the level is low add the specified transmission oil through the dipstick threaded hole to bring the level up to the maximum mark on the dipstick Description...

Page 112: ...h cover under the indented edge of the cover a c b 39506 a Access cover b Molded clip c Indented edge b Align the access cover with the opening in the top cover c Press down evenly on the front of the...

Page 113: ...Fluid Capacity Fluid Type Fluid Part Number Transmission only without drop box 4 L 4 1 4 US qt Synthetic Power Steering Fluid SAE 0W 30 92 858077K01 Transmission and drop box 5 1 4 L 5 1 2 US qt Tran...

Page 114: ...ronment is restricted by law Use caution not to spill oil coolant or other fluids into the environment when using or servicing your boat Be aware of the local restrictions governing the disposal or re...

Page 115: ...drop box remove the drain cap from the lower port side of the drop box Drain the transmission oil into a suitable container a b 41195 a Drop box b Drain cap NOTE Except in the cases of extreme contami...

Page 116: ...ilter cover assembly e O ring f O ring g Filter element h Seal i Oil pipe 10 Coat the new O rings with transmission oil 11 Install the new O rings and filter element NOTICE Improper installation of th...

Page 117: ...a b 28239 a Assembly screw b Fluid filter assembly Description Nm lb in lb ft Filter assembly screw 7 62 IMPORTANT Use new sealing washers to avoid leaks 14 On models with a drop box install the drai...

Page 118: ...oper level with the specified oil Refer to Filling 17 After first start up check for leaks If leaks exist stop operation immediately Check the components and repair as needed 18 Install the drive cove...

Page 119: ...ooler 6 On models equipped with a seawater strainer refer to Seawater Strainer 7 Depending on equipment apply sealant to the transmission oil cooler drain plug or anode plugs before installation Tight...

Page 120: ...manufacturer for instructions and close the seawater inlet valve or seacock 2 On models using the through drive seawater inlet close the seawater inlet seacock Rotate the handle in the direction indic...

Page 121: ...he seawater hose from the outlet end of the primary cooler for the hydraulic oil Drain the seawater 7 Remove the drain screw on the seacock Drain the seawater b c 41264 d a a a Dual hose clamps b Prim...

Page 122: ...ler Tube Ref No Description Where Used Part No 19 Perfect Seal Drain plug 92 34227 1 b Install the drain plug c Tighten the drain plug securely 12 On models with a drop box and engine mounted transmis...

Page 123: ...age in freezing temperatures If the boat is in the water keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system If the boat is not fitted with a...

Page 124: ...Cruiser Diesel Authorized Repair Facility for additional information Battery All lead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below battery...

Page 125: ...rgent compounds etc or washed with solvents such as trichlorethylene turpentine etc Electrical System 1 Check for loose damaged or corroded fasteners 2 Check for loose damaged or corroded wiring and c...

Page 126: ...veshaft slip joint The plug retains grease in the spline cavity A hole in the center of the plug acts as a pressure relief for grease in the spline cavity 3 Pump grease into the grease fitting for the...

Page 127: ...engine end 36 27 Driveshaft U Joints NOTE In addition to the task and interval for inspecting and lubricating the driveshaft U joints every 250 hours or one year whichever occurs first you must repla...

Page 128: ...tions exist contact 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 f...

Page 129: ...Driveshaft shield retaining screw and washer 4 Description 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...

Page 130: ...t flow causes the metal that is most chemically active or anodic to erode This is known as galvanic corrosion and if not controlled it will in time cause the need for replacement of power package comp...

Page 131: ...the transmission The system should be tested to ensure adequate output The test should be performed where the boat is moored using the Quicksilver Reference Electrode and Test Meter For testing conta...

Page 132: ...nd decrease the corrosion protection b a 41163 a Anode b Reference electrode not visible in this view MerCathode Anode CHECKING Inspect the MerCathode anode and replace the anode if damaged b a 41163...

Page 133: ...or more 41251 Trim tab anodes REPLACING IMPORTANT The trim tab cylinder is equipped with a check valve to avoid the lowering of the trim tab after shut down When service is required lower the trim ta...

Page 134: ...e information about vessel mounted anodes and related continuity circuits The drive system is equipped with ground circuit wires to ensure good electrical continuity between the drive components Good...

Page 135: ...osion protection devices follow these 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 Corr...

Page 136: ...ystem components Propellers Propeller Removal WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or remo...

Page 137: ...Propeller nut tool Propeller Nut Tool 91 805457T 1 10677 Aids in the removal and installation of the front propeller nut 5 Slide the front propeller and the front thrust hub off the propeller shaft 28...

Page 138: ...silver lubricants NOTE Anti corrosion grease is for saltwater applications only Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Propeller shaft splines 92 802865Q02 95 2 4 C Marine...

Page 139: ...c Propeller nut tool Propeller Nut Tool 91 805457T 1 10677 Aids in the removal and installation of the front propeller nut Description Nm lb in lb ft Front propeller nut 136 100 7 Check the propeller...

Page 140: ...m tab and the propeller 12 Tighten the rear propeller nut to specification a b 24037 a Block of wood b Trim tab 25876 a b c d e f Zeus drive propeller assembly a Front thrust hub b Front propeller c F...

Page 141: ...torage Table of Contents Storage Descriptions 134 Drive Storage 134 Cold Weather Freezing Temperature Storage 134 Seasonal and Extended Storage Instructions 135 Engine Storage 135 Battery Storage 135...

Page 142: ...could result in freeze damage Corrosion damage is the result of saltwater polluted water or water with a high mineral content trapped in the seawater cooling system Saltwater should not stay in an eng...

Page 143: ...tom Black Outside of drive components when painted black 92 802878Q1 Marine Cloud White paint CMD part number 4918660 Outside of engine Obtain locally Corrosion Guard Outside of engine and drive 92 80...

Page 144: ...nals with a battery terminal anti corrosion spray to help retard corrosion NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provid...

Page 145: ...m Problems 138 Electrical Connections 138 Troubleshooting Charts 138 Troubleshooting Engine Related Problems 138 Check VesselView First 138 Poor Performance 139 Joystick 139 Electronic Remote Controls...

Page 146: ...bend radius should be 7 6 cm 3 in for installation Fasten harnesses to the boat at least every 45 7cm 18 in using appropriate fasteners Do not attempt diagnostics without the proper approved service t...

Page 147: ...heck VesselView for Guardian fault codes that cause engine power reduction If found have the system checked by your Authorized Cummins MerCruiser Diesel Repair Facility Joystick Symptom Remedy Joystic...

Page 148: ...Unlock the Automatic Tab Override switch or raise tabs ERC lever controls engine and drive but does not respond in a linear manner Check TROLL button on DTS track pad Put handles in Neutral and push T...

Page 149: ...e sluggish Check that both engines are on and functioning properly Restart stopped engine Check VesselView for fault codes Check fuel quality Check and drain the water separating fuel filter Boat vibr...

Page 150: ...k from GREEN light Open capacitor in Galvanic Isolator Replace Galvanic Isolator RED light on Two blinks from GREEN light Shorted diode in Galvanic Isolator Replace Galvanic Isolator RED light on Thre...

Page 151: ...quired After Submersion 144 Replacement Service Parts 144 Parts and Accessories Inquiries 145 Resolving a Problem 145 Customer Service Literature 145 English Language 145 Other Languages 146 Andre spr...

Page 152: ...ctory or by using the service locator on the Cummins MerCruiser Diesel website www cmdmarine com If for any reason you cannot obtain service contact the nearest Regional Service Center Outside the Uni...

Page 153: ...act your Cummins MerCruiser Diesel Authorized Repair Facility If additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already be...

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Page 156: ...Section 8 Customer Assistance Information Page 148 90 866938081 MAY 2009 Name Address City State Province ZIP or postal code Country Quantity Item Stock Number Price Total Total Due...

Page 157: ...ble of Contents Pre Delivery Information 150 Dealer Pre Delivery Checklist for Zeus Products Before Delivery to the Customer 150 Skyhook If Equipped 150 Before Starting Key Off 151 Before Starting Key...

Page 158: ...r pre delivery checks inspection or servicing of this Cummins MerCruiser Diesel product could result in damage to the product or personal injury to those servicing and operating the product Dealer Pre...

Page 159: ...uid level check fill ZOM Section 5 Transmission fluid level check fill ZOM Section 5 Drive gear lube fluid level check fill ZOM Section 5 Seacocks open See Starting and Stopping the Engines ZOM Sectio...

Page 160: ...ection 3 After On Water Test Dealer Check Checklist Item Manual Code or Task Fluid leaks monitor and document Visual Inspection Oil and fluid levels visual check ZOM Section 5 Drive interface ring sea...

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