Mercury Zeus User manual

© 2011 Mercury Marine CMD Zeus 3000 Series Pod Drives *879172181* 90-879172181 211
Identification Information
Drive serial number and model number—The serial numbers are the manufacturer’s keys to numerous engineering
details that apply to your Cummins MerCruiser Diesel product. When contacting Cummins MerCruiser Diesel (CMD) about
service, always specify model and serial numbers.
The serial number, model number, and other information needed for the identification record is located as shown.
Drive identification
a - Transmission identification plate
b - Drive identification decal
c - Pod location stamping
Drive identification 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 electronic control system (refer to
Section 2—General Information) have an Electronics Serial Number (ESN) data tag located on the inside of the Vessel
Interface Panel (VIP) door. The number is needed for the identification record.
ELECTRONICS SERIAL NO:
88 500 000
MADE IN USA
www.cmdmarine.com
44343
Typical ESN data tag and VIP
Engine serial number and model number—Refer to the engine operation and maintenance manual available from the
engine manufacturer for the location of the engine data tag that contains the engine serial number and model number
needed in the identification record.
44122
ab
c
c
d
be
f
44121
a

Identification Record
Please record the following information:
Drive Location Zeus Drive Serial Number Zeus Drive Model Number Transmission Serial Number
Starboard
Center
Port
Starboard Center
Port Center
Engine Serial Number
Starboard Starboard Center
Center Port Center
Port –
Engine Model and Horsepower Propeller Information Propeller Part Number Pitch
/Front –
Rear –
Boat Hull Identification Number (HIN) Purchase Date
/
Boat Manufacturer Boat Model Boat Length
.
Exhaust Gas Emissions Certificate Number (Europe Only) Electronic Control Serial Number
/
The description and specifications contained herein were in effect at the time this guide was approved for printing. CMD, whose
policies are based on continuous improvement, reserves the right to discontinue models at any time or to change specifications
or designs without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A.
Printed in U.S.A.
© 2011, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, Alpha, Axius, Bravo One, Bravo Two, Bravo Three, K‑Planes, MerCathode, OptiMax, Precision Pilot, Pro
Max, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Total Command, Verado, VesselView, Zero Effort, Zeus, #1 On The Water, M
with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury
Product Protection logo is a registered service mark of Brunswick Corporation.
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure
operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read this manual, which contains specific instructions for using and
maintaining your product. We suggest that this manual remain with the product for reference whenever you are on the water.
Thank you for purchasing one of our Cummins MerCruiser Diesel products. We sincerely hope your boating will be pleasant.
Cummins MerCruiser Diesel
Warranty Message
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 contains a description of what is covered, what is not
covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages,
and other related information. Please review this important information.

Read this Manual Thoroughly
IMPORTANT: If you do not understand any portion of this manual, contact your dealer for a demonstration of the actual starting
and operating procedures.
Notice
Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the
International Hazard Symbol !, may be used to alert the installer and user to special instructions concerning a particular service
or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These safety alerts alone cannot eliminate the hazards that they signal. Installers must comply strictly with these special
instructions and should exercise common sense during operation to prevent accidents.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious 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 moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.
NOTE: Indicates information that helps in the understanding of a 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 that the operator read this Operation, Maintenance and Warranty Manual and
thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.
! WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other
reproductive harm.

90-879172181 eng FEBRUARY 2011 Page i
TABLE OF CONTENTS
Section 1 - Limited Warranty
Warranty Information.................................................................2
Warranty Registration—United States and Canada...........2
Warranty Registration—Outside the United States and
Canada...............................................................................2
World‑Wide Limited Warranty.............................................2
Emission Warranty..............................................................8
Transfer Of Warranty..........................................................8
Section 2 - Getting to Know Your Power Package
General Information.................................................................10
Models Covered................................................................10
Drive Serial Number and Decal Placement......................10
Identifying Your Engine Control System...........................10
Electronic Control Serial Number.................................10
Electronic Control System Architecture........................10
SmartCraft 2.2 Control System.....................................11
SmartCraft 3.0 Control System.....................................11
Features and Controls.............................................................11
E‑Stop (Emergency Stop) Switch, If Equipped.................11
Instrumentation.................................................................13
VesselView...................................................................13
SmartCraft Speedometer 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 Control (ERC)—Features
and Operation...................................................................15
Operation......................................................................15
Optional SportFish Electronic Remote Control (ERC)—
Features and Operation....................................................15
Operation......................................................................15
Adjustment....................................................................16
Joystick—Basic Operation................................................18
Operating With an Auxiliary Joystick (If Equipped)...........18
Electrical System Overload Protection.....................................19
General Information..........................................................19
Vessel Interface Panel (VIP) Overload Protection—
SmartCraft 2.2 .................................................................19
Vessel Interface Panel (VIP) Overload Protection—
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 Monoxide Poisoning...........................25
Good Ventilation...........................................................25
Poor Ventilation ...........................................................25
Basic Boat Operation...............................................................25
Freezing Temperature and Cold Weather Operation.......25
Drain Plug and Bilge Pump...............................................26
Protecting People in the Water.........................................26
While the Boat is Moving..............................................26
While the Boat is Stationary.........................................26
Wave and Wake Jumping.................................................27
Impact with Underwater Hazards......................................27
Zeus Drive Impact Protection...........................................28
Zeus Drive Alignment.......................................................28
Conditions Affecting Boat Operation........................................28
Weight Distribution (Passengers and Gear) Inside the
Boat..................................................................................28
Bottom Of Boat.................................................................28
Cavitation..........................................................................28
Ventilation.........................................................................29
Propeller Selection............................................................29
Getting Started.........................................................................29
Break‑In Period (New or With Replacement Gears).........29
DC‑to‑DC Voltage Regulator Switch, If Equipped............29
Starting and Stopping the Engines...................................30
Normal Starting.............................................................30
Normal Stopping...........................................................31
Starting an Engine Using the VIP SmartStart Switch...32
Stopping the Engine Using the VIP SmartStart Switch 34
Traditional Maneuvering with Steering and Thrust...........35
To Maneuver the Boat in Forward................................35
To Steer the Boat in Tight Turns at Low Speeds..........36
To Spin the Boat on its Axis at Low Speeds.................36
Maneuvering with a Joystick.............................................36
Auxiliary Joystick Station—Special Features....................41
General Information......................................................41
Auxiliary Joystick Station and Throttle Only Feature....42
Stopping the Engines from an Auxiliary Joystick Station42
Trim Tabs, If Equipped.....................................................42
Automatic Control.........................................................42
Manual Control.............................................................43
Trim Tab Offset.............................................................43

Page ii 90-879172181 eng FEBRUARY 2011
Special Digital Throttle and Shift (DTS) Features........... 44
Troll and Throttle Response........................................44
Dock............................................................................45
Throttle Only................................................................46
Single Lever (1 Lever) Operation................................46
Synchronizing the Engines..........................................47
DTS Shadow Mode—Triple Engines.......................... 48
DTS Shadow Mode—Quad Engines.......................... 48
Cruise Control................................................................. 48
Helm Transfer—Standard Stations.........................................48
Helm Transfer..................................................................48
Requesting Helm Transfer.............................................. 49
Helm Transfer and Precision Pilot...................................49
Helm Transfer—Auxiliary Joystick Stations............................50
Auxiliary Joystick Station Transfer.................................. 50
Requesting Transfer to an Auxiliary Joystick Station...... 50
Requesting Transfer from an Auxiliary Joystick Station..50
Precision Pilot.........................................................................50
Features.......................................................................... 50
Autopilot Screen..............................................................51
Trackpad......................................................................... 51
Trackpad Lights...............................................................51
Trackpad Buttons with the Power Icon............................52
Skyhook Station Keeping (If Equipped)........................... 52
Track Waypoint............................................................... 54
Engaging Track Waypoint Mode.................................55
Disengaging Track Waypoint Mode............................ 56
Turn Buttons in Track Waypoint Mode........................57
Auto Heading Button in Track Waypoint Mode ..........57
Acknowledging a Turn During a Waypoint Arrival.......57
Waypoint Sequence....................................................58
Response Button.............................................................60
Auto Heading...................................................................61
Engaging Auto Heading..............................................61
Course Adjustment Using the Turn Buttons or Joystick62
To Resume a Heading ............................................... 63
Disengaging Auto Heading......................................... 64
Contingent Operations............................................................65
Steering—Emergency Alternative Method...................... 65
Loss of Engine Operation................................................65
Loss of Starboard Side Control System......................65
Operating on Less than all Available Engines............ 65
Gear Engagement—Emergency Procedure.................... 66
Steering and Trim—Manual Override..............................67
Procedure for a Stuck 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 Oil............................................... 72
Approved Paints..................................................................... 72
Approved Lubricants...............................................................72
Section 5 - Maintenance
Product Responsibilities......................................................... 74
Owner and Operator Responsibilities..............................74
Dealer Responsibilities....................................................74
Do‑It‑Yourself Maintenance Suggestions........................74
Inspection........................................................................74
Drive Service Point Locations.................................................75
Starboard.........................................................................75
Port..................................................................................76
Top.................................................................................. 76
Drop Box......................................................................... 76
Maintenance Schedules......................................................... 77
Application.......................................................................77
Routine Maintenance...................................................... 77
Scheduled Maintenance..................................................77
Maintenance Log.............................................................78
Drive Cover, If Equipped........................................................ 80
Removing the Drive Cover.............................................. 80
Cleaning and Inspecting the Drive Cover........................80
Installing the Drive Cover................................................ 80
Drive Gear Lubrication............................................................82
Checking......................................................................... 83
Filling...............................................................................85
Changing.........................................................................86
With the Boat in the Water.......................................... 86
With the Boat Out of the Water................................... 89
Steering Actuator and Trim—Hydraulic Oil.............................91
Checking......................................................................... 92
Filling...............................................................................93
Changing.........................................................................94
Transmission Oil (Fluid) and Filter..........................................94
Checking......................................................................... 94
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
Flushing (Cleaning) the Seawater System....................105
Electrical System..................................................................105
Fasteners, Connectors, and Wiring...............................105
Checking Gauges..........................................................105
Cleaning Gauges...........................................................105
E‑Stop Switch Tests......................................................105
Battery...........................................................................105
Cooling System and Exhaust System..................................106
Lubrication and Torque Maintenance...................................106
Driveshaft Slip‑Joint .....................................................106
Driveshaft U‑Joints .......................................................107
Propeller Shaft...............................................................109
Driveshaft Connection Torque.......................................110
Corrosion and Corrosion Protection.....................................111
The Causes of Corrosion..............................................111
Corrosion Protection......................................................111
Anodes and MerCathode System ................................111

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

Page iv 90-879172181 eng FEBRUARY 2011

Section 1 - Limited Warranty
90-879172181 eng FEBRUARY 2011 Page 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 Limited Warranty..........................................2
Emission Warranty...........................................................8
Transfer Of Warranty.......................................................8
1

Section 1 - Limited Warranty
Page 2 90-879172181 eng FEBRUARY 2011
Warranty Information
Warranty Registration—United States and Canada
The CMD warranty registration center will coordinate warranty registration for both CMD/Cummins and Mercury Marine
products, only one Warranty Registration Form is required to be filed for each engine/drive system.
1. To ensure that your warranty coverage begins promptly, your selling dealer should fill out the Warranty Registration Card
completely and mail it to the factory immediately upon sale of the new product.
2. The Warranty Registration Card identifies the name and address of the original purchaser, product model and serial
number(s), date of sale, type of use and selling dealer’s code, name, and address. The dealer also certifies that you are the
original purchaser and user of the product. A temporary Owner Warranty Registration Card will be presented to you when
you purchase the product.
3. Upon receipt of the Warranty Registration Card at the factory, you will be sent an owner resource guide that includes your
warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product
sale, please contact your selling dealer.
4. Because of your selling dealer’s ongoing interest in your satisfaction, the product should 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 marine products sold in the United States in the
event that a safety recall notification under the Federal Boat Safety Act is required.
6. You may change your registration address at any time, including at time of warranty claim, by calling CMD or sending a letter
or fax with your name, old address, new address, and engine serial number to CMD's warranty registration department. Your
dealer can also process this change of information.
United States customers or dealers may contact:
Cummins MerCruiser Diesel LLC, Inc.
Attn: Warranty Registration Department
4500 Leeds Avenue - Suite 301
Charleston, South Carolina 29405-9987
1-800-668-0407
Fax Fax [phone]
Warranty Registration—Outside the 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 MerCruiser Diesel Authorized Dealer responsible for administering the warranty
registration and claim program for your area.
2. The Warranty Registration Card identifies your name and address, product model and serial numbers, date of sale, type of
use and the selling distributor's and dealer's code number, name and address. The distributor or dealer also certifies that you
are the original purchaser and user of the product.
3. A copy of the Warranty Registration Card, designated as the Purchaser's Copy, MUST be given to you immediately after the
card has been completely filled out by the selling distributor or dealer. This card represents your factory registration
identification, and should be retained by you for future use when required. Should you ever require warranty service on this
product, your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on
the card to prepare the warranty claim forms.
4. In some countries, the Cummins MerCruiser Diesel Distributor or Cummins MerCruiser Diesel Authorized Dealer will receive
the Factory Copy of the Warranty Registration Card from your distributor or dealer. If you receive a plastic Warranty
Registration Card, you may discard the Purchaser's Copy that you received from the distributor or dealer when you purchased
the product. Ask your distributor or dealer if this plastic card program applies to you. Center will issue you a permanent (plastic)
Warranty Registration Card within 30 days after
5. For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing, refer to
the International Warranty. See Table of Contents. IMPORTANT: Registration lists must be maintained by the factory and
dealer in some countries by law. It is our desire to have ALL products registered at the factory should it ever be necessary to
contact you. Make sure your Cummins MerCruiser Diesel Distributor 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.
World‑Wide Limited Warranty
Products included in this coverage
Marine Drives

Section 1 - Limited Warranty
90-879172181 eng FEBRUARY 2011 Page 3
Zeus 2000 and Zeus 3000 pod drives, Alpha, Bravo One, Bravo Two, Bravo Three, and NXT sterndrives sold
with CMD engines
Products Warranted
Cummins MerCruiser Diesel (herein CMD) warrants to the owner that the purchased product is free from any
material or workmanship defects. This warranty covers any failures of the Product, which results from a defect
in CMD material or workmanship (Warrantable Failure). Underwater impact damage is not a warrantable failure.
This Warranty applies to new drives (herein Product) sold by CMD that are branded as CMD products and
used in approved marine propulsion applications anywhere CMD authorized service is available. The Product
includes the drive as delivered from the factory. Engines, controls, and accessories are covered under a
separate warranty.
Ratings
Coverage is impacted by the rating of the drive. Drives have the same rating of the engine with which they are
used.
All ratings require a majority of operation to be at or below the engines cruise speed. Engine cruise speed is
dependent on the engine’s maximum engine rated speed (RPM):
Engine Rated Speed (RPM) Engine Maximum Cruise Speed
2000–2800 RPM 200 RPM below rated
2801–3500 RPM 300 RPM below rated
3501–4500 RPM 400 RPM below rated
High Output Rating (HO)
The High Output Rating applies to variable load applications where annual use is less than 500 hours per year
and full power is one (1) out of every eight (8) hours of operation. Reduced power operation must be at or
below cruise speed.
Drives with this rating are intended for powering recreational/pleasure use vessels only. Use of this rating in
commercial applications will void 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 product is only occasionally used for such purposes. However, this rating may be used in Six Pack
Charter applications without voiding this warranty if the other rating requirements are met.
Intermittent Rating (INT)
The Intermittent Rating applies to variable load applications where annual use is less than 1500 hours per year
and full power is two (2) out of every eight (8) hours of operation. Reduced power operation must be at or below
cruise speed.
Drives with this rating are intended for commercial applications. Commercial use is defined as any work or
employment related use of the product, or any use of the product which generates income, for any part of the
warranty period, even if the product is only occasionally used for such purposes. However, this rating may be
used in recreational/pleasure applications.
Light Commercial (LC)
The Light Commercial Rating applies to variable load applications where annual use is less than 500 hours
per year and full power is one (1) out of every eight (8) hours of operation. Reduced power operation must be
at or below cruise speed.
Drives with this rating are intended for commercial applications. Commercial use is defined as any work or
employment related use of the product, or any use of the product which generates income, for any part of the
warranty period, even if the product is only occasionally used for such purposes. However, this rating may be
used in recreational/pleasure applications.
Government Service (GS)
The Government Service Rating applies to variable load applications where annual use is less than 500 hours
per year and full power is one (1) out of every eight (8) hours of operation. Reduced power operation must be
at or below cruise speed.

Section 1 - Limited Warranty
Page 4 90-879172181 eng FEBRUARY 2011
Drives with this rating are intended for non‑revenue generating government service applications. Use of this
rating in applications other than non‑revenue generating government service applications will void the warranty.
This rating is not to be used in any revenue generating government or commercial applications nor is it to be
used in recreational/pleasure applications. Commercial use is defined as any work or employment related use
of the product, or any use of the product which generates income, or any part of the warranty period, even if
the product is only occasionally used for such purposes.
Duration of Coverage
The coverage duration commences on the date of delivery of the product to the first user; or when the Product
is first leased, rented or loaned; or when the Product has been operated for 125 hours for HO ratings, 50 hours
for INT, GS, and LC ratings, or when the Product has been in inventory stock and properly laid up for three
years from date of shipment from CMD. Unexpired warranty can be transferred from one customer to a
subsequent customer, provided the new application meets the rating guidelines, and only upon 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
Labor
HO 24 1000 Yes Yes Yes Yes
HO/GS (NXT only) 12 500 Yes Yes Yes Yes
INT (Zeus 3000 only) 24 3000 Yes Yes Yes Yes
INT (sterndrive only) 12 400 Yes Yes Yes Yes
GS 24 1000 Yes Yes Yes Yes
LC 24 500 Yes Yes Yes Yes
*whichever occurs first
Table 2: Extended Coverage
Coverage Removal and Installation Labor
Coverage Category Months Hours Parts Labor Travel Removal and Installation
Extended Components 72 3000 Yes Yes Yes Yes
Extended Major Components Warranty—The
Extended Major Components Warranty provision
is concurrent with the Base Warranty and
continues beyond the expiration of the Base
Warranty for an additional four years or 2000
hours, whichever occurs first. Only the Zeus
2000/3000 HO applications have this warranty
provision.
The Extended Major Components Warranty covers the Warrantable Failures of the following drive parts
(Covered Parts):
Zeus 3000:
Marine Gear Housing
Marine Gear Drop Box Housing
Steering Actuator Housing Casting
Drive Midsection Casting
Lower Gear Housing Casting—(Underwater Impact Damage Excluded)
Trim Tab Casting—(Underwater Impact Damage Excluded)
Bearing Carrier Casting—(Underwater Impact Damage Excluded)
Intermediate Shaft—(Underwater Impact Damage Excluded)
Clamp Rings

Section 1 - Limited Warranty
90-879172181 eng FEBRUARY 2011 Page 5
Steering and Trim Oil Tank
Skeg—(Underwater Impact Damage Excluded)
Zeus 2000:
Marine Gear Housing
Marine Gear Drop Box Housing
Steering Housing
Midsection Casting
Lower Gear Housing Casting—(Underwater Impact Damage Excluded)
Bearing Carrier Casting—(Underwater Impact Damage Excluded)
Intermediate Shaft—(Underwater Impact Damage Excluded)
Clamp Rings
Skeg—(Underwater Impact Damage Excluded)
Gearcase Aft Fairing—(Underwater Impact Damage Excluded)
Conditions to be met to obtain warranty coverage
Warranty Coverage becomes effective upon proper registration of the Product by the seller to the first end‑user.
Inaccurate warranty registration information or a change of use from recreational to commercial will void the
warranty. Every CMD Product installed in a vessel must be backed by an approved Installation Review. CMD
reserves the right to make any warranty coverage contingent upon proof of proper maintenance and approved
installation review.
CMD Responsibilities
During the Base Engine and Drive Limited Warranty
CMD will pay for all 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 is necessary for the mechanics to make on‑site Warranty repairs, CMD will pay reasonable travel expenses,
including meals, lodging and mileage, for mechanics to travel to and from the repair site. Labor must be
performed by an authorized CMD Repair Facility.
CMD will pay for the lubricating oil, transmission oil, hydraulic oil, filter elements and other maintenance items
that are not reusable due to the Warrantable Failure. CMD will pay reasonable costs for Product removal and
reinstallation when necessary to repair a warrantable failure.
CMD reserves the right to improve or modify products from time to time without assuming an obligation to
modify products previously manufactured.
CMD will pay for failures of CMD supplied maintenance components for 90 days from the Coverage duration
start date. Maintenance components are identified as:
• Anodes
• Gearcase oil filters
• Transmission oil filters
• Hydraulic oil filters
• Hoses
CMD Limitations
CMD is not responsible for failures or damage resulting from what CMD determines to be abuse or neglect, or
abnormal use or service, including but not limited to:

Section 1 - Limited Warranty
Page 6 90-879172181 eng FEBRUARY 2011
• Operation without adequate coolants or lubricants
• Improper propping that does not allow the engine to run at its maximum rated speed
• Unapproved installation
• Lack of maintenance
• Improper storage set up and maintenance
• Unauthorized modifications
• Submersion, freezing temperatures, improper service, removal of parts, or running the product out of the
water
• Vessel overloading that prevents the engine from reaching its rated maximum speed
• Water ingestion, or water intrusion, unless caused by the Warrantable Failure
• Operating the Product in a manner inconsistent with the recommended operation and drive rating
CMD is not responsible for routine maintenance, normal wear and tear, or additional work requested by the
customer. Labor not performed by a CMD Authorized Repair Facility except when such facility is not available
and prior factory approval has been granted to perform the work at an alternative facility is not covered. CMD
will not pay for expenses related to haul out, launch or towing, unless as part of the Warrantable Failure Repair.
Parts used in Warranty repairs may be new CMD parts; CMD approved rebuilt parts or repaired parts, at the
discretion of CMD. Any new, rebuilt or repaired part used to replace a Warranted Part assumes the identity of
the replaced part. CMD is not responsible for failures resulting from the use of parts not supplied by CMD.
CMD is not responsible for incidental or consequential damages. This Warranty set forth herein is the
sole warranty made by CMD in regard to this Product. CMD makes no other warranties, express or
implied, or of merchantability or fitness for a particular purpose.
Use of the Product for racing or other competitive activity, even by a previous owner of the product, will void
the warranty.
In the US and Canada, this Warranty gives you specific legal rights, and you may also have other rights with
vary from state to state. Outside the US and Canada, in the case of consumer sales, in some countries the
Owner has statutory rights 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 Responsibilities
During the warranty period, the Owner is responsible for the operation and maintenance of the Product as
specified in the applicable CMD Operations and Maintenance Manual. The Owner may be required to provide
proof that all recommended maintenance has been performed. Exceeding the operational parameters of the
HO rating will void the warranty. The warranty will be void on any Product misapplied, misused or not properly
maintained. The Owner is responsible for maintaining the Engine Hourmeter in good working condition and
ensuring it reflects the accurate total hours of operation. Before the expiration of the applicable warranty, the
Owner must notify a CMD distributor, authorized dealer or CMD approved repair site of any Warrantable Failure
and make the Engine available for repair.
Check www.cmdmarine.com for approved repair sites.
The Owner is responsible for the cost of towing the boat to the repair dock and for all associated docking and
harbor charges. All communication expenses, meals, lodging and similar costs incurred as a result of the
Warrantable Failure will be borne by the Owner.
The Owner is responsible for the costs to investigate complaints, unless the problem is caused by a defect in
CMD material or workmanship. The Owner is responsible for non‑Product repairs, downtime expenses, cargo
damage, fines, applicable taxes, business costs and other losses resulting from a Warrantable Failure.
The Owner is responsible for ensuring the Warranty Registration is filed and kept up to date with changes in
addresses and contact information.
If the Product is stored or placed in inventory, the Owner of the Product at the time is responsible for properly
laying up the Product, conducting routine lay up maintenance to preserve the Product, and properly starting
up the Product when finally installed, in accordance with CMD procedures as outlined in the appropriate Service
Bulletin. The Owner will be responsible for proving proper storage procedures were followed and maintained
during the storage period or the warranty will be void.

Section 1 - Limited Warranty
90-879172181 eng FEBRUARY 2011 Page 7
The Owner is responsible for providing reasonable access to the Product to effect repairs; the owner may be
responsible for expenses incurred as the result of reasonable access being denied or unavailable.
Drive Limited Warranty Against Corrosion (Worldwide)
What Is Covered
CMD warrants the Zeus 2000 and Zeus 3000 pod drives, Alpha, Bravo One, Bravo Two,Bravo Three, and NXT
sterndrives are covered.
Product will not be rendered inoperative as a direct result of corrosion for the period of time described below.
Duration of Coverage
This limited corrosion warranty provides coverage from either the date the product is first sold, or the date on
which the product is first put into service, whichever occurs first.
Table 3: Corrosion Coverage
Coverage*
Used with Engine
Rating of: Months Hours
Zeus 3000 50 2500
Zeus 2000 48 2000
NXT Sterndrive 36 1500
SeaCore sterndrive 48 2000
Non‑SeaCore
sterndrive 36 1500
*Whichever comes first
The repair and replacement of parts, or the performance of service under this warranty does not extend the
life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to
subsequent purchaser upon proper re‑registration of the product. Warranty coverage is terminated for used
product repossessed from a retail customer, purchased at auction, from a salvage yard, or from an insurance
company that obtained 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 be in use
on the boat, and routine maintenance outlined in the Operation, Maintenance, and Warranty manual must be
timely performed (including without limitation the replacement of sacrificial anodes, use of specified lubricants,
and touch‑up of nicks and scratches) in order to maintain warranty coverage. CMD reserves the right to make
warranty coverage contingent upon proof of proper maintenance.
What CMD Will Do
CMD’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part,
replacing such part or parts with new or CMD certified, remanufactured parts, or refunding the purchase price
of the CMD product. CMD reserves the right to improve or modify products from time to time without assuming
an obligation to modify products previously manufactured.
How to Obtain Warranty Coverage
The customer must provide CMD with reasonable access to the product for warranty service and a reasonable
opportunity to repair the product. CMD dealer will arrange for the inspection and any covered repair. If the
service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any
other expenses associated with that service. Purchaser shall not, unless requested by CMD, ship the product
or parts of the product directly to CMD. Proof of registered ownership must be presented to the dealer at the
time warranty service is requested in order to obtain coverage.

Section 1 - Limited Warranty
Page 8 90-879172181 eng FEBRUARY 2011
What Is Not Covered
This limited warranty does not cover electrical system corrosion; corrosion resulting from damage; corrosion
that causes purely cosmetic damage; abuse or improper service; corrosion to accessories, instruments, or
steering systems; damage due to marine growth; replacement parts (parts purchased by the customer); or
products used in applications not approved for the drive rating.
Emission Warranty
Product Warranted
This Emission Warranty applies to new Engines certified to United States EPA 40 CFR 94 sold by CMD
that are installed in vessels flagged or registered in the Unites States.1.2.
Coverage
CMD warrants to the first user and each subsequent purchaser that the Engine is designed, built, and
equipped so as to conform at the time of sale by CMD with all U.S. Federal emission regulations applicable
at the time of manufacture and that it is free from defects in workmanship or material which would cause it
not to meet these regulations within the longer of the following periods:
1. High Output Recreational use: five years or 500 hours of operation, whichever occurs first. Intermittent
Commercial use: five years or 5000 hours of operation, whichever occurs first. The Emissions Warranty
starts from the date of delivery of the Engine to the first user, or the date the unit is first leased, rented,
or loaned, or when the Engine has been operated for 50 hours, whichever occurs first, or
2. The Base Engine Warranty.
Limitations
The owner may elect to have maintenance, replacement, or repair of the emission control parts performed
by a facility other than a CMD distributor, an authorized dealer or a repair location approved by CMD, and
may elect to use parts other than new genuine Cummins/Mercury Marine or Cummins / Mercury
Marine‑approved rebuilt parts and assemblies for such maintenance, replacement or repair; however, the
cost of such service or parts and subsequent failures resulting from such service or parts will not be covered
under this emission control system warranty.
Failures, except those 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 warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
Outside the United States2. and Canada, in case of consumer sales, in some countries the Owner has
statutory rights 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
Transfer Of Warranty
The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial applications.
To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner's name,
address and engine serial number to CMD's warranty registration department.
In the United States mail to:
Cummins MerCruiser Diesel LLC, Inc.
Attn: Warranty Registration Department
4500 Leeds Avenue - Suite 301
Charleston, South Carolina 29405
1-800-668-0407
Fax Fax [phone]
Upon processing the transfer of warranty, CMD will send registration verification to the new owner of the product by mail. There
is no charge for this service.
For products purchased outside the United States and Canada, contact the Cummins MerCruiser Diesel Distributor or Cummins
MerCruiser Diesel distributor in your country.
1. Locations in the United States and Canada are listed in the Cummins United States and Canada Sales and Service Directory; other locations are
listed in the Cummins International Sales and Service Directory.
2. United States includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and the U.S. Virgin Islands.

Section 2 - Getting to Know Your Power Package
90-879172181 eng FEBRUARY 2011 Page 9
Section 2 - Getting to Know Your Power Package
Table of Contents
General Information.............................................................. 10
Models Covered.............................................................10
Drive Serial Number and Decal Placement...................10
Identifying Your Engine Control System........................10
Electronic Control Serial Number .......................... 10
Electronic Control System Architecture ................. 10
SmartCraft 2.2 Control System ............................. 11
SmartCraft 3.0 Control System ............................. 11
Features and Controls.......................................................... 11
E‑Stop (Emergency Stop) Switch, If Equipped..............11
Instrumentation..............................................................13
VesselView ............................................................ 13
SmartCraft Speedometer 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 Control (ERC)—Features
and Operation................................................................15
Operation ............................................................... 15
Optional SportFish Electronic Remote Control (ERC)—
Features and Operation.................................................15
Operation ............................................................... 15
Adjustment ............................................................ 16
Joystick—Basic Operation.............................................18
Operating With an Auxiliary Joystick (If Equipped)........18
Electrical System Overload Protection................................. 19
General Information.......................................................19
Vessel Interface Panel (VIP) Overload Protection—
SmartCraft 2.2 ..............................................................19
Vessel Interface Panel (VIP) Overload Protection—
SmartCraft 3.0 ..............................................................19
Overload Protection for the DC‑to‑DC Voltage System (If
Equipped)......................................................................20
Overload Protection for Other Circuits...........................21
2

Section 2 - Getting to Know Your Power Package
Page 10 90-879172181 eng FEBRUARY 2011
General Information
Models Covered
Models Covered Serial Number
Zeus 3000 Series Pod Drive 0M963371 and above
Drive Serial Number and Decal Placement
Serial numbers are the manufacturer's key to numerous engineering details that apply to your drive.
Drive serial number
locations
a - Transmission serial
number plate
b - Drive serial number
decal and stamping
Refer to the engine owners manual supplied with the engine for the location of the engine data tag that contains the engine serial
number and model number.
Identifying Your Engine Control System
Electronic Control Serial Number
The engine control system for some engines and pod drives is assigned a serial number that is printed on data tags. Two data
tags are placed on these products: one is located on the engine near the engine serial number data tag and one is located 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 identifies the control system architecture used on the vessel and guides
service personnel to the appropriate parts manual, service manual, and other related documentation.
Electronic Control System Architecture
There are two different control system architecture options for use with the Zeus 3000 Series pod drives:
•SmartCraft 2.2—First generation architecture; initial release of Zeus electronic control system architecture.
NOTE: SmartCraft 2.2 supports a maximum of two helm stations and will not allow the use of an auxiliary joystick station.
•SmartCraft 3.0—Second generation architecture; initially released for triple and quad system installations. This architecture
allows the operation of separate auxiliary joystick stations from up to three helm stations.
NOTE: SmartCraft 3.0 architecture is also used in some dual system applications and allows auxiliary joystick station and
third station compatibility.
41269
a
b

Section 2 - Getting to Know Your Power Package
90-879172181 eng FEBRUARY 2011 Page 11
SmartCraft 2.2 Control System
The control system option used on your vessel can be identified by the following:
• Two separate Vessel Interface Panels (VIP), one for each engine system.
43914
Typical SmartCraft 2.2 VIP
SmartCraft 3.0 Control System
The control system option used on your vessel can be identified by the following:
• One or more auxiliary joystick 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 Controls
E‑Stop (Emergency Stop) Switch, If Equipped
An E‑stop (emergency stop) switch turns off the engines in an emergency situation, such as a person overboard or a tangled
propeller. When activated, an E‑stop switch interrupts the power supply to the engine and transmission. The E‑stop switch turns
off all of the engines when the switch is at the helm or an auxiliary joystick station.
Typical E-stop switch at the helm
a - "E‑STOP" switch
34014
a

Section 2 - Getting to Know Your Power Package
Page 12 90-879172181 eng FEBRUARY 2011
IMPORTANT: Some E‑stop switches are equipped with a lock to prevent unintentional activation. The switch must be first unlocked
to depress the rocker switch and activate the emergency stop.
To activate the switch:
1. Push and slide the lock up.
2. Depress the rocker of the switch.
3. Ensure the engines shutdown.
Typical E-stop switch with lock
a - "E‑STOP" switch
b - Lock
The E‑stop switch on a Vessel Interface Panel (VIP) stops only the engine connected to VIP, unless the vessel is equipped with
a SmartCraft 3.0 VIP where the single E‑stop switch will shutdown all the engines.
E-stop switch on a typical VIP for dual pod equipped vessels
a - Red "E‑STOP" switch
b - VIP (one for each engine)
E-stop switch on a typical VIP for triple, quad, and
some dual pod equipped vessels
a - Red "E‑STOP" switch (one for all engines)
b - VIP (one for all engines)
Activation of an E‑stop switch stops the engine or engines immediately, but the boat can continue to coast for some distance
depending upon the velocity and degree of any turn at shutdown. While 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 procedures should they need to operate the engines
in an emergency.
Accidental or unintended activation of the switch during normal operation is also possible, which can cause any or all of the following
potentially hazardous situations:
• Occupants can be thrown forward due to unexpected loss of forward motion, and passengers in the front of the boat could
be ejected over the bow and possibly struck by the propulsion or steering components.
• The operator can lose power 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 without first turning the key switch to the off
position for at least 30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous
situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting some fault
codes are still being displayed, contact your Authorized Cummins MerCruiser Diesel Repair Facility.
44717
a
b
34022
a
b
a
b
43911