Zeus Installation Manual

Cummins MerCruiser Diesel
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,
Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, 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.
QSB AND QSC DIESEL ZEUS DRIVE MODELS

INSTALLATION MANUAL
Notice
Models Covered
Models Covered Engine Model and Rating Serial Number Or Year
QSB5.9‑330 (High Output)
QSB5.9‑355 Intermittent
Zeus 3500 QSB5.9‑380 (HO) Information not available at time of printing
QSB5.9‑425 (HO)
QSB5.9‑480 (HO)
Zeus 3800 QSC8.3‑550 (HO) Information not available at time of printing
NOTICE
After completing installation, place these instructions with the product for the owner's future use.
NOTICE
Predelivery preparation procedures must be performed before delivering the boat to the product
owner.
Notice to the Boat Manufacturer and Installer

This publication uses dangers, warnings, cautions, and notices (accompanied by the
international hazard symbol) to alert the manufacturer or installer about special instructions
concerning a particular service or operation that may be hazardous if it is performed
incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006 for product
safety information in product manuals, instructions, and other collateral materials. Observe
Them Carefully!
These safety alerts alone cannot eliminate the hazards that they signal. Complying with
these safety alerts must also be accompanied by the exercise of common sense 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.
Page i © 2007 Mercury Marine 90-866927070 SEPTEMBER 2007

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.
NOTE: Refer to the appropriate Cummins MerCruiser Diesel applications manual for
application recommendations.
This installation manual has been written and published by Cummins MerCruiser Diesel
(CMD®) to aid the boat manufacturer (OEM) in the installation of the products described
herein.
This manual assumes that OEM personnel are familiar with marine product installation and
are familiar with, if not trained in, the recommended installation procedures of Cummins
MerCruiser Diesel products.
We cannot anticipate all conceivable installations and their possible hazards or results.
Therefore, the OEM is responsible for any installation that does not fulfill the requirements
of this manual.
It is the responsibility of the boat manufacturer to select the appropriate engine‑drive
package (including the correct propellers) for a given boat. Cummins MerCruiser Diesel
recommends that any new or unique hull–power package combination be thoroughly
water‑tested before sale to verify that the boat performs as desired and that the engine
operates in the appropriate RPM range.
For assistance contact a Cummins MerCruiser Diesel distributor applications engineer.
All information, illustrations, and specifications contained in this manual are based on the
latest product information available at time of publication. Cummins MerCruiser Diesel
reserves the right to make changes at any time without obligation.
Page ii
Manual Outline
1 - Important Information
Important Information
1
2 - Boat Construction
3 - Exhaust System
Boat Construction
2
3
4 - Cooling System
Exhaust System
5 - Drive System Installation and Alignment
6 - Remote Control and Electrical
7 - Predelivery Preparation and Storage Cooling System
4
Drive System Installation and
Alignment
5
Remote Control and Electrical
6
Predelivery Preparation and
Storage
7
Page iii
Page iv
SECTION - 1 IMPORTANT INFORMATION
SECTION 1 - IMPORTANT INFORMATION 1

Table of Contents
Important Information.............................................................................................................................................. 2
Sales and Technical Assistance........................................................................................................................2
Product Accessories.......................................................................................................................................... 2
Special Installation Tools...................................................................................................................................2
Engine Mount Fixture ................................................................................................................................. 2
Engine‑to‑Drive Alignment Tool ................................................................................................................. 2
Drive Serial Number and Decal Placement.......................................................................................................3
Corrosion................................................................................................................................................................. 4
Corrosion Protection..........................................................................................................................................4
Anodes and the MerCathode System ..............................................................................................................4
Reference Electrode Wire of the MerCathode System.....................................................................................5
Painting the Boat...............................................................................................................................................5
90-866927070 SEPTEMBER 2007 Page 1 / 6

IMPORTANT INFORMATION SECTION - 1
Sales and Technical Assistance
The Cummins MerCruiser Diesel (CMD) distributor network of trained individuals can assist you
with sales and technical issues, including application engineering and service.
If you have an issue with the application of our product that cannot be resolved, contact your CMD
distributor Application Engineer for assistance. All requests for assistance should be directed to
your local CMD distributor.
To find the local CMD distributor for your area use the service locator on the Cummins website
(www.cmdmarine.com) or by contacting 1‑800‑DIESELS (1‑800‑343‑7357). For further technical
assistance contact us at our email address, wave.master@cummins.com.
Product Accessories
Other accessories are available for this product. Contact your Cummins Distributor for a complete
listing.
Outside of U.S.A., order parts through your distribution center or distributor.
Special Installation Tools
ENGINE MOUNT FIXTURE
We recommend you build an engine mount fixture based on design information we supply. Contact
your CMD distributor Application Engineer for assistance. This fixture saves installation time by
allowing you to drill engine mounting holes in the engine bed before installing the engine. The
fixture also permits preliminary adjustment of the engine bed or stringer height before engine
installation.
26770
Typical engine mount fixture tool

a - Front mounts
b - Rear mounts
Engine Mount Fixture

QSB and QSC Model Part Number
With drop box and 261 mm (10.27 in.) driveshaft Not available at time of printing
Without drop box and 721 mm (28.375 in.) driveshaft Not available at time of printing
ENGINE-TO-DRIVE ALIGNMENT TOOL

An engine‑to‑drive alignment tool has been developed to accurately check the engine and drive
alignment on the Zeus power package. This tool should be used as indicated at the following times:
• During initial installation of the engine and drive.
• Whenever the drive or engine is removed and installed.
Page 2 / 6 90-866927070 SEPTEMBER 2007

• For checking engine and drive alignment at the interval specified in the appropriate
maintenance schedule.
a
d e
c
b
29799
Engine‑to‑drive alignment—typical
a - Drive input flange d - Hand‑held engine‑to‑drive alignment
b - Alignment tool flange tool
c - Marking e - Sliding shaft in slot
Description Cummins Part Number

for 26 cm (10‑1/4 in.) shaft 4980379
Hand‑held engine‑to‑drive alignment tool
for 72 cm (28‑3/8 in.) shaft Not available at time of printing.
Drive Serial Number and Decal Placement

Serial numbers are the manufacturer's key to numerous engineering details that apply to your
drive.
27495
Drive serial number locations
a - Transmission serial number plate
b - Drive serial number decal and stamping
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.
90-866927070 SEPTEMBER 2007 Page 3 / 6

Corrosion
Corrosion Protection
These power packages have anodes as standard equipment to help protect them from galvanic
corrosion under moderate conditions. However, for severe conditions, we recommended the
Quicksilver Anti‑Corrosion Anode Kit. Refer to the Diesel Parts and Accessories Guide
( 90‑892645005) or the Mercury Accessories Guide (90‑420000006) for part numbers.
The MerCathode System and sacrificial anodes will provide corrosion protection under normal
usage. However, boats connected to AC shore power require additional protection to prevent
destructive low‑voltage galvanic currents from passing through the shore‑power ground wire. A
Quicksilver Galvanic Isolator can be installed to block the passage of these currents while
providing a path to ground for dangerous fault (shock) currents. Refer to the Diesel Parts and
Accessories Guide (90‑892645005) or the Mercury Accessories Guide (90‑420000006) for part
numbers.
IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and
anodes may be unable to handle the increased galvanic corrosion potential.
Anodes and the MerCathode System
The following sacrificial anodes are installed at different locations on the power package. These
anodes help protect against galvanic corrosion by sacrificing their metal to be slowly eroded
instead of the metal components on the power package.
The MerCathode system is an electrode controller and anode assembly. Test the MerCathode
system where the boat is moored to ensure adequate output using the Quicksilver Reference
Electrode and Test Meter.
Refer to the appropriate Cummins MerCruiser Diesel Drive Service Manual..
IMPORTANT: Replace the sacrificial anodes if they are eroded 50 percent or more.
Anodes and MerCathode System Locations

Description Location Figure
Trim tab anode

On the trim tab
plate
25261
The MerCathode
reference electrode
and anode on the
composite cover on
the bottom of the
MerCathode drive. The
System MerCathode
controller is on the
transmission. The
controller harness 27955
connects the
components.
Anode kit (if

On the boat transom.
equipped)
20341
Page 4 / 6 90-866927070 SEPTEMBER 2007

Reference Electrode Wire of the MerCathode System

NOTICE
Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do
not use any cleaning equipment such as brushes or high‑pressure washers to clean the
MerCathode assembly.
IMPORTANT: Do not pressure‑wash the reference electrode of the MerCathode assembly. Doing
so will damage the coating on the reference electrode wire and decrease the corrosion protection.
a
b
25885
a - Anode
b - Reference electrode (not visible in this view)
Painting the Boat

IMPORTANT: The limited warranty does not cover corrosion damage as a result of improper paint
application.
IMPORTANT: Paint renders anodes and the MerCathode system ineffective as inhibitors of
galvanic corrosion.
When painting the boat hull with anti‑fouling paint, observe the following:
• Use high‑quality, anti‑fouling paint designed for marine use.
• Avoid using anti‑fouling paint that contains copper material, which could conduct electrical
current.
• If using copper‑based or tin‑based paints is necessary, ensure that you comply with all local
and federal laws prohibiting their use.
• Do not paint drain holes or items as specified by the boat manufacturer.
• Do not paint any anodes or the MerCathode system components.
90-866927070 SEPTEMBER 2007 Page 5 / 6

• Avoid any electrical interconnection between the paint and drive, anodic blocks, trim tab
anodes, or MerCathode system by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area
on the hull of the boat around these items and as shown in the following figure.
a
25260
Unpainted area
a - Minimum unpainted 40 mm (1‑1/2 in.) area around the interface ring seal
(grommet) on models with a molded‑in tunnel opening or around the bolt‑on
interface ring assembly (if equipped)
Page 6 / 6 90-866927070 SEPTEMBER 2007

SECTION - 2 BOAT CONSTRUCTION
SECTION 2 - BOAT CONSTRUCTION

Table of Contents
Boat Construction.................................................................................................................................................... 2
Fiberglass Boats................................................................................................................................................2
2
Tunnel Design ............................................................................................................................................ 2
Method of Tunnel Installation ..................................................................................................................... 3
Tunnel and Drive Interface ....................................................................................................................... 3
Models with a Fabricated (Molded‑In) Tunnel Opening....................................................................................4
Models with a Tunnel Cut‑out Opening.............................................................................................................5
General Information ................................................................................................................................... 5
Cutting Out the Tunnel Opening ................................................................................................................ 5
Hull Specifications and Drive Interface............................................................................................................ 11
Engine Foundation Design.................................................................................................................................... 11
Engine Bed......................................................................................................................................................11
Drop Box and Engine Installed Height............................................................................................................12
90-866927070 SEPTEMBER 2007 Page 1 / 14

BOAT CONSTRUCTION SECTION - 2
Boat Construction
! WARNING
Improper boat design and construction may result in serious injury or death. Adhere to all
applicable marine regulations (United States Coast Guard [USCG], European Union–
Recreational Craft Directive [EU‑RCD], etc.) and the standards they reference (American Boat
and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards
Organization [ISO], etc.) when designing and constructing the boat and other components, such
as the engine compartment, fuel delivery system, or exhaust system.
For additional boat construction information, refer to the appropriateCummins MerCruiser Diesel
Applications Manual.
! WARNING
Failure to comply with regulations can result in injury from fire or explosion. Electrical system
components on this engine are not rated as external ignition–protected (EIP). Do not store or
use gasoline on boats equipped with these engines, unless provisions have been made to
exclude gasoline vapors from the engine compartment (REF: 33 CFR).
If you have an issue with the application of our product that cannot be resolved, contact your CMD
distributor application engineer. Direct all requests for assistance to your local CMD distributor.
Find the distributor for your area by using the service locator on the Cummins website
(www.cmdmarine.com) or by contacting 1‑800‑DIESELS (1‑800‑343‑7357). If you need further
technical assistance, contact us at our email address: wave.master@cummins.com.
Fiberglass Boats
TUNNEL DESIGN
For fiberglass (fiberglass reinforced plastic or FRP) hulls, the integrated tunnel recess is formed
using a removable mold insert built from design information provided by your CMD Factory
Application Engineer.
23829
Typical hull underside

a - Integrated tunnel
Page 2 / 14 90-866927070 SEPTEMBER 2007

If you need further technical assistance regarding tunnel design information, contact your
authorized CMD Distributor or contact CMD at their email address:
wave.master@cummins.com.
24809
Hexagonal pipe tunnel design
METHOD OF TUNNEL INSTALLATION
The tunnel method of installation provides some flexibility of position and allows the Cummins
MerCruiser Diesel Zeus drive to be installed in almost all hull types.
The following outlines a typical method of tunnel installation:
1. Trim the aft section of the fiberglass mold to match the transom angle so the fiberglass mold
insert sits neatly in the hull mold and squarely against the vessel transom.
2. Place the tunnel mold in the hull mold parallel to the vessel keel or baseline to assure alignment
of the Zeus drive with the engine.
3. Prepare the hull for lay‑up.
4. Place the fiberglass tunnel mold into the female hull mold.
5. Secure the fiberglass mold insert temporarily into the female hull mold.
6. Ensure the center line of the mold is aligned within specification to the boat.
Mold Alignment
Angular alignment relative to boat keel ± 1°
Lateral spacing (distance from keel) ± 6.35 mm (± 0.25 in.)
7. Coat the surface with mold release to ensure removal after laminating.
IMPORTANT: Laminate thickness in the interface ring mounting area must meet specifications
depending upon the application. Refer to the product application manual for additional information.
8. Laminate schedule should be as per suppliers instructions and depending on the model—a
model with a fabricated (molded‑in) tunnel opening or a model with a tunnel cut‑out opening
using a bolted‑on interface ring.
TUNNEL AND DRIVE INTERFACE
The drive is mounted into either a fabricated (molded‑in) tunnel opening or a bolted‑on interface
ring that is incorporated into the tunnel.
NOTE: The following application methods apply to twin Zeus drive installations in V‑bottom
vessels.
90-866927070 SEPTEMBER 2007 Page 3 / 14

On models with a fabricated tunnel opening (molded-in interface ring). The interface ring is
formed into the hull using cut fiberglass sheets layered to specific dimensions and laminated into
the hull with increased laminate thickness extending outward toward the tunnel, the stringers, and
the transom. The controlled thickness and the precise shape of the pre‑molded ring provides the
sealing surface for the Zeus drive.
23825
a - Hull and surrounding area

b - Close molded fiberglass ring
On models with tunnel cut-out opening (bolted-on interface ring). A one‑piece interface ring
made of composite material is sealed and bolted onto the hull around an opening cut out of the
hull tunnel where the Zeus drive will be mounted. The process is similar to cutting out the transom
on a sterndrive model. Cutting the hull precisely, using a special tool and the controlled thickness
provided by the bolted‑on interface ring, creates the sealing surface for the Zeus drive.
d
c
26701
a- Interface ring with stainless steel studs

b- Section of hull and formed opening
c- Stainless steel washer
d- M12 locknut
Models with a Fabricated (Molded‑In) Tunnel Opening

Some boat designs have fabricated (molded‑in) fiberglass openings cast into the hull tunnels
where the drives are to be installed. In this molded‑in design the hull lamination forms the sealing
and mounting surface for the drive.
Refer to the product application manual for procedures and laminate specifications required to
fabricate molded‑in tunnel openings.
IMPORTANT: Laminate thickness in the interface ring mounting area must meet specifications
depending upon the application. Refer to the product application manual for additional information.
Check the tunnel opening thickness and surface before installing the drive. Refer to Section 5.
Page 4 / 14 90-866927070 SEPTEMBER 2007

Models with a Tunnel Cut‑out Opening

Unless the boat has fabricated (molded‑in) tunnel openings, it will be necessary to cut openings
in the hull tunnels for the drives and to mount (bolt‑on) interface rings to the hull.
GENERAL INFORMATION
Observe the following information.
• Ensure that the final dimensions of the opening are within specifications after the tunnel
opening is cut out of the hull.
• Use the drill bushing fixture tool to ensure the interface ring assembly mounting holes are
drilled perpendicular to the hull. Improper drilling could prevent the interface ring assembly
from sealing properly and in extreme cases could cause assembly binding or damage.
b
a
23014
Typical
a - Hull
b - Cutout
The drill bushing fixture tool, consists of the clamping ring (inside the boat) and the bottom interface
ring assembly (under the boat), to make the cutouts for the interface rings.
Description Part Number

Drill bushing fixture tool Not available at time of printing
CUTTING OUT THE TUNNEL OPENING

Instructions for cutting out the opening in the tunnel are outlined in the following steps.
NOTE: To assist in aligning the cutout for the openings, front drill points were precisely located
and molded into the hull. Refer to the appropriate Zeus product application manual for additional
information.
1. Check the location of the molded‑in port and starboard front drill points to be as specified.
Drill Point Alignment

Longitudinal location relative to transom ± 6.35 mm (± 0.25 in.)
2. Working outside the boat, position the locating bar of the drill bushing fixture tool over the front
molded‑in drill point on the bottom of the boat tunnel.
90-866927070 SEPTEMBER 2007 Page 5 / 14

3. Drill the front hole for the locating bar.
b d
c a
23021
Typical hull tunnel

a- Hull
b- Tunnel
c- Locating bar
d- Front locating hole
Front locating hole

Drill size 16 mm (5/8 in.)
4. Insert the quick‑release pin in the drilled hole and through the locating bar to align the front of
the drill bushing fixture.
23025
c
a - Front drilled hole
b - Quick release pin
c - Locating bar
5. Working outside the boat, align the locating bar as specified, to establish the rear drill point in
the tunnel.
Top plate alignment specifications

Page 6 / 14 90-866927070 SEPTEMBER 2007

6. Drill the rear hole for the locating bar of the drill bushing fixture tool.
c a
d 23026
Typical hull tunnel with locating bar in place

a- Hull
b- Tunnel
c- Locating bar
d- Rear hole
Front locating hole

7. Remove the quick‑release pin and the locating bar from the bottom of the hull.
8. Working inside the boat, install the top plate of the drill bushing fixture tool for routing the drive
cut out.
a. Align the drill bushing fixture top plate with the front and rear pre‑drilled fixture holes.
b. Insert the two flat‑head bolts in pre‑drilled fixture holes.
a
b
c
23413
Top plate for drive cut‑out
a - Top plate
b - Flat‑head bolts
c - Inside of boat hull
9. Working outside the boat, install the bottom plate of the drill bushing fixture tool.
a. Install the bottom plate onto the two fixture bolts extending through the hull.
90-866927070 SEPTEMBER 2007 Page 7 / 14

b. Position four pieces of foam board of the appropriate thickness and shape inside of the
bottom plate as shown.
a b
c
c
23414
a - Foam pieces
b - Bottom plate
c - Fixture bolts
c. Install the two wing‑nuts on the fixture bolts.

d. Tighten the wing‑nuts until the bottom plate securely contacts the boat hull and the pieces
of foam are compressed to support the fiberglass during the cut‑out operation.
23724
b
c
d
Bottom plate for drive cut‑out
a- Foam piece
b- Bottom plate
c- Wing‑nut
d- Outside of boat hull
10. The assembled cut‑out fixture from inside and outside the boat should appear as shown.
23760
Assembled fixture inside the boat Assembled fixture on the bottom of the boat
Page 8 / 14 90-866927070 SEPTEMBER 2007

11. Working outside the boat, using the specified drill size, drill the remaining holes in the hull for
mounting the interface ring assembly.
23768
a - Cut‑out fixture on bottom of boat

b - Drilling locations
Interface ring mounting

12. Install a guide or bearing to the router drill bit indicated. Set the router bit maximum depth as
specified.
Router bit specifications

Bearing or guide diameter
Router bit diameter Not available at time of printing
Router bit depth (maximum)
13. Working inside the boat, align the router with the appropriate bit to the inner edge of the top
plate as indicated. Using the router, as recommended by the router manufacturer, cut the hole
for the Zeus drive.
NOTE: Ensure that the router bit is only long enough to cut through the hull but not contact the
drill bushing fixture bottom plate under the boat. When the cut is complete, the fiberglass cut‑out
piece will be supported on the four foam pieces on the fixture under the boat.
a
d
23766
c
b
a- Router
b- Router bit
c- Guide or bearing
d- Top plate inner edge
90-866927070 SEPTEMBER 2007 Page 9 / 14

14. Remove and discard the cut‑out fiberglass.

15. Disassemble and remove the drill bushing fixture tool.
NOTE: Some hull construction materials may require that the inside edge of cutout opening be
sealed with a gel‑coat or suitable sealant to prevent water absorption and deterioration of the hull.
16. Check that the final dimensions of the opening are within specifications.
28499
Dimensions of a tunnel cut‑out opening

a - 90.10 cm ± 0.76 mm (35.474 in. ± 0.030 in.)
b - 54.50 cm ± 0.76 mm (21.459 in. ± 0.030 in.)
17. Using a suitable material, fabricate an inspection gauge with the measurements indicated.
d b
a
24926
a- 38 mm (1.50 in.)
b- 38.10 mm (1.50 in.)
c- 30.98 mm (1.22 in.)
d- 51 mm (2 in.)
18. After the tunnel opening is cut out of the hull, verify the final dimensions of the opening are
within specification by placing the fabricated inspection gauge at all points around the opening.
Final dimensions of hull around the tunnel opening

Nominal thickness 31.75 mm (1.25 in.)
Maximum thickness 38.1 mm (1.50 in.)
Minimum thickness 30.98 mm (1.22 in.)
NOTE: If you use a router to remove material, do not create sharp edges that could damage the
drive grommet (interface ring).
Page 10 / 14 90-866927070 SEPTEMBER 2007

19. If the thickness of the opening is greater than specified, sand (or router) the irregular area
to specification and apply a gel coat.
20. If the thickness of the opening is less than specified, sand the irregular area and fill with
a marine grade epoxy. Apply a gel coat.
21. Check that the final dimensions of the tunnel opening are within specification before
proceeding.
Hull Specifications and Drive Interface
IMPORTANT: Hull thickness must comply with the following specifications for proper operation of
the power package. Failure to comply could result in the following:
• Improper material or insufficient hull thickness or interface ring thickness may allow the hull
to deflect from propeller thrust during operation . This deflection could cause failure of the
engine coupler.
• Correct hull and interface ring thickness is critical for proper mating of the drive assembly and
engine components. A hull or interface ring that is out of specifications prevent sufficient
engagement of the mid‑section clamping ring assembly fastener (and pilot), and U‑joint
knocking.
• Compliance with the inner and outer hull surface finish specifications is required to prevent
water leakage into the boat.
NOTE: All measurements are taken in the interface ring assembly area. See the product
application manual for additional information on hull thickness and lay‑up techniques near the
stringers, tunnel openings, and transom.
Hull and Molded‑In Interface Ring Specifications
Material Composite
Hull thickness at drive opening cutout (models using
a composite [bolted‑on] interface ring)
38.10 mm (1.50 in.) to 30.98 mm (1.22 in.)
See the product application manual for additional
information.
Hull thickness at drive molded in opening (models
with fabricated [molded‑in] tunnel opening)
24.60 mm (0.97 in.) to 26.10 mm (1.03 in.)
See the product application manual for additional
information.
Hull outside surface: conventional FRP production
Surface finish at hull opening (molded‑in opening) practice; Hull inside and bull‑nose surface:125 RMS
after finish gel coat
Hull outside surface: conventional FRP production
Surface finish at hull opening (cut‑out opening)
practice
IMPORTANT: Hull thickness, parallelism and flatness must be measured on every installation after
making the interface ring cutout or after forming the interface ring area of the hull. Fabricate and
use the recommended inspection gauge for each type of installation.
Engine Foundation Design

Engine Bed
The engine bed and the stringers must be designed to support the gravitational forces imposed
by the engine during the most severe duty for which the boat is intended. It must also handle the
torque produced by the engine. Deflection of the engine bed could cause engine misalignment
and possible engine coupler failure. The proper design of the engine bed varies considerably from
one boat design to the next. Therefore, Cummins MerCruiser Diesel makes no attempt to provide
detailed engine bed design requirements to cover all possible applications. The proper design of
the engine bed is the responsibility of the boat manufacturer.
Observe the following general guidelines.
90-866927070 SEPTEMBER 2007 Page 11 / 14

• Refer to the latest Cummins Marine Installation Drawings for engine mount spacing and
other dimensions at the website: www.cmdmarine.com.
• The engine bed must be firmly affixed to the boat and should be made as large as possible
to distribute the load evenly. Reinforcements should be used where necessary. Mount pad
locations should be as large as possible.
• The front engine mount isolators must rest squarely on the engine bed so that the rubber
isolator is not loaded in one direction or the other. Improper loading of the engine mount will
cause increased vibration.
• Engine mount isolators have provisions for 13 mm (1/2 in.) fasteners for securing mounts to
the engine bed. Fasteners should be selected as appropriate for the type of engine bed
material being used and the gravitational forces to be encountered.
• Do not install engine mount fasteners at an angle.
• The engine bed must position the engine in approximately the middle of the mounting stud
after performing the final engine alignment. If necessary, shim the mount height to the middle
of the mounting stud to allow for realignment in the future. Engine mount isolators will
compress slightly over time.
• The engine bed design must incline the installed engine at 0° ± 1° fore and aft with boat at
rest in the water.
• The engine bed must position the engine aligned to the center of the drive input shaft and
parallel to the vessel centerline.
IMPORTANT: Engine mount isolators must be located as close as possible to the vertical height
of the engine crank centerline for proper isolation of vibration. The engine mounts provided with
the engine are designed to achieve proper isolation and must not be modified to change isolator
height.
• The engine bed height for the mounts should be the same on both sides. This can be checked
by tying a string from the right front mount location to the left rear mount location, and another
string from the left front to the right rear. The strings should just touch where they cross.
b
24325
Typical engine bed
a - Front mount location
b - Rear mount location
c - Strings cross
Drop Box and Engine Installed Height

Part of the CAD (Computer Aided Design) effort of the hull, with assistance from the CMD Naval
Architect, will determine if the drive needs to be equipped with a drop box.
Using the drop box sets the engine lower in the vessel relative to the drive. The drop box is available
in two ratios. Contact your CMD Distributor application engineer for proper drop box application.
Page 12 / 14 90-866927070 SEPTEMBER 2007

Drop box
1.75:1
QSB
Gear ratios available 2.0:1
QSC 1.75:1
Refer to the Cummins MerCruiser Diesel Zeus Drive Application Manual for additional
information.
a
27942
Lower engine installed height possible using a drive equipped with a drop box
a - Lower output coupling
b - Drop box
90-866927070 SEPTEMBER 2007 Page 13 / 14

NOTES:
Page 14 / 14 90-866927070 SEPTEMBER 2007

SECTION - 3 EXHAUST SYSTEM
SECTION 3 - EXHAUST SYSTEM

Table of Contents
Important Information.............................................................................................................................................. 2
Exhaust System Description—Flange‑Type Connection........................................................................................ 2
Exhaust Elbow Height............................................................................................................................................. 3
3
Measuring Procedure.............................................................................................................................................. 3
Measuring Methods................................................................................................................................................. 4
Straight Edge Method........................................................................................................................................4
Clear Hose Method...........................................................................................................................................5
Exhaust Back Pressure........................................................................................................................................... 6
General Information .......................................................................................................................................... 6
Exhaust Back Pressure Test ............................................................................................................................ 7
Tools .......................................................................................................................................................... 7
Procedure .................................................................................................................................................. 7
90-866927070 SEPTEMBER 2007 Page 1 / 8

EXHAUST SYSTEM SECTION - 3
! WARNING
Improper boat design and construction may result in serious injury or death. Adhere to all
applicable marine regulations (United States Coast Guard [USCG], European Union–
Recreational Craft Directive [EU‑RCD], etc.) and the standards they reference (American Boat
and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards
Organization [ISO], etc.) when designing and constructing the boat and other components, such
as the engine compartment, fuel delivery system, or exhaust system.
Exhaust System Description—Flange‑Type Connection

The engine exhaust containing some overboard (return) seawater connects to the center section
of the drive on a flange. Using a 90° elbow the drive flange is connected to an exhaust pipe from
the exhaust elbow at the turbocharger of the engine. The exhaust and overboard seawater are
funneled through a cavity in the steering actuator housing down though a port that is sealed by a
special gasket assembly. The exhaust then enters the drive lower housing and finally exits through
the propeller hub. Additional overboard seawater is routed through one or two fluid coolers,
depending on the model of the drive, and exits through a seacock on the rear of the drive. Additional
exhaust relief is provided by an idle bypass system that channels some exhaust and cooling water
to a water lift muffler and then, to an overboard fitting and out through the hull.
Some of the major components of the exhaust system are shown.
e f m g
l
k
d a h
c b i
j
29976
Typical flange connection exhaust system installation
a - Exhaust pipe h - Upper exhaust elbow
b - Lower exhaust bellows i - Upper exhaust bellows
c - Lower exhaust elbow with flange j - Fitting for exhaust idle bypass hose
d - Water overboard hose k - Exhaust idle bypass hose to water lift
e - Primary fluid cooler muffler
f - Drive exhaust flange l - Exhaust pipe
g - Water supply hose m - Seawater bypass hose
Page 2 / 8 90-866927070 SEPTEMBER 2007

a
d
b
c
26862
Typical water lift muffler installation
a- Typical water lift muffler
b- Exhaust idle bypass hose
c- Seawater overboard hose
d- Seawater overboard fitting
Exhaust Elbow Height

1. Verify that the exhaust elbow height at the turbocharger outlet flange provides the required
dimension "c" or a distance greater than "c," as indicated.
Model "c" = "a" Minus "b"

All Models "c" must be at least 30.5 cm (12 in.) or more
d
b
a
24181
Typical installation
a- From waterline to top of transom
b- From lowest point on turbocharger outlet (or riser, if equipped) to top of transom
c- From "a" minus "b"
d- Waterline at rest
2. If "c" is less than specified in the chart, changes in the exhaust elbow such as the use of an
exhaust riser will be necessary to assist in obtaining the proper height. See Measuring
Procedure.
Measuring Procedure
The height of the exhaust elbows must be within the dimensions specified to prevent water
intrusion. Exhaust elbow risers may need to be installed to obtain the proper height. Take the
measurements with the boat in the water and the boat loaded as outlined to simulate the maximum
loading conditions likely to be encountered in normal operation.
90-866927070 SEPTEMBER 2007 Page 3 / 8

IMPORTANT: Load distribution recommendations are the responsibility of the boat manufacturer.
Clearly communicate any load distribution conditions that will affect the exhaust system height
and slope compliance to the operator in the owner's manual. For example, include in the manual
the number of people that can be located on the swim platform simultaneously if this could pose
a problem.
1. Fill all fuel, water, gray water, and heater tanks to maximum capacity. Use people or weights
to simulate these loads if desired. See conversions:
• 1 U.S. gallon of water = 8.3 lb.
• 1 liter of water = 1 kg
• 1 U.S. gallon of Grade 2 diesel fuel = 7 lb.
• 1 liter of Grade 2 diesel fuel = 3.2 kg
2. Add the maximum allowable cargo weight to the boat in areas where it will be stowed, including
the refrigerator and lockers. Do not forget personal watercraft, if applicable.
NOTE: ABYC specifies an average passenger weight of 64 kg (141 lb.) for boat loading
calculations. Use this as a minimum. An average passenger weight of 86 kg (190 lb.) is preferable.
3. Add the average passenger weight of 86 kg (190 lb.) in all locations where each passenger
will sit during normal operation.
4. Measure the exhaust elbow height. See Measuring Methods.
5. Leave fluid and cargo weights where they are, but remove passenger weights from the boat.
Beginning at the bow, reload passenger weight (the equivalent of one person at a time) while
retaking readings. Use all of the available seating areas in the bow first. Continue adding
passenger weight (and taking readings), moving from the bow to the stern, until the maximum
passenger weight has been added on board.
IMPORTANT: Be sure to consider swim platform loading and personal watercraft.
6. Repeat Step 5, but this time, start at the stern of the boat and work toward the bow.
7. Measurements under all loading conditions must be within specifications.
8. Check exhaust system measurements. See Measuring Methods - Straight Edge Method
or Clear Hose Method.
Description All Models

Minimum exhaust elbow height from bottom of elbow to waterline 30.5 cm (12 in.)
9. If measurements are less than specified, modify the installation to achieve the proper
dimension.
Measuring Methods
Straight Edge Method
1. Place a straight edge across the boat.
2. With the straight edge above the engine and parallel to the water, measure the distances
between the straight edge and the bottom of the exhaust elbow.
3. With the straight edge above the engine and parallel to the water measure the distance
between the straight edge and the outside waterline.
IMPORTANT: The difference between these two measurements is the exhaust elbow height
(above the water line).
Page 4 / 8 90-866927070 SEPTEMBER 2007

4. Compare the measurement to the specifications. See Exhaust Elbow Height.
c b
a
e
d
24084
Typical
a- Waterline
b- Bottom of exhaust elbow
c- Straight edge
d- Measurement between straight edge and bottom of exhaust elbow
e- Measurement between straight edge and water line
Clear Hose Method

1. Obtain an 8–10 mm (5/16–3/8 in.) inner diameter hose approximately 4.5 m (15 ft.) long. Put
a metal fitting or a weight on one end of the hose to keep that end of the hose below the water
line.
2. Put the weighted end of the hose over the port or starboard side of the boat, keeping it in line
with the engine's exhaust elbow.
3. Route the remainder of the hose toward the engine's exhaust manifold and elbow. Ensure that
this open end section of the hose is as vertical as possible from the boat's bilge to the top of
the exhaust elbow
4. Coil excess hose in the bilge of the boat, keeping it below the water line.
5. Lower the open end of the hose and siphon the water until it starts to come out of the hose.
Put a finger over the hose and lift the open end until it is at the top of the exhaust elbow.
6. Slowly take your finger off the end of the hose to let the water level stabilize. The water will
seek the level of the water outside the boat. Keep the hose close to the exhaust elbow and
as vertical as possible.
7. Ensure that the boat is level.
90-866927070 SEPTEMBER 2007 Page 5 / 8

8. The measurement between the water in the hose and the bottom of the exhaust elbow is the
exhaust elbow height. Compare the measurement to the specifications. See Exhaust Elbow
Height.
b
c
a
e
24086
Typical
a- Waterline
b- Bottom of exhaust elbow
c- Clear plastic hose
d- Weight
e- Measurement—waterline to bottom of exhaust elbow
Exhaust Back Pressure

General Information
IMPORTANT: We recommend checking exhaust back pressure on all new applications to ensure
that it is within specifications.
The power output of an engine is directly related to the amount of exhaust that can flow out of the
exhaust system. All exhaust systems have some restriction to flow or exhaust back pressure.
Because the Zeus drive power package uses through the propeller exhaust, the back pressure is
largely related to the path of the exhaust through the drive and the displacement of the engine.
The production exhaust system benefits from the use of an idle bypass circuit and waterlift muffler
system.
The back pressure at rated RPM must be no greater than shown.
Maximum exhaust back pressure

QSB engines 16.93 kPa (5.0 in. Hg)
QSC engines 10.15 kPa (3.0 in. Hg)
A higher output engine will cause a greater back pressure using the same size exhaust system
as an engine with less output. The boat's exhaust system should be designed and tested for the
highest horsepower engine to be offered in that boat.
If pressure is excessive, changes must be made to the system to reduce the pressure. These
changes could include:
• Reduce exhaust system length
• Eliminate sharp bends
• Increase exhaust system diameter
• Reduce muffler restriction
Page 6 / 8 90-866927070 SEPTEMBER 2007

Exhaust Back Pressure Test

TOOLS
Service tachometer Obtain locally
Brass 1/8 in. NPT male adapter fitting–1 required per engine 22‑808002
Pressure gauge accurate in 25 mm Hg (1 in Hg) increments Obtain locally
PROCEDURE
During this procedure the boat will need to be in the water and underway. No special loading of
the boat is necessary. Engine must be capable of reaching the specified rated RPM as verified
using an accurate service tachometer or scan tool.
1. With the engine off, remove the 1/8 in. NPT pipe plug from the exhaust elbow or riser.
27062
Location of back pressure test port
NOTE: The exhaust gas temperature can be extremely high in the exhaust system where back
pressure is measured. Use a length of coiled steel tubing as a heat sink to isolate the gauge from
the exhaust system or buy a suitable heat sink to dissipate heat before attaching the test gauge.
2. Assemble a suitable heat sink onto an adapter that fits the pipe plug hole in the exhaust elbow
or riser.
3. Set the pressure gauge to zero.
4. Attach the test gauge to the heat sink or exhaust system.
5. Start the engine and put the boat underway. Operate the engine at 1000, 2000, 3000, and
wide‑open throttle RPM respectively. Record back pressure at each setting.
6. Repeat these steps for remaining engines on multiple‑engine applications.
7. If the pressure exceeds specification (see General Information), change the exhaust system
to reduce the pressure.
8. Install the exhaust elbow or riser pipe plug.
90-866927070 SEPTEMBER 2007 Page 7 / 8

NOTES:
Page 8 / 8 90-866927070 SEPTEMBER 2007

SECTION - 4 COOLING SYSTEM
SECTION 4 - COOLING SYSTEM

Table of Contents
Specifications—Cooling System............................................................................................................................. 2
Seawater Connections............................................................................................................................................ 2
Seacock.............................................................................................................................................................2
Seawater Hoses—Supply (Inlet).......................................................................................................................2
Requirements ............................................................................................................................................ 2
Installation .................................................................................................................................................. 3
Seawater Strainer..............................................................................................................................................3
4
Requirements ............................................................................................................................................ 3
Installation .................................................................................................................................................. 3
Auxiliary Heating Circuits .................................................................................................................................3
Seawater Hose—Return (Outlet)......................................................................................................................4
90-866927070 SEPTEMBER 2007 Page 1 / 4

COOLING SYSTEM SECTION - 4
Specifications—Cooling System
Description All Models
Integrated into drive
Seawater pickup
unit
51 mm (2 in.) provided
Seacock size (internal cross‑sectional area)
with drive unit
Seawater inlet hose QSB engines Minimum 51 mm (2 in.)

inner diameter QSC engines Minimum 64 mm (2‑1/2 in.)
265 liter/min.
QSB engine
Seawater strainer flow (70 U.S.gal/min.)
rate 303 liter/min.
QSC engine
(80 US gal/min.)
Seawater inlet
Maximum 125 mm Hg (5 in Hg)
restriction.
265 liter/min.
QSB engine
Seawater pump flow (70 U.S.gal/min.)
rates 303 liter/min.
QSC engine
(80 US gal/min.)
Seawater Connections
Seacock
A 51 mm (2 in.) seacock for seawater inlet is provided with the Zeus drive product. It may be
necessary to locally obtain fittings for the connection and proper routing of the seawater inlet hose,
depending on the application.
a b
24091
a - Seacock (provided)
b - 90° fitting, if required (obtain locally)
Seawater Hoses—Supply (Inlet)

REQUIREMENTS
Seawater hoses are not provided with the product. Refer to the Marine Recreational High Output
Propulsion Units B and C Series Installation Directions manual (CMD 3884649) available from
the engine manufacturer for additional information on seawater inlet hose connections.
IMPORTANT: Use a wire‑reinforced seawater hose to avoid collapsing the hose when suction is
created by the seawater pump impeller.
The minimum size seawater inlet hose for each engine can be no smaller than the inlet connection
on the seawater pump. Larger hose is required if the seawater inlet hose is especially long or has
multiple bends which increase water inlet restriction.
Secure the connections for the wire‑reinforced hose with double hose clamps.
Page 2 / 4 90-866927070 SEPTEMBER 2007

SECTION - 4 COOLING SYSTEM
Secure the hoses to prevent contact with any hot or moving parts.
See Specifications—Cooling System.
INSTALLATION
See Section 5—Drive System Mounting and Alignment for installation procedures.
Seawater Strainer
REQUIREMENTS
The seawater strainer used must be large enough to ensure an adequate supply of water for
cooling the engine. See Specifications—Cooling System.
INSTALLATION
Refer to manufacturer's instructions for installation, operation, and maintenance.
IMPORTANT: Read and observe the following when mounting and connecting a seawater strainer.
• Never mount the seawater strainer on the engine.
• Mount the seawater strainer in an easily accessible location.
• Hoses must not be kinked.
• Hoses must not be allowed to contact hot or moving parts.
1. Position the seawater strainer in an appropriate location.
2. Ensure that the arrow that indicates the direction of seawater flow points toward the seawater
pump.
3. Install the seawater strainer using appropriate flat washers and lag bolts or thru‑bolts and nuts.
a
b
23797
Typical seawater strainer installation
a - Seawater strainer
b - Mounting screw hole location (screws not visible)
Auxiliary Heating Circuits

NOTICE
Prevent engine damage from overheating. In models equipped with closed cooling, low coolant
levels may allow an air pocket to form when the hot water heater or cabin heater is mounted
higher than the fill cap on the heat exchanger. Mount the heater lower than the fill cap of the
heat exchanger and maintain the recommended coolant level.
Auxiliary heating circuits (such as hot water heaters) must be installed according to the information
and procedures found in the Marine Recreational High Output Propulsion Units B and C
Series Installation Directions manual available from the manufacturer of the engine.
90-866927070 SEPTEMBER 2007 Page 3 / 4

COOLING SYSTEM SECTION - 4
Seawater Hose—Return (Outlet)

A 38 mm (1.5 in) reinforced seawater hose is provided with the QSB power package, while the
QSC is 51 mm (2.0 in.). Ensure proper routing of the seawater hose from a fitting on the exhaust
elbow to the primary fluid cooler assembly on models without a drop box or to a secondary fluid
cooler assembly on models with a drop box. Excess return seawater flows from a fitting on the
exhaust elbow to the fluid coolers for cooling the drive transmission and steering systems.
a c
26736
Shown without a drop box, all similar
a - Seawater hose
b - Exhaust elbow fitting
c - Primary fluid cooler
Seawater is routed overboard (returned) from the primary fluid cooler through a separate seacock.
c
b
a
24420
a- Seawater overboard (return) fitting
b- Seacock
c- Seacock lever
d- Seawater hose from primary fluid cooler
e- Primary fluid cooler
This section of seawater hose must be installed and routed by the installer. See Section 5—Drive
System Installation and Alignment for additional information.
Page 4 / 4 90-866927070 SEPTEMBER 2007

SECTION - 5 DRIVE SYSTEM INSTALLATION AND ALIGNMENT
SECTION 5 - DRIVE SYSTEM INSTALLATION AND

ALIGNMENT
Table of Contents
Checking the Tunnel Opening Alignment, Thickness, and Surface........................................................................ 2
On Models with a Tunnel Cut‑Out Opening—Using a Bolt‑On Interface Ring..................................................2
On Models with a Fabricated (Molded‑In) Tunnel Opening............................................................................... 3
Installing the Bolt‑on Interface Ring........................................................................................................................ 4
Engine Mounting..................................................................................................................................................... 8
Crankshaft Center Lines....................................................................................................................................8
Installing the Engine Mounts.............................................................................................................................8
Tool Selection ............................................................................................................................................ 8
Initial Engine Mount Alignment .................................................................................................................. 8
Zeus Drive Installation........................................................................................................................................... 10
Identifying the Drives.......................................................................................................................................10
Installing the Interface Ring Seal.....................................................................................................................10
5
Installing the Drive Using an Installation Stand and Forklift............................................................................11
Installing the Drive Using the Shipping Container...........................................................................................12
Installing the Engine........................................................................................................................................21
Final Engine Alignment...................................................................................................................................22
Driveshaft Installation......................................................................................................................................23
Installing the Exhaust System—Flange‑Type Connection..............................................................................26
Connecting the Seawater Inlet and Strainer....................................................................................................28
Installing the Drive Skeg..................................................................................................................................29
Corrosion Continuity Circuits...........................................................................................................................30
Electrical Connections........................................................................................................................................... 32
Connecting the Wiring.....................................................................................................................................32
Continuity Wire Connections...........................................................................................................................33
Drive Application Extension Harness..............................................................................................................33
Installing the Drive Application Extension Harness.........................................................................................34
Vessel Interface Panel (VIP)...........................................................................................................................35
Mounting the Vessel Interface Panel (VIP).....................................................................................................35
T‑Harness........................................................................................................................................................36
Installing the T‑Harness..................................................................................................................................36
Engine‑to‑VIP Extension Harness...................................................................................................................37
Installing the Engine‑to‑VIP Extension Harness.............................................................................................. 37
TVM (Thrust Vector Module) Extension Harness............................................................................................38
Installing the TVM Extension Harness............................................................................................................39
Vessel Sensor Harness (Optional)..................................................................................................................40
Installing the Vessel Sensor Harness.............................................................................................................. 41
Vessel Sensor Extension Harness (Optional).................................................................................................42
Installing the Vessel Sensor Extension Harness.............................................................................................42
Connecting the Vessel Sensors......................................................................................................................42
VIP and ECM Power Harnesses.....................................................................................................................43
Installing the VIP Unswitched Power Harness................................................................................................44
Installing the ECM Switched Power Harness..................................................................................................44
Clean Power Harness for the Backup Hydraulic Pump...................................................................................44
Installing the Clean Power Harness for the Backup Hydraulic Pump.............................................................. 45
Installing the Drive Cover...................................................................................................................................... 45
90-866927070 SEPTEMBER 2007 Page 1 / 46

DRIVE SYSTEM INSTALLATION AND ALIGNMENT SECTION - 5
Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
Interface ring to hull
BoatLIFE® 1033, or equivalent Obtain Locally
Stainless steel studs and locknuts
10 Loctite 277 Driveshaft shield retaining screw and nut Obtain Locally
Stainless steel studs and locknuts
34 Special Lubricant 101 92-802865Q02
Clamp ring flanged screws
42 U-joint and Gimbal Bearing Grease Driveshaft slip-joint 92-802870A1
91 Engine Coupler Spline Grease Driveshaft slip-joint 92-802869A1
95 2-4-C with Teflon Seacock adapter and O-ring 92-802859A1
Checking the Tunnel Opening Alignment, Thickness, and Surface

On Models with a Tunnel Cut‑Out Opening—Using a Bolt‑On Interface Ring
1. Confirm that the tunnel cut‑out openings are aligned within specification.
Tunnel opening alignment specifications

2. Using a suitable material, fabricate an inspection gauge (mandrel) with the measurements
indicated.
d b
a
24926
a- 51 mm (2 in.)
b- 38.10 mm (1.50 in.)
c- 30.98 mm (1.22 in.)
d- 51 mm (2 in.)
Page 2 / 46 90-866927070 SEPTEMBER 2007

3. After cutting out the tunnel opening, ensure that the final dimensions of the opening are within
specification by placing the fabricated inspection gauge at all points around the opening.
b
a
28358
a - Inspection gauge
b - Tunnel opening
Final dimensions of hull around the tunnel opening

Nominal thickness 31.75 mm (1.25 in.)
4. Refer to Section 2—Boat Construction for additional information if required.
On Models with a Fabricated (Molded‑In) Tunnel Opening
1. Confirm that the tunnel openings are aligned within specification.
Tunnel opening alignment specifications

2. Using a suitable material, fabricate an inspection gauge (mandrel) with the measurements
indicated.
d b
a
24926
a- 51 mm (2 in.)
b- 26.1 mm (1.03 in.)
c- 24.6 mm (0.97 in.)
d- 51 mm (2 in.)
90-866927070 SEPTEMBER 2007 Page 3 / 46

3. Ensure the final dimensions of the fabricated (molded‑in) tunnel opening and interface lip are
within specification by placing the fabricated inspection gauge at all points around the opening.
b
a
28358
a - Inspection gauge
b - Tunnel opening
Final dimensions of the tunnel opening

4. Refer to Section 2—Boat Construction for additional information if required.
Installing the Bolt‑on Interface Ring

1. Ensure the center line of the tunnel cut‑out opening is aligned within specification.
Top plate alignment specifications

2. Ensure that the hull surface flatness and thickness where the drive will be mounted are within
specifications. See Checking the Hull Surface and Thickness.
3. Ensure that the inside hull surface flatness around each stud hole (where the stainless steel
washers will seat) is within specification. Sand or fill any irregularity that would affect the
seating of the stainless steel washers. See Section 2—Boat Construction if necessary.
4. Ensure that the mounting stud holes are the specified size.
Interface ring mounting

Mounting stud required hole size 16 mm (5/8 in.)
5. Test fit the interface ring into the mounting stud holes to ensure a correct fit, then remove the
interface ring.
6. Clean any debris from around the upper and lower surfaces of the formed opening.
NOTE: Refer to the manufacturer of the sealant you have selected for sealing the interface ring
(as outlined later in this procedure) and use the cleaners and solvents recommended.
Page 4 / 46 90-866927070 SEPTEMBER 2007

7. Clean the interface ring contact surfaces and the corresponding hull surfaces with
recommended cleaners and solvents. Remove wax and other contaminates that could
interfere with the sealing of the interface ring.
c
d 26753
a- Interface ring
b- Outer contact surface
c- Hull contact surface
d- Inner contact surface
8. Prepare the interface ring contact surfaces and corresponding hull surfaces as recommended
by the the manufacturer of the sealant, if any recommendations are stated.
IMPORTANT: Refer to the instructions provided by the manufacturer of the specified sealant for
the amount of time allowed for proper sealing between application and mounting of the interface
ring.
9. Apply an appropriate amount of the specified or equivalent sealant around the studs and on
the interface ring to fully fill the inside and outside spaces created between the ring and the
hull when the ring is installed into the hull.
d
a
b
c
25318
Inside and outside spaces that must fill with sealant
a - Hull
b - Outside space
c - Inside space
d - Interface ring

BoatLIFE® 1033, or equivalent Interface ring to hull Obtain Locally
NOTE: BoatLIFE is a registered trademark of Life Industries Corporation.
90-866927070 SEPTEMBER 2007 Page 5 / 46

10. Position the trim tab recess in the interface ring assembly to the rear of the opening in the
boat.
11. From beneath the boat, lift the interface ring up and into the mounting holes of the cut‑out
opening.
12. Clamp or suitably retain the interface ring to the bottom of the hull.
13. From the inside and outside the boat, tool and smooth any sealant that may have pushed out
from the space between the interface ring and the hull.
IMPORTANT: Be careful when installing the stainless steel fasteners. Hand tighten only, without
the use of pneumatic tools. Apply an appropriate compound to prevent galling the stainless steel
studs and locknuts.
14. Apply one of the specified compounds or an equivalent anti‑galling compound to the stainless
steel studs and locknuts.

Stainless steel studs and
34 Special Lubricant 101 92-802865Q02
locknuts

Loctite Anti-Seize Compound - Stainless steel studs and
Obtain Locally
92-FT2987-1 locknuts
15. Install the twenty stainless steel washers and locknuts, as shown.
f
e a f
c e
d d
c
b
b c
a 26761
Interface ring installation shown

a - Stud d - Hull tunnel
b - Interface ring e - Washer
c - Sealant smoothed around opening f - Locknut
16. Hand‑tighten each locknut several times in small increments until the interface ring surface
contacts the hull. Do not use pneumatic tools.
Page 6 / 46 90-866927070 SEPTEMBER 2007

17. Initially torque the interface ring locknuts to specification in the sequence shown. Tighten each
locknut several times in small increments to obtain the specified torque.
2 6 10 11
4
8 14
16
19 13
18
15
12
20
7
3
17 1
5 24392
9
Torque sequence for initial tightening of interface ring to hull
Description Nm lb. in. lb. ft.

Initial torque on interface ring locknut 7 60
18. Continue to torque the interface ring locknuts in the torque sequence shown. Tighten each
locknut until the specified first pass torque is achieved. Make a final pass torque check on
each locknut at the specified torque.
2 6 10 11
4
8 14
16
19 13
18
15
12
20
7
3
17 1
5 24392
9
Torque sequence for final tightening of interface ring to hull

First pass 33.8 25
Interface ring locknuts
Final pass 40.6 30
IMPORTANT: Check the final pass torque on the interface ring locknuts before boat delivery. Refer
to the boat manufacturer for additional information.
90-866927070 SEPTEMBER 2007 Page 7 / 46

Engine Mounting
Crankshaft Center Lines
The vertical height of the engine crankshaft will vary according to whether the power package has
a drop box and the length of the drive shaft. Refer to Cummins Marine Installation Drawings
for more information. The drop box is standard equipment on QSC engines, optional for QSB
engines.
The engine‑to‑drive center line vertical offset is dictated by the requirement that the drive shaft
connecting the two be installed at a 1° to 3° angle from the horizontal. Both U‑joints on the drive
shaft must be at the same angle.
Installing the Engine Mounts
TOOL SELECTION
To determine the correct location for the engine mounts you can choose one of the following
methods:
• install the engine complete with engine mounts attached.
• obtain a special engine mount fixture (contact your CMD distributor Application Engineer for
assistance).
• fabricate a special engine mount fixture.
Contact your Cummins MerCruiser Diesel application engineer for additional part numbers or
assistance.
Engine Mount Fixture

QSB and QSC Model Part Number
With drop box and 261 mm (10.27 in.) driveshaft
Without drop box and 261 mm (10.27 in.) driveshaft
INITIAL ENGINE MOUNT ALIGNMENT

IMPORTANT: Engine mounts (vibration isolators) are provided by the engine manufacturer.
Engine mounts must be preliminarily adjusted to center the mount and establish a uniform height
on all mounts. Refer to the Marine Recreational High Output Propulsion Units B and C Series
Installation Directions manual for additional information.
IMPORTANT: Engine mounting studs are not for lifting the engine. Support the engine with a lifting
hoist when adjusting the engine mounts.
NOTE: The engine mounting fixture tool discussed in the following procedure is for use in
applications without a drop box. Separate fixtures must be ordered or fabricated for the different
driveshaft lengths for use with and without a drop box. Contact your CMD distributor Application
Engineer for assistance.
Page 8 / 46 90-866927070 SEPTEMBER 2007

1. Install four separate engine mounts onto the engine mount fixture. If four separate engine
mounts are not available, remove and install the four engine mounts provided with the engine
power package.
26770
a - Front mounts
b - Rear mounts
2. Adjust the four engine mounts so that equal amounts of up and down adjustment are available
on the vibration isolator adjusting nuts.
3. Inside the boat, position the engine mount fixture on the hull over the opening in the tunnel.
4. Lift the clamp ring up from under the boat to the engine mount fixture in the tunnel opening.
Install the screws.
5. Ensure that the engine mount fixture is properly seated in the opening and parallel to the center
line of the boat.
6. Securely tighten the four screws to attach the engine mount fixture firmly to the clamp ring.
d
26769
Typical setting
a- Engine mount fixture
b- Hull
c- Clamp ring
d- Screws
IMPORTANT: The finished boat stringer must position the engine so that a minimum of
6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer.
This allows for future engine alignment or adjustments. Make alterations to the boat stringer
(structure) height to obtain the 6 mm (1/4 in.) dimension.
7. If the mounts contact the stringers, mark the position of the mounting holes for the four engine
mounts. If the mounts do not contact the stringer, appropriately shim the mounts, modify the
stringers, or adjust the mounts (within specification) until they rest on the boat stringers. Then
mark the position of the mounting holes.
90-866927070 SEPTEMBER 2007 Page 9 / 46

8. Drill the stringers appropriately for the type of mounting hardware that will be used for the
engine mounts.
9. Remove the engine mount fixture.
10. Loosen and remove the mounts from the engine mount fixture, and install them on the engine
if they were taken from the engine.
Zeus Drive Installation

Identifying the Drives
The design of the Zeus drive results in a unique port and starboard drive. The drives will have the
letters "PORT" or "STBD" stamped in the metal of the center section near the drive serial number
and decal.
1. Identify if the drive is a port ("PORT") or starboard ("STBD") drive.
2. Install the drive on the side of the vessel indicated by the stamped‑in marking.
b
31665
a - Stamped‑in identification letters
b - Center section
Installing the Interface Ring Seal

1. Ensure that the interface ring opening in the hull or the bolted‑on interface ring assembly,
mounted in the tunnel, is complete and ready to accept installation of the Zeus drive assembly.
See Installing the Bolt-on Interface Ring.
2. Clean the hull or bolted‑on interface ring surfaces with a suitable wax‑removing solvent. Allow
the surfaces to dry completely.
! WARNING
The rubber interface ring seal has an outside coating that protects the inner core. Tears, cuts,
scrapes, or exposure to lubricants or sealing compounds can damage this coating and the inner
core causing water to leak into the boat. Use caution when installing and working around the
interface ring seal to prevent damage. Do not use any lubricants or sealing compounds during
installation.
NOTE: The rubber interface ring seal is symmetrical so that there is not a specific top and bottom
or front and rear to the seal.
Page 10 / 46 90-866927070 SEPTEMBER 2007

3. Install the rubber interface ring seal (grommet). Do not use any lubricants, solvents, or sealing
compounds. Install the seal into the boat hull molded‑in opening or into the bolted‑on interface
ring assembly, depending upon the type of installation. Do not tear, scrape, cut or similarly
damage the seal.
23942
Interface ring seal installed

Installing the Drive Using an Installation Stand and Forklift
The Zeus drive may be installed using a fabricated installation stand and a hydraulic forklift.
1. Carefully remove all shipping hardware.
2. Read and remove all tags attached to the drive assembly.
3. Attach a suitable sling and hoist to the lifting point rings on the transmission.
25830
Lifting point
Lifting capacity required

Approximate total drive weight as shipped 454 kg. (1000 lb.)
4. Remove the Zeus drive assembly from the shipping container. Mount the drive on a fabricated
installation stand.
90-866927070 SEPTEMBER 2007 Page 11 / 46

5. Mount the drive and installation stand on the forks of a forklift truck.
23925
Typical using installation stand

a - Zeus drive assembly
b - Installation stand
IMPORTANT: The installation stand must have screws to lock the stand or container to the lift
forks as indicated. This will provide more control during installation and assembly. The added
screws will help secure the installation stand if the stand is extended on the forks.
6. Secure the installation stand to the lift forks using screws for locking. Tighten the lock screws
securely.
23917
Typical using installation stand

a - Lock screws
7. Ensure the boat fixture provides the necessary mounting clearance between the ground and
the boat tunnel for the drive and installation stand.
8. Proceed to Mounting the Drive.
Installing the Drive Using the Shipping Container
The drive may be installed using the shipping container and a forklift or overhead hoist.
1. Carefully remove all shipping hardware.
a. Remove the clips and pins holding the four cross braces to the shipping container frame
and pallet.
Page 12 / 46 90-866927070 SEPTEMBER 2007

b. Remove the ten screws holding the upper and lower shipping container frames together.
e a
d
c b
27441
a - Upper frame screw d - Lower frame screw

b - Clips and pins e - Cross brace
c - Shipping container pallet f - Shipping container
c. Remove the frames from the shipping container pallet.
27444
Shipping container pallet

2. Read and remove all tags attached to the drive assembly.
NOTE: The Zeus drive with gearcase and skeg mounted on the shipping container will require a
minimum ground to tunnel total clearance as specified in the following chart. The specified distance
allows ample clearance to be able to slide the drive under the tunnel in the shipping container.
The shipping container adds about 76 mm (3 in.) to the total height of the drive with the skeg
installed.
3. Ensure the boat fixture provides the specified mounting clearance between the ground and
the boat tunnel for the drive in the shipping container.
Boat fixture mounting clearance with Zeus drive in the shipping container
Ground to tunnel 165.1 cm (65 in.)
Drive to tunnel (after ground to tunnel clearance is established) 12.7 cm (5 in.)
4. Proceed to Mounting the Drive.
90-866927070 SEPTEMBER 2007 Page 13 / 46

Mounting the Drive

! WARNING
The rubber interface ring seal has an outside coating that protects the inner core. Tears, cuts,
scrapes, or exposure to lubricants or sealing compounds can damage this coating and the inner
core causing water to leak into the boat. Use caution when installing and working around the
interface ring seal to prevent damage. Do not use any lubricants or sealing compounds during
installation.
1. To increase clearance during installation, remove the seacock and adapter by removing the
screws.
c a
b
28814
a - Front screw
b - Aft screw
c - Seacock and adapter
2. Pull the seacock and adapter out of the recess in the center section plate. Note the position
of the adapter O‑ring.
c b
28828
a- O‑ring
b- Adapter
c- Screw (2)
d- Seacock
Page 14 / 46 90-866927070 SEPTEMBER 2007

3. To avoid component damage during installation, detach the primary and secondary harness
connectors from the steering sensors.
c
b
d
28832
a- Secondary steering sensor
b- Secondary steering sensor harness connector
c- Primary steering sensor
d- Primary steering sensor harness connector
4. Mounting the drive using a forklift.

a. Move the drive and installation stand (or shipping container pallet) into position under
the boat.
b. Ensure that the interface ring mounting surface on the drive is parallel to the hull of the
boat and to the interface ring opening when supported.
d 23962
Typical with installation stand, similar with shipping container pallet

a - Hull of boat
b - Drive assembly
c - Installation stand
d - Lift fork in installation stand—locked in place
5. Mounting the drive using a overhead hoist.

a. Position the installation stand or shipping container under the drive opening in the craft.
b. From inside the boat and using an appropriate sling, attach an overhead hoist to the
lifting rings of the transmission. The overhead hoist must be capable of lifting the weight
of the drive with an reasonable safety margin.
90-866927070 SEPTEMBER 2007 Page 15 / 46

Lifting capacity required

Approximate total drive weight as shipped 454 kg (1000 lb.)
b
c
27457
Typical
a - Hoist and suitable sling
b - Lifting point for standard drive
c - Lifting point for drive with a drop‑box
c. Ensure that the interface ring mounting surface of the center section is parallel to the hull
of the boat and to the interface ring opening when suspended.
6. Lift or hoist the drive assembly into the interface ring opening. Do not tear, scrape, cut or
similarly damage, the inner core of the interface ring seal. Do not use any lubricants, solvents,
or sealing compounds on the interface ring seal except for a solution of a small part of mild
soap (such as dish soap) and clean water.
23975
NOTE: Aligning the drive may require tilting the drive side‑to‑side or fore and aft as it is raised into
position.
7. Align the drive so that it is parallel to the hull bottom and the center line of the boat.
Page 16 / 46 90-866927070 SEPTEMBER 2007

8. Raise the drive into the final position in the center of the interface ring seal (grommet).
27466
Drive in final position using an overhead hoist, similar with installation stand and forklift truck
9. Hold the drive firmly in place using the overhead hoist or with the forklift firmly supporting the
installation stand.
b a
23976
Drive firmly supported using an installation stand and forklift truck, similar with overhead hoist
a - Drive parallel and fully seated
b - Installation stand
10. Install the dowel pins, if not already installed, on the rear clamp ring (the smaller of the two
clamp rings).
b
a
23996
a - Rear clamp ring
b - Dowel pin
90-866927070 SEPTEMBER 2007 Page 17 / 46

11. Spray the upper surface of the interface ring seal with a solution made from a small part of
liquid dish soap and water. To prevent damage to the interface ring seal (grommet) do not use
any other lubricants or solvents.
12. With the clamp ring dowel pins installed, position the rear clamp ring (the smaller of the two
clamp rings) around the back of the center section of the drive.
27471
a - Rear of center section
b - Rear clamp ring
c - Dowel pin
13. Move the front clamp ring (the larger of the two clamp rings) into position and align with the
rear clamp ring dowel pins.
c
a
27479
a - Rear clamp ring
b - Dowel pin
c - Front clamp ring
Page 18 / 46 90-866927070 SEPTEMBER 2007

14. Join the front and rear clamp rings together by pressing the dowel pins into the dowel pin
holes. Then, press down evenly on the clamp ring assembly to seat the assembly in the
interface ring seal and around the drive.
a b
a
c
c
b
23986
Clamp rings seated in a typical installation

a - Front clamp ring
b - Rear clamp ring
c - Joint between front and rear clamp ring
IMPORTANT: Carefully install the stainless steel fasteners. Hand tighten only, without the use of
pneumatic tools. Apply an appropriate compound to prevent galling.
15. Apply lubricant to the threads of the clamp ring flanged screws.

34 Special Lubricant 101 Clamp ring flanged screws 92-802865Q02
16. Install the front and rear clamp ring flanged screws. Ensure that all screws are started by
hand into their respective holes before beginning to tighten with a tool.
IMPORTANT: Ensure that the clamp ring assembly is slowly and evenly seated into the interface
ring seal and onto the center section.
17. Read and follow the instructions on the information decal affixed to each clamp plate. Tighten
each flanged screw evenly one turn maximum per fastener in a crisscross pattern until the
clamp ring assembly is seated on the center section.
b
c 24000
a - Rear clamp ring

b - Clamp ring flanged screw
c - Front clamp ring
90-866927070 SEPTEMBER 2007 Page 19 / 46

18. After the clamp ring assembly is completely seated, torque the flanged screws in a crisscross
pattern taking several passes to achieve the specified value, or torque in sequence according
to instructions on the decal, if equipped.
a 27483
a - Clamp ring screw
b - Torque wrench

Clamp ring flanged screw 88 – 65
19. Attach the primary and secondary harness connector to the appropriate steering sensor. Do
not interchange the connectors.
c
b
d
28832
a- Secondary steering sensor
b- Secondary steering sensor harness connector
c- Primary steering sensor
d- Primary steering sensor harness connector
20. Check the O‑ring for damage. Replace a damaged O‑ring. Then, properly position the O‑ring
on the seacock adapter.
21. Apply lubricant to the O‑ring and the adapter flange.

95 2-4-C with Teflon Seacock adapter and O-ring 92-802859A1
Page 20 / 46 90-866927070 SEPTEMBER 2007

22. Install the seacock and adapter.
c b
28828
a- O‑ring
b- Adapter flange
c- Screw (2)
d- Seacock
23. Install and torque the screws for the seacock adapter.
c a
b
28814
a - Front screw
b - Aft screw
c - Seacock and adapter

Seacock adapter screws 20.3 180 –
Installing the Engine

For engine installation information and procedures refer to the Marine Recreational High Output
Propulsion Units B and C Series Installation Directions manual (CMD 3884649).
Before installing the engine, it is recommended that the hand‑held drive‑to‑engine alignment tool
be attached to the engine.
29797
Hand‑held drive‑to‑engine alignment tool
90-866927070 SEPTEMBER 2007 Page 21 / 46

The hand‑held drive‑to‑engine alignment tool is used for final alignment of engines. The tool is
designed specifically for the drive shaft length used on the boat model, and has a built‑in vertical
offset to give a 2° shaft angle when installed. The engine coupler flange will be slightly lower than
the drive input flange when properly aligned. It is assumed that the engine can be set on the stringer
fore‑aft to within ±6 mm (± ¼ in.) of the correct location.
1. With the engine out of the boat, locate the "UP" mark on the alignment tool and position it on
top.
2. Attach the alignment tool to the coupling (flywheel) cover using the four M10 × 1.5 screws.
3. Hand‑tighten the four screws.
4. Rotate the drive input flange so that the through‑holes in the flange will line up with the pins
on the alignment tool when the engine is brought into the boat.
5. Attach the engine mounts (isolators) to the engine and adjust to the midpoint of their travel on
the studs, if not already accomplished.
6. Make the engine ready to install.
Final Engine Alignment
NOTE: Ensure that the engine mounts (isolators) are attached to the engine and that the engine
is ready to install.
1. Check that the mating faces on the transmission input flange and the hand‑held
engine‑to‑drive alignment tool flange are clean and flat.
2. Bring the engine into the boat using an appropriate hoist.
IMPORTANT: Do not move the lower adjusting nut without supporting the engine's weight. This
will avoid damage to the threads on the adjusting stud and nuts.
3. Lower the engine onto the stringers in the approximate location and gently slide the engine
rearward until the pins on the hand‑held engine‑to‑drive alignment tool engage the
through‑holes on the drive input flange. Adjust the engine mount (vibration isolator) heights
at this time if necessary.
4. Adjust the fore‑aft location of the engine so that the sliding shaft in the alignment tool is
approximately centered in the slot when the flanges are in contact. There are reference marks
at the slot to assist. The slot is designed so that the sliding shaft can move up to
13 mm (½ in.) forward or aft of this center line.
a
d e
c
b
29799
Engine‑to‑drive alignment—typical
a - Drive input flange d - Hand‑held engine‑to‑drive alignment
b - Alignment tool flange tool
c - Marking e - Sliding shaft in slot
Description Cummins Part Number

for 26 cm (10‑1/4 in.) shaft 4980379
Hand‑held engine‑to‑drive alignment tool
for 72 cm (26‑3/8 in.) shaft Not available at time of printing.
5. After positioning the engine as required in step 4, extend the shaft fully from the fixture such
that the fixture flange and drive flange are in contact (if not already in contact).
Page 22 / 46 90-866927070 SEPTEMBER 2007

NOTE: The engine mounts (vibration isolators) must be parallel to the engine crankshaft
longitudinal center line.
6. Check the gap around the flange circumference with a feeler gauge. Adjust the engine mount
(vibration isolator) nuts, engine mount position in the mount slots, or position of the engine on
the stringers to achieve the specified parallel alignment of the flanges.
Flange parallel alignment

Alignment tool flange‑to‑transmission input flange 0.05–0.10 mm (0.002–0.004 in.)
NOTICE
Operating the engine with the driveshaft installed at an incorrect angle will result in damage to
the driveshaft and the universal joint bearings. Align the engine correctly before operating.
7. If the flange faces are not aligned as specified, readjust the position of the engine until within
specification.
8. If not already accomplished, fasten the engine mounts (isolators) to the boat stringer using
the appropriate hardware (lag bolts or thru‑bolts, etc.).
9. Remove the lifting hoist.
10. Torque all of the locking nuts on the engine mounts (vibration isolators).

Engine mount (vibration isolator) locking nuts 108–135 – 80–100
NOTE: If operating in a saltwater environment, apply Quicksilver Perfect Seal to the engine mount
stud threads and nuts to help protect against corrosion to allow for easier loosening in the future
if readjustment becomes necessary.
11. Remove the alignment tool.
Driveshaft Installation
NOTE: We recommend a digital electronic level or universal protractor for measuring angles in
the following steps. In these procedures the terms should be considered interchangeable and
dependent upon the tool used.
1. Fully collapse (push) the splined portion of the driveshaft together.
2. Attach the driveshaft to the transmission input shaft flange and the engine coupler.
3. Torque the locknuts on the transmission input shaft flange bolts.
d c b
24052
a- Locknut
b- Transmission input shaft flange
c- Bolt, 1/2‑20 × 1‑1/2 in. long (4 per flange)
d- Driveshaft
90-866927070 SEPTEMBER 2007 Page 23 / 46


Transmission input shaft flange locknuts 102 – 75
4. Torque the screws on the engine coupler.
a
c
b 24054
a - Screw, 1/2‑20 × 2‑1/4 in. long (4 per flange)
b - Engine coupler
c - Driveshaft

Engine coupler‑to‑drive shaft flange screws 102 – 75
NOTE: Measure the inclination of the engine at the valve cover after the boat is made level.
5. The driveshaft angle should be as specified with the boat and the engine level (0°). Position
a protractor on the driveshaft and check the angle of inclination. If the driveshaft angle is not
within specification, see Final Engine Alignment and repeat the appropriate steps.
Driveshaft
Angle of inclination 1°–3°(2° preferred)
6. Lubricate the driveshaft slip‑joint through the grease fitting by applying approximately 3‑6
pumps of specified grease from a typical hand‑operated grease gun.
27749
a - Driveshaft slip‑joint
b - Grease fitting

U-joint and Gimbal Bearing
42 Driveshaft slip-joint 92-802870A1
Grease
Page 24 / 46 90-866927070 SEPTEMBER 2007


91 Engine Coupler Spline Grease Driveshaft slip-joint 92-802869A1
7. Apply adhesive to the threads of the screws and bolts of the shields on the engine and
transmission ends.

Driveshaft shield retaining
10 Loctite 277 Obtain Locally
screw and nut
8. Install the engine end driveshaft shield onto the flywheel housing cover. Torque the driveshaft
shield retaining screws.
a
b
24182
a - Engine end driveshaft shield
b - Hex‑head screw, M10 × 1.25 25 mm (1 in.) long

Driveshaft shield retaining screw—engine end 36 – 27
9. Install the top and bottom driveshaft shields on the transmission end as shown. Torque the
driveshaft shield retaining screws and nuts on the transmission end.
a c
d
b
24126
Top shield and bottom shield at transmission end
a - Top shield
b - Bottom shield
c - Socket‑head driveshaft shield retaining screw and nut, M10 × 1.25 25 mm 1 in.long,
and washer
d - Driveshaft shield upper‑to‑lower retaining screw and nut, M8 × 1.25
12 mm (1/2 in.) long and nut
90-866927070 SEPTEMBER 2007 Page 25 / 46


Driveshaft shield retaining screw and nut—transmission end 36 – 27
Driveshaft shield upper‑to‑lower retaining screw and nut 23 204 –
Installing the Exhaust System—Flange‑Type Connection

NOTE: Refer to the Marine Recreational High Output Propulsion Units B and C Series
Installation Directions manual (available from CMD) for information on exhaust elbow
connections at the turbocharger if not already installed.
IMPORTANT: Secure the exhaust hoses and tubes at each connection with at least 2 hose clamps.
Refer to Section 3 for more information the exhaust system.
1. Install the O‑ring into the groove on the exhaust flange of the drive center section.
b a
29979
a - Exhaust flange
b - O‑ring
2. Install the lower 90° exhaust elbow onto the exhaust flange of the drive center section. Torque
the six flange screws.
IMPORTANT: Do not allow the exhaust bellows connections to restrict the flow of discharge water.
3. Connect the exhaust pipe to the lower 90° exhaust elbow on the drive center section using
the lower exhaust bellows. Use double clamps on each connection.
a b
c
d
d e
29980
a - Lower 90° exhaust elbow d - Double clamps
b - Flange screws e - Exhaust pipe lower bellows
c - Exhaust pipe

Lower exhaust elbow flange screws 23 – 18
4. Connect the exhaust pipe to the upper 90° exhaust elbow on the engine using the upper
exhaust bellows. Use double hose clamps on each connection. Do not allow the connection
to restrict the flow of discharge water from the exhaust elbow.
5. Position a hose clamp on each end of the water supply hose.
Page 26 / 46 90-866927070 SEPTEMBER 2007

6. Install the water supply hose (water overboard) from the engine heat exchanger to the upper
90° exhaust elbow.
7. Install a hose clamp on the upper end of the seawater bypass hose.
8. Install the seawater bypass hose onto the fitting of the upper 90° exhaust elbow.
9. Install a hose clamp on the upper end of the idle bypass hose.
10. Install the idle bypass hose (to water lift muffler) onto the lower fitting of the exhaust pipe.
h a
g
f b
c
d
d e
29984
a- Water supply hose and clamps e- Exhaust pipe upper bellows
b- Heat exchanger f- Idle bypass hose and clamp
c- Exhaust elbow g- Exhaust pipe
d- Double hose clamps h- Seawater bypass hose and clamp
11. Install the idle bypass hose (from the lower fitting on the exhaust pipe) to the water lift muffler.
a
d
b
c
26862
a- Typical water lift muffler
b- Idle bypass hose
c- Seawater hose
d- Seawater overboard fitting
12. On models with a drop box. Install the seawater bypass hose from the exhaust elbow on to
the inlet of the secondary fluid cooler.
90-866927070 SEPTEMBER 2007 Page 27 / 46

13. On models without a drop box. Install the seawater bypass hose from the exhaust elbow
on to the inlet of the primary fluid cooler.
a
d
b
28060
Shown with drop box, all similar
a- Drop box
b- Inlet of secondary fluid cooler
c- Inlet of primary fluid cooler (on models without a drop box)
d- Secondary fluid cooler assembly and hose with clamps (on models with a drop box)
14. Torque all exhaust system hose clamps as indicated, unless otherwise specified.

Exhaust system hose clamp 3.4–6.8 30–60 –
Seawater hose clamp (all) 3.4–6.8 30–60 –
15. Keep the return (overboard) seacock for the seawater bypass hose closed until the engine
must be operated.
Connecting the Seawater Inlet and Strainer
IMPORTANT: Use wire‑reinforced seawater hose to avoid collapsing the hose when suction is
created by the seawater pump impeller.
1. Cut the wire reinforced seawater hose to the required length to make the appropriate
connections.
2. Fit hose clamps on the hose ends.
3. Install the seawater hose from the seawater inlet fitting to the seawater strainer.
c a d
b
24378
Typical seacock installation shown, all similar
a- Seawater hose
b- Inlet fitting
c- Hose clamps
d- To seawater strainer
4. Install the seawater hose from the strainer to the seawater inlet fitting on the seawater pump
of the engine.
Page 28 / 46 90-866927070 SEPTEMBER 2007

5. Tighten the hose clamps securely.
c
a b
24372
a - Seawater hose
b - Strainer
c - Inlet Fitting
Installing the Drive Skeg

1. Clear the slot where the skeg attaches to the drive gearcase of dirt or debris.
24026
a - Slot
b - Drive gearcase
2. Insert the skeg into the slot on the drive gearcase.

NOTE: If necessary use a block of wood and a hammer to seat the skeg.
90-866927070 SEPTEMBER 2007 Page 29 / 46

3. Install the two roll pins into the retaining passages until they are flush with the outside of the
housing.
c
d a
b
24017
a - Slot d - Roll pin

b - Skeg e - Roll pin flush with outside
c - Gearcase
Corrosion Continuity Circuits

Good continuity must be maintained between the Zeus drive components for the galvanic
corrosion protection systems to function effectively. CMD Zeus drives are equipped with a
continuity circuit to ensure good continuity. One circuit from the king pin to the steering actuator
housing is an internal circuit and not shown in the following images. Ensure that the corrosion
protection systems and external continuity wires are installed as shown.
25883
Anode on trim tab
a
a
d
b
c
29068
Trim tab ground (‑) continuity wire and connections
a - Trim tab hinge block
b - Trim tab
c - Screw
d - Continuity wire
Page 30 / 46 90-866927070 SEPTEMBER 2007

27488
Connection lug for drive ground (–) continuity wire
a
b
25885
MerCathode system anode

a - Anode
b - Reference electrode (not visible in this view)
e f a
d
b
c
29037
MerCathode system controller
a - MerCathode controller d- Anode wire
b - Reference electrode wire e- Controller positive wire (+) with fuse to
c - Controller ground wire (–) to battery battery positive, unswitched side of
negative, negative terminal strip, or battery disconnect, or (with circuit
negative DC bus bar breaker) to unswitched positive DC
bus bar
f - Controller black/green ground wire (–)
to ground lug, with connection
continuing to the negative DC bus bar
90-866927070 SEPTEMBER 2007 Page 31 / 46

Good continuity must be maintained between other anodes, if equipped, and the negative DC bus
bar for the vessel galvanic corrosion protection systems to function effectively. Ensure that vessel
corrosion protection systems and appropriate continuity wires are installed.
25887
Typical transom mounted anode (continuity wire and connections not shown)
Electrical Connections
NOTE: Refer to Section 6 Electrical System Architecture diagrams and for additional electrical
information.
IMPORTANT: To avoid damage to the electrical system, refer to the following precautions when
working on or around the electrical harness or when adding other electrical accessories.
• Do not tap accessories into the engine harness.
• Do not puncture wires for testing (probing).
• Do not reverse the battery leads.
• Do not splice wires into the harness.
• Do not route harness near sharp edges, hot surfaces, or moving parts.
• Fasten cables away from and sharp edges, fasteners, or objects that could wear into the
harness or pinch the harness.
• Avoid sharp bends in a data harness. Minimum 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 tools.
• Disconnect both the negative (–) and positive (+) battery cables from the battery before electric
arc welding on the vessel. Attach the welder ground cable no more than 0.61 meters [2 feet]
from the part being welded. Do not connect the ground cable of the welder to any ECM cooling
plate or ECM. Welding on the engine, drive, or engine or drive mounted components is not
recommended or damage to the engine or drive or related components can result.
Connecting the Wiring
The wiring to the various electrical components on the vessel may not always be connected directly
to the positive or negative side of a battery.
On large vessels some power supply wires may connect indirectly to the positive (+) battery
terminal through a battery switch (battery disconnect switch), a positive terminal strip, or to a fuse
panel. The position of the wire connection to the battery switch determines if the power is switched
(will be off with the switch) or unswitched (is on constantly).
Negative wiring or ground (–) wires may connect indirectly to the negative (–) battery terminal
through a negative terminal strip or a neutral bus bar.
Page 32 / 46 90-866927070 SEPTEMBER 2007

Here are two examples of positive wire connections. The type of terminal strip shown could also
be used for negative wire connections if it was connected only to the negative battery terminal.
b
a
31677
a - Battery switch
b - Positive terminal strip (similar for negative)
Continuity Wire Connections

IMPORTANT: Do not attach any accessory ground (–) wires to drive ground connection.
Accessory ground wires can only be attached to the ground stud on the engine or to the battery.
1. Ensure that the black/green ground wire (–) from the MerCathode controller is securely
attached to the ground (–) connection lug on the rear of the drive center section.
26299
Drive shown with cover
a - Black/green ground (–) wire
b - Ground (–) connection lug
c - Drive center section
IMPORTANT: Both the engine block and the grounding (–) connection lug should be connected
to the bonding bus of the vessel with a minimum of a 8 mm² (8 AWG) wire.
Drive Application Extension Harness
The drive application extension harness connects between the engine and the drive. This harness
contains the power and ground connections for the solenoids on the drive. Pressure sensors,
transmission speed sensors, and temperature sensors are also powered and grounded through
this harness.
90-866927070 SEPTEMBER 2007 Page 33 / 46

One drive application extension harness is required for each drive.

a
c b
31279
a - Drive application extension harness
b - Engine connector
c - Drive connector
Installing the Drive Application Extension Harness

1. Connect the drive application extension harness to the 19‑pin connector on the electrical
bracket of the drive. Fully engage and tighten the threaded connector collars.
26312
Shown with cover installed, same without
a - Drive application harness connector
b - Electrical bracket
.
2. Connect the drive application extension harness to the 19‑pin connector on the engine.
a
26113
a - Drive application harness
b - Drive application harness connector on engine harness
Page 34 / 46 90-866927070 SEPTEMBER 2007

Vessel Interface Panel (VIP)

The Vessel Interface Panel (VIP), one per engine, must be located on a bulkhead with easy access
and free from excessive heat. Numerous extension harnesses are available for the spans between
the engine and the VIP, and between the VIP and the various sensors, to account for location.
The space claim for these units is shown in the graphic below.
a b
c
25540
One of the two VIPs required

a- Height 19.1 cm ( 7‑½ in.)
b- Height with connections 41.9 cm ( 16‑½ in.)
c- Width 29.2 cm ( 11‑½ in.)
d- Depth 15.3 cm ( 6 in.)
Electrical wiring requirements from the helm to engine room should be planned at this time based
on the electrical system architecture diagram. Wiring connections will also be made between the
VIP, engine, and drive. Allow 22.8 cm (9 in.) below the VIP for wire connections.
NOTE: Leave full access to the front of the VIP for resetting breakers and performing diagnostics.
The VIP is an integral part of the Zeus system architecture. The VIP is a required component of
the system and contains the following.
• The system integration module (SIM)
• The SmartCraft power protection devices (circuit breakers)
• Mounting locations for 9‑pin diagnostic connector
• Connection points for the helm harness, VIP power harness, and engine harness, plus an
interface for the manual start and stop of the engine.
• Connection points for the vessel sensor harness
The VIP option is dependant on the system integration module (SIM) contained within the VIP.
When ordering the engine, the corresponding VIP must also be ordered based on the configuration
of the drive system.
Mounting the Vessel Interface Panel (VIP)
The Vessel Interface Panel (VIP) is intended for mounting on the bulkhead of the vessel in the
engine compartment.
IMPORTANT: Mount the VIP with the connectors oriented downward, to the port or starboard side,
or laid down. Do not mount the VIP with the connectors facing upward.
Mount the VIP:
• In an easily accessible location.
• Above the waterline at rest and not near any moving parts.
• Clear of deck water run‑off and engine compartment water spray.
• So that the circuit breakers are easily accessible.
90-866927070 SEPTEMBER 2007 Page 35 / 46

• In an area that is free of excessive heat and a minimum 30.5 cm (12 in.) distance from all
exhaust components.
• With a minimum of 22.9 cm (9 in.) of free space directly below the VIP for wire harness routing.
• Free from excessive vibration and not directly or indirectly mounted to the engine.
1. Using a template, or the VIP itself, mark the location of the six mounting holes.
2. Drill the appropriate size holes for the mounting screws.
3. Install and securely tighten the mounting screws.
b a
b
b
31456
Typical VIP, all similar
a - VIP
b - Mounting screw (6 total, 2 not visible)
T‑Harness
The T‑harness allows the helm extension harness and TVM extension harness to be connected
to the VIP.
One T‑harness is required for each VIP.
b
a
c
31295
a- T‑harness
b- Helm extension harness connector
c- TVM extension harness connector
d- VIP connector
Installing the T‑Harness

1. Connect the T‑harness to the connector on the VIP marked "HELM". Make this connection on
the port and starboard VIP.
Page 36 / 46 90-866927070 SEPTEMBER 2007

2. Fully engage and tighten the threaded connector collars.
b
31296
One VIP shown, both similar
a - VIP
b - T‑harness connector
Engine‑to‑VIP Extension Harness

The engine‑to‑VIP extension harness interfaces the engine with the VIP.
One engine‑to‑VIP extension harness is required for each engine.
d b
c
31282
a- Engine‑to‑VIP extension harness
b- Zeus‑to‑Engine connector
c- Connector not used
d- Zeus‑to‑VIP connector
Installing the Engine‑to‑VIP Extension Harness

IMPORTANT: The engine‑to‑VIP extension harness can be mounted in two different orientations.
To avoid problems in the control system, ensure that the harness ends with tags stating
"Zeus‑to‑VIP" are connected to the VIP and the harness ends with the tags stating "Zeus‑to‑Eng"
are connected at the engine.
NOTE: The socket head screws used to retain the harness ends require a 4mm Allen key and
socket (not provided).
90-866927070 SEPTEMBER 2007 Page 37 / 46

1. At the engine. Attach the engine‑to‑VIP extension harness connector tagged

"Zeus‑to‑Eng" (and "Other‑ To VIP") to the engine harness connector on the mounting bracket.
Torque the socket head screw on the extension harness connector. Make this connection for
the port and starboard engines.
b
26127
a - Mounting bracket
b - Engine‑to‑VIP extension harness connector
2.
Extension harness connector socket head screw 2.8 25 –
3. At the VIP.Attach the engine‑to‑VIP extension harness connector tagged "Zeus‑ To VIP" (and
"Other‑ To Eng") to the "ENGINE" connector on the appropriate VIP. Torque the socket head
screw on the extension harness connector. Make these connections for the port and starboard
VIP.
d
b
c a
26123
a- Starboard "Zeus‑ To VIP" extension harness connector
b- Starboard VIP and connector
c- Port "Zeus‑ To VIP" extension harness connector
d- Port VIP and connector

Extension harness connector socket head screw 2.8 25 –
TVM (Thrust Vector Module) Extension Harness

The TVM extension harness connects the drive to the T‑harness on the VIP. The TVM extension
harness provide key switched power and ground connections for the TVM.
Page 38 / 46 90-866927070 SEPTEMBER 2007

One TVM extension harness is required for each drive.

a
c b
31279
a - TVM extension harness
b - Drive connector
c - T‑harness connector
Installing the TVM Extension Harness

NOTE: The required aluminum retainer nut and washer are attached to the electrical bracket on
the drive where the TVM extension harness will mount.
1. Remove the washer and aluminum retainer nut before the connector is installed.
2. Insert the threaded end of the TVM extension harness through the electrical bracket on the
drive.
3. Install the washer and thread the retainer nut onto the TVM extension harness. Torque the
nut.
4. Connect the 14‑pin TVM connector from the drive to the 14‑pin TVM extension harness
connector on the electrical bracket. Connector collars must be fully engaged and secure.
Tighten the threaded connector collar.
e a
b
d
c
26304
Shown with cover installed, same without
a - Washer d - TVM extension harness threaded
b - Retainer nut connector
c - TVM connector from drive e - Electrical bracket

Retainer nut 5.6 50 –
NOTE: There are two connectors available on the T‑harness at the VIP. The TVM extension
harness can be connected to either connector.
5. Make the following port and starboard connections.
90-866927070 SEPTEMBER 2007 Page 39 / 46

a. Connect the TVM extension harness to one end of the T‑harness.
h d
b
f
c
g
a
e 26120
a - Starboard TVM extension harness to e - Port TVM extension harness to

T‑harness T‑harness
b - Starboard T‑harness connector on f - Port T‑harness connector on VIP
VIP g - Port T‑harness to main station (helm)
c - Starboard T‑harness to main station extension harness
(helm) extension harness h - Port VIP
d - Starboard VIP
Vessel Sensor Harness (Optional)

The vessel sensor harness is a key component in the Zeus system architecture. The vessel sensor
harness allows the vessel manufacturer to easily interface to key signal inputs and outputs that
are available in the SmartCraft system. The vessel sensor harness contains connections for
various sensors that are monitored by the engine. These include water‑in‑fuel (WIF), halon fire
suppression breakout, CAN P, accessory relay, steering / pitot, tank level, and paddle wheel, This
is an optional harness.
The vessel sensor harness comes as two different options. One option is the complete harness
that includes all connectors to the various sensors. The other available option is simply a kit that
includes only the connectors that were previously mentioned to allow building the harness as
required to meet the exact input/output requirements of that particular vessel.
If the vessel manufacturer does not choose to interface with any of the sensor inputs available on
the vessel sensor harness then this connection on the VIP will contain a blank connector (included
with the VIP) with only two pins connected by a jumper. Connection of these two pins completes
the fire suppression breakout circuit. It is required that this circuit be complete for the engine to
operate correctly. The blank connector also contains a breakout for the WIF sensors.
It is recommended that the vessel manufacturer implement the prefabricated vessel sensor
harness to avoid issues that may arise due to poor fabrication techniques. This harness connects
directly to the vessel interface panel and will typically reside in the engine compartment area. This
harness potentially could be subjected to an extremely harsh operating environment. The CMD
supplied options have been designed, tested and refined to survive in this type of operating
environment. CMD will not warrant failures due to an improperly constructed vessel sensor
harness.
Page 40 / 46 90-866927070 SEPTEMBER 2007

Each engine requires one vessel sensor harness, as an option.
31303
Vessel sensor harness
NOTE: If the vessel sensor harness, once installed, is too short to reach the required sensors, an
extension harness is available. This extension harness will connect between the VIP and the
vessel sensor harness. Different lengths are available.
Installing the Vessel Sensor Harness
1. Connect the starboard vessel sensor harness to the "VESSEL" connector on the starboard
VIP.
2. Connect the port vessel sensor harness to the "VESSEL" connector on the port VIP.
NOTE: The socket head screws used to retain the harness ends require a 4mm Allen key and
3. Torque the socket head screws on both the port and starboard harness connectors.
d
c
a
b
26305
a- Starboard vessel sensor harness
b- Port vessel sensor harness
c- Starboard VIP
d- Port VIP
90-866927070 SEPTEMBER 2007 Page 41 / 46

Vessel Sensor Extension Harness (Optional)

The vessel sensor extension harness connects between the vessel sensor harness and the VIP.
This allows the vessel sensor harness to be extended beyond the VIP. The extension harness
comes in multiple lengths. This is an optional harness and not required to be used.
a b
d
c c
31306
a- Vessel sensor extension harness
b- Vessel sensor harness connector
c- Protective cap
d- VIP connector
Installing the Vessel Sensor Extension Harness

1. Connect the starboard vessel sensor extension harness to the "VESSEL" connector on the
starboard VIP.
2. Connect the port vessel sensor harness to the "VESSEL" connector on the port VIP.
NOTE: The socket head screws used to retain the harness ends require a 4 mm Allen key and
3. Torque the socket head screws on both the port and starboard harness connectors.
d
c
a
b
26305
a- Starboard vessel sensor extension harness
b- Port vessel sensor extension harness
c- Starboard VIP
d- Port VIP

Harness connector socket head screw 2.8 25 –
4. Connect the port and starboard vessel sensor extension harness to the corresponding port
and starboard vessel sensor harness.
Connecting the Vessel Sensors
1. If equipped, connect the fuel tank level sensor, or sensors, to the vessel sensor harness. See
the specifications for the fuel tank level sensors.
NOTE: For your reference, pins 3 and 4 are for tank 1 and pins 1 and 2 are for tank 2.
Page 42 / 46 90-866927070 SEPTEMBER 2007

Fuel tank level sensor specifications

Full: 33 ohms
240–33 ohm sender
Empty: 240 ohms
2. On boats equipped with fire suppression systems and fire detection sensors. Remove
the halon break‑out jumper, and connect any fire detection sensor, or sensors, to the vessel
sensor harness. Refer to the applicable fire suppression system documentation for further
instructions.
3. If equipped with a paddle wheel sensor, connect it to the vessel sensor harness.
NOTE: WIF (water in fuel) sensors are integrated into the engine control system via a WIF
harness. Refer to Section 6—Zeus Engine And Drive System Architecture for the location to
connect the WIF harness to the engine control system. CMD offers several WIF sensor and
harness options to meet the customers needs. WIF harnesses have provisions for two WIF
sensors for dual water separating primary filter installations. A Y‑harness is used at the connection
for two WIF sensors. If only one primary filter is installed, a 220 kΩ biasing resistor plug, supplied
with the appropriate WIF harness option, must be installed in the vacant WIF harness sensor plug.
Failure to terminate both WIF harness sensor plug with either a WIF sensor or resistor plug will
result in WIF related fault codes and alarms.
4. Connect the wiring for the water in fuel (WIF) sensor or sensors, if equipped, to the WIF wiring
extension of the vessel sensor harness. For connector identification refer to the tags on the
WIF sensor Y‑harness.
31693
WIF sensor Y‑harness
5. A temperature switch on the exhaust elbow monitors the cooling water temperature in the
seawater system. Connect the seawater temperature switch on the exhaust elbow to the
engine harness.
VIP and ECM Power Harnesses
An unswitched power harness provides constant power from the battery to the VIP. A switched
power harness provides power from the battery to the ECM.
Each power harness is protected by an in‑line 30‑amp fuse (provided) or a 30‑amp circuit breaker
(obtain locally).
90-866927070 SEPTEMBER 2007 Page 43 / 46

Two harnesses—one for the ECM and one for the VIP—are required for both the port and the
starboard power packages.
_
31297
Typical VIP or ECM power harness
Installing the VIP Unswitched Power Harness

NOTE: VIP power should be powered ON at all times to maintain the system time clock. The VIP
requires minimal battery power and will not drain the battery.
1. Using the 30‑amp fuse (provided) or a 30‑amp circuit breaker (obtain locally), connect the red
wire ring terminal labeled "+" to the unswitched side of a battery disconnect or to a terminal
strip connected to an unswitched battery positive (+) terminal.
2. Connect the black wire ring terminal labeled " –" to a negative terminal strip or ground (‑) bus
bar connected to the negative (–) battery terminal.
3. Connect the 4‑pin connector to the mating power connector located on the bottom side of the
VIP. Fully seat the connector.
Installing the ECM Switched Power Harness
IMPORTANT: Do not use the ECM switched power harness circuit breaker switch to shut down
the engine.
1. Using the 30‑amp fuse (provided) or a 30‑amp circuit breaker (obtain locally), connect the red
wire ring terminal labeled " +" to the switched side of a battery disconnect or to a terminal strip
connected to the battery positive (+) terminal.
2. Connect the black wire ring terminal labeled " –" to a negative terminal strip or ground (‑) bus
bar that is connected to the negative (–) battery terminal.
3. Connect the 4‑pin connector to the mating connector located on the ECM. Fully seat the
connector.
Clean Power Harness for the Backup Hydraulic Pump
The clean power harness for the backup hydraulic pump provides the pump with the necessary
power when operation is required..
One clean power harness is required for the backup hydraulic pump on each drive. Backup
hydraulic pump clean‑power harnesses are currently available in multiple lengths.
Page 44 / 46 90-866927070 SEPTEMBER 2007

Installation of a clean‑power circuit including a 35‑amp circuit breaker for each drive is required.
Wire terminal ends are not provided on the wire ends opposite the hydraulic pump connector.
Circuit breakers (not provided) are necessary to protect the backup hydraulic pump circuit for the
drives.
31276
Typical backup pump clean power harness
Installing the Clean Power Harness for the Backup Hydraulic Pump
NOTE: The clean power harness for the backup hydraulic pump is not terminated on the battery
end and no circuit protection is provided. It is up to the OEM to provide the necessary terminals
for connecting the harness to the battery, and adding an in‑line 35 amp fuse or circuit breaker to
the positive side.
1. For each drive, select a suitable location for a 35 amp fuse or circuit breaker (not provided)
within the limits of the clean power harness length ordered.
2. Provide and connect a positive (+) 12 VDC power wire from the load side of a battery switch
or terminal strip connected to battery positive for each circuit breaker or fuse.
3. Route each clean power harness to the appropriate circuit breaker or fuse. Secure the
harnesses to the boat.
4. Install an appropriate wire terminal end (not provided) to each clean power harness wire.
5. Connect the positive wire of each harness to the appropriate circuit breaker or fuse connection.
6. Connect the negative wire of each harness to a negative (–) terminal strip or bus bar connected
to the negative side of the battery..
7. Connect each clean power harness to the connector on the hydraulic backup pump labeled
"Battery Connection".
Installing the Drive Cover

1. Remove and retain the two lifting rings, if installed.
2. Carefully install the top of the drive cover. Align the top with the two threaded holes in the
transmission where lifting rings were removed.
3. Install the two upper screws.
4. Install the starboard side cover and the three upper screws and one lower screw.
5. Install the port side cover and the three upper and two lower screws.
90-866927070 SEPTEMBER 2007 Page 45 / 46

6. Tighten all screws securely.
f a
e
d
c
b
26863
Typical drive cover
a- Upper screw—port shown
b- Lower screw—port shown
c- Port side cover
d- Top of the drive cover
e- Starboard side cover
f- Top screw
Page 46 / 46 90-866927070 SEPTEMBER 2007

SECTION - 6 REMOTE CONTROL AND ELECTRICAL
SECTION 6 - REMOTE CONTROL AND ELECTRICAL

Table of Contents
Zeus Electronic System Architecture....................................................................................................................... 4
Zeus Helm System Architecture........................................................................................................................4
Zeus Engine And Drive System Architecture....................................................................................................6
Wiring Guidelines.................................................................................................................................................... 8
Wiring Guidelines for Electrical Boat Accessories ........................................................................................... 8
Harness Installation Guidelines ........................................................................................................................ 8
System Component Descriptions............................................................................................................................ 8
Drive Components ............................................................................................................................................ 8
Engine Components ......................................................................................................................................... 9
VIP Components ........................................................................................................................................ 9
Helm Components ..................................................................................................................................... 9
Helm Connections ..................................................................................................................................... 9
CAN V Components ................................................................................................................................ 11
Vessel Interface Panels (VIP)............................................................................................................................... 11
Main Station Extension Harness........................................................................................................................... 12
Installation ...................................................................................................................................................... 12
Helm Harness........................................................................................................................................................ 12
Installation ...................................................................................................................................................... 13
6
Helm Connections .......................................................................................................................................... 13
Command and Control Module (CCM).................................................................................................................. 13
Installation ...................................................................................................................................................... 14
Single or Main Helm Installation ............................................................................................................. 15
Second Helm Installation, If Equipped ..................................................................................................... 16
Standard 6‑way Junction‑box................................................................................................................................ 17
Installation ...................................................................................................................................................... 17
Smart Junction Box............................................................................................................................................... 18
Smart Junction Box Connections ................................................................................................................... 18
Installation ...................................................................................................................................................... 18
SmartCraft Data Extension Harness..................................................................................................................... 19
Dual‑Handle Electronic Remote Control............................................................................................................... 20
Locating and Drilling Mounting Area for Dual‑Handle Electronic Remote Control..........................................20
Dual‑Handle Electronic Remote Control Cut‑Out Template............................................................................21
Installing the Dual‑Handle Electronic Remote Control with DTS Trackpad..................................................... 21
Electronic Steering Column................................................................................................................................... 24
Manual Tilt Steering Column Installation.........................................................................................................24
Steering Column Location ....................................................................................................................... 24
Drilling Steering Column Holes Using the Special Tool ........................................................................... 24
Drilling Steering Column Holes Using the Template ................................................................................ 26
Installing the Steering Column ................................................................................................................. 28
Steering Wheel Installation..............................................................................................................................32
Electronic Steering Helm Connections............................................................................................................32
Joystick.................................................................................................................................................................. 32
Joystick Location Requirements...................................................................................................................... 32
Joystick Installation.........................................................................................................................................34
Trim Tab................................................................................................................................................................ 36
Trim Tab Panel................................................................................................................................................36
Trim Tab Smart Multiplex Module (SMM)........................................................................................................ 37
Installation ................................................................................................................................................ 37
Key Switch............................................................................................................................................................. 38
Preparation......................................................................................................................................................38
Standard Mounting ‑ With Housing.................................................................................................................39
Optional Mounting ‑ Without Housing.............................................................................................................. 41
90-866927070 SEPTEMBER 2007 Page 1 / 70

REMOTE CONTROL AND ELECTRICAL SECTION - 6
Key Switch Extension Harness.......................................................................................................................41

Installation ................................................................................................................................................ 42
Start/Stop Panel.................................................................................................................................................... 42
Preparation ..................................................................................................................................................... 42
Installation ...................................................................................................................................................... 43
Precision Pilot Track Pad...................................................................................................................................... 43
Installation with Supplied Nut ......................................................................................................................... 44
Installation with Four Mounting Screws .......................................................................................................... 44
Guidance Equipment Installation........................................................................................................................... 45
Inertial Measurement Unit (IMU).....................................................................................................................45
IMU Mounting Considerations ................................................................................................................. 45
Installation ................................................................................................................................................ 46
Horizontal Surface ............................................................................................................................. 46
Vertical Surface ................................................................................................................................. 47
Global Positioning Sensor (GPS) ...................................................................................................................48
GPS Mounting Considerations ................................................................................................................ 48
Installation ................................................................................................................................................ 48
Horizontal Surface ................................................................................................................................... 49
Marine Pole Mount ................................................................................................................................... 49
Navigation System Extension Harness .................................................................................................... 50
Installation ................................................................................................................................................ 50
IMU Connection ....................................................................................................................................... 50
GPS Connection ...................................................................................................................................... 51
Navigation System Y‑Harness........................................................................................................................51
Installation ................................................................................................................................................ 51
E‑Stop Switch........................................................................................................................................................ 52
Installation ...................................................................................................................................................... 52
Installation Recommendations: ................................................................................................................ 52
Starboard Helm Clean Power Harness................................................................................................................. 52
Installation ...................................................................................................................................................... 53
VesselView Installation.......................................................................................................................................... 53
VesselView......................................................................................................................................................53
VesselView Harness Connection....................................................................................................................53
CAN V Components.............................................................................................................................................. 53
CAN V Genset Adaptor Harness.....................................................................................................................53
Installation ................................................................................................................................................ 53
CAN V Termination Harness...........................................................................................................................54
Installation of the CAN V Device .............................................................................................................. 54
CAN V Terminator ................................................................................................................................... 54
Smart Junction Box .................................................................................................................................. 54
CAN V Extension Harness..............................................................................................................................54
Pre‑Calibration Requirements............................................................................................................................... 55
Initial Configuration of VesselView and Steering................................................................................................... 55
Initial VesselView Configuration......................................................................................................................55
Start‑up .................................................................................................................................................... 55
Engine Setup ........................................................................................................................................... 55
Number of Engines .................................................................................................................................. 55
How Engines are Displayed ..................................................................................................................... 55
VesselView Device Setup ........................................................................................................................ 56
Calibrating Tanks ..................................................................................................................................... 56
Manual Calibration (Fuel Tanks Only) ............................................................................................... 56
Generator ................................................................................................................................................. 56
Environment or Depth Alarm ................................................................................................................... 57
Troll Limits ............................................................................................................................................... 57
Cruise Limits ............................................................................................................................................ 57
Factory Reset .......................................................................................................................................... 57
Vessel Configuration............................................................................................................................................. 57
Page 2 / 70 90-866927070 SEPTEMBER 2007

Initial Out of the Water Drive Alignment..........................................................................................................57

Vessel Configuration (VesselConfig)............................................................................................................... 59
Accessing VesselConfig..................................................................................................................................59
Main Menu.......................................................................................................................................................60
Vessel Personality List ............................................................................................................................. 61
Factory Configuration .............................................................................................................................. 61
Unlock Feature Upgrades ........................................................................................................................ 63
Calibrate Maretron Compass ................................................................................................................... 64
Load Libraries .......................................................................................................................................... 65
Sea Trial .................................................................................................................................................. 66
Drive Initialization .............................................................................................................................. 67
Drive Alignment ................................................................................................................................. 67
Import/Export ........................................................................................................................................... 68
90-866927070 SEPTEMBER 2007 Page 3 / 70

Zeus Electronic System Architecture

Zeus Helm System Architecture
68
67
66
65 1
3
2
64 4
10
AUTO
63 5
9
7 8 11
62 6
61
60 17 14
18 16 12
59
Port Starbo
15 13
58 19
57
56
55
54
69 20
51 52 53
50
49
70
47 48 71
46
45
E-STOP
43 44
42
41 40
31 21
36 34 30 28 26
38 33 24
39 35 32 29
25
37 27 23 22
26183
a b c d
Helm Harness and Components
Page 4 / 70 90-866927070 SEPTEMBER 2007

1 - Global position sensor (GPS) 37 - Port CCM

2 - Navigation system extension 38 - CAN X terminator
harness 39 - Zeus twin engine extension harness
3 - Navigation system Y‑harness 40 - Halon breakout
4 - Standard junction box (J‑box) 41 - Key switch extension harness
5 - Precision Pilot pad 42 - Key switch
6 - System Tachometer 43 - Start/Stop panel
7 - Starboard link gauges 44 - E‑Stop switch
8 - Port link gauges 45 - Key switch
9 - VesselView 46 - Key switch extension harness
10 - USB extension harness 47 - Halon breakout
11 - Starboard link gauges 48 - Steering tilt actuator wiring
12 - VesselView harness 49 - Force‑feedback steering column
13 - Ambient air temperature sensor 50 - Steering motor wiring
14 - NMEA0183 extension harness 51 - Harness carrying port engine data
15 - Starboard 2nd station Link Gauge 52 - Port ERC (Electronic Remote Control)
16 - Port 2nd station Link Gauge lever
17 - Audio warning alarm horn 53 - Port ERC lever 1 wiring
18 - SystemTach harness 54 - Starboard ERC lever 1 wiring
19 - Alarm horn 55 - Starboard ERC lever
20 - Harness carrying starboard engine 56 - DTS pad (mounted in ERC head [see
data number 64])
21 - Zeus twin engine helm harness 57 - Joystick
22 - CAN X terminator 58 - CAN V terminator
23 - Starboard CCM (Command Control 59 - Smart junction box
Module) 60 - Alarm horn
24 - Switched load connector 61 - Port link gauges
25 - Starboard main power relay 62 - System Tachometer
26 - Starboard ECU main power 63 - Trim tab panel
disconnect 64 - DTS pad (mounted in ERC head [see
27 - Starboard clean‑power harness number 56])
28 - Starboard main power disconnect 65 - Trim tab Smart Multiplex Module
29 - Alarm horn (SMM)
30 - 2nd station starboard levers 66 - Trim tab SSM harness
31 - 2nd station port levers 67 - Navigation system extension harness
32 - Alarm horn 68 - Inertial Measurement Unit (IMU)
33 - Port ECU main power disconnect 69 - CAN V extension harness
34 - Starboard main power disconnect 70 - Port E‑Stop wiring
35 - Port main power relay 71 - Starboard E‑Stop wiring
36 - Switched load connector
Refer to the Zeus Engine and Drive System Architecture diagram for the continuation of the
harnesses indicated by the callouts a – d.
90-866927070 SEPTEMBER 2007 Page 5 / 70

Zeus Engine And Drive System Architecture

1
56 57
54 55
2
53 47 58
52 51 49 48 3
59
50 30A FUSE a
-+ 4
42 46 5
30A FUSE
43 6
35A
+12VDC
7
GND
41 44
20A 45
+12VDC
FUSE 8
b
9
40
11
10
20A
+12VDC
CB
GND
12
39 c
29 37 38
14
36 13
28 30 35
31 32 34 16
33 15
30A FUSE
d
17
27 18 -+
26 30A FUSE
23 19
35A
25 20
+12VDC
GND
24 21
+12VDC
20A 22
FUSE
25479
Typical engine and drive system electrical architecture
Page 6 / 70 90-866927070 SEPTEMBER 2007

1 - Port Vessel Interface Panel (VIP) 31 - Starboard halon breakout

2 - Main station extension harness— 32 - Starboard accessory relay
port 33 - Starboard steering position
3 - Port VIP unswitched power harness 34 - Starboard tank level
4 - 30A fuse 35 - Starboard paddle wheel
5 - Port battery 36 - CAN P
6 - 30A fuse 37 - Vessel sensor harness—starboard
7 - Port engine unswitched power 38 - Vessel sensor extension harness—
harness starboard (optional)
8 - Port engine 39 - Genset
9 - CAN V extension harness 40 - CAN V terminator
10 - Starboard helm clean power 41 - Port MerCathode power harness
harness 42 - Port backup pump clean power circuit
11 - Circuit breaker wiring—starboard breaker wiring
helm clean power harness 43 - Port backup pump clean power
12 - Starboard VIP harness
13 - Not used (starboard throttle) 44 - Port drive
14 - Main station extension harness— 45 - Port drive application extension
starboard harness
15 - T‑harness 46 - Port Thrust Vector Module (TVM)
16 - Starboard VIP unswitched power extension harness
harness 47 - Port CAN P
17 - 30A fuse 48 - Port paddle wheel
18 - Battery 49 - Port tank level
19 - 30A fuse 50 - Port steering position
20 - Starboard engine unswitched power 51 - Port accessory relay
harness 52 - Port halon breakout
21 - Starboard engine 53 - Port WIF bias resistor
22 - Starboard drive application 54 - Port WIF sensor
extension harness 55 - Port WIF sensor harness
23 - Starboard Thrust Vector Module 56 - Vessel sensor harness—port
(TVM) extension harness
57 - Vessel sensor extension harness—
24 - Starboard MerCathode power port (optional)
harness
58 - Not used (port throttle)
25 - Starboard drive
59 - T‑harness
26 - Starboard backup pump clean
power harness
27 - Starboard backup pump clean
power circuit breaker wiring
28 - Starboard WIF (water‑in‑fuel) bias
resistor
29 - Starboard WIF sensor
30 - Starboard WIF sensor harness
Refer to the Zeus Helm System Architecture diagram for the continuation of the harnesses
indicated by the callouts a – d.
90-866927070 SEPTEMBER 2007 Page 7 / 70

Wiring Guidelines
IMPORTANT: Refer to the following precautions when working on or around the electrical harness,
or when adding other electrical accessories, to avoid damage to the electrical system.
• Do not tap accessories into the engine harness.
• Do not puncture wires for testing (probing).
• Do not reverse the battery leads.
• Do not splice wires into the harness.
• Do not attempt diagnostics without the proper, approved service tools.
• Never attempt to connect, network, tie into, switch, sink source voltage or current from the
wiring harnesses.
• Never attempt to connect any type of communication or navigation equipment into the wiring
harnessing other than at the designated connection point.
• Always install boat accessory equipment using an appropriate power source connection, such
as a fuse panel or junction box.
• Never attempt to tap directly into any of the electrical wiring harnesses for a source of power.
Wiring Guidelines for Electrical Boat Accessories

IMPORTANT: Do not connect boat accessories to ignition key switch circuits. Use a separate,
switched 12‑volt source for wiring boat accessories.
Splicing or connecting accessories to the ignition key switch circuits could cause an open circuit
at the fuse or overload circuits, causing intermittent or complete loss of operation.
Harness Installation Guidelines

• Ensure the total length of installed CAN V harnessing is less than 70 m ( 229 ft. 8 in.). Locate
an appropriate path for routing the harness connections to their installation points.
• Inspect the routing path to ensure that surfaces are free of any sharp edges or burrs that could
cut the harness.
• Fasten and support the harness with clamps or cable ties along the routing path. A clamp or
cable tie must be used within 25.4 cm (10 in.) of any connection and every 45.8 cm (18 in.)
along the routing path.
• Ensure that all connections are tight.
• Seal all unused connectors with weather caps.
• Route the harness at least 1 m (3 ft. 3 in.) from any EMC device such as VHF radio and radar
equipment.
System Component Descriptions

Drive Components
Backup Pump Clean Power Harness – The Backup Pump Clean Power Harness provides the
backup hydraulic pump with the necessary power. It is protected by an inline 35 Amp fuse located
close to the positive battery terminal.
MerCathode Power Harness ‑ The MerCathode Power Harness provides power to the
MerCathode system on the pods. Use of the MerCathode system minimizes galvanic corrosion of
the pod.
Drive Application Extension Harness ‑ The drive application extension harness is an interface
between the Vessel Interface Panel and the pod. This harness contains power and ground
connections for solenoids on the drive. Pressure sensors, transmission speed sensors, and
temperature sensors are also powered and grounded through this harness.
Thrust Vector Module (TVM) – The TVM monitors and controls the lower unit of the pod. TVM
inputs include drive position, tab position, and various pressure sensors. The TVM sends
commands to the steering coils, tab coils, and pump pressure control coil.
Page 8 / 70 90-866927070 SEPTEMBER 2007

Thrust Vector Module (TVM) Extension Harness ‑ The TVM extension harness carries the CAN
bus signals between the drive, Vessel Interface Panel (VIP), and helm command and control
module. It also provides power and ground for the TVM. The extension harness is offered in
multiple lengths. Check with CMD for specific length availability.
Engine Components
Engine-to-VIP Extension Harness ‑ The engine extension harness interfaces engine with the
VIP. This allows engine parameters to be read by the VIP and on system gages at the helm. The
engine extension harness comes in multiple Check with CMD for specific length availability.
ECM Unswitched Power Harness – The ECM Unswitched Power Harness provides constant
power from the battery to the engine control module. The harness is by an inline 30 Amp fuse,
located close to the positive battery terminal.
VIP COMPONENTS
Vessel Interface Panel (VIP) ‑ The VIP contains the components that interact with the engine
and controls at the helm, various circuit breakers, and start / stop buttons for cranking the engine.
The VIP houses the System Integration Module (SIM).
System Integration Module (SIM) – The SIM processes inputs from the helm components and
sends command to the engine and drive. Engine and drive data is read by the SIM and sent to
display devices at the helm.
VIP Unswitched Power Harness – The VIP Unswitched Power Harness provides constant power
from the battery to the Vessel Interface Panel. The harness is protected by an inline 30 Amp fuse,
located close to the positive battery terminal.
T-Harness ‑ The T‑harness allows the helm extension harness and Thrust Vector Module (TVM)
extension harness (both described in this document) to be connected to the Vessel Interface
Panel.
Vessel Sensor Harness – The vessel sensor harness contains connection points for various
sensors that are read by the engine. Some of these sensor inputs include tank levels, water‑in‑fuel,
and Halon (fire suppression) breakout.
Vessel Sensor Extension Harness – The vessel sensor extension harness connects between
the vessel sensor harness and the VIP. This allows the vessel sensor harness to be extended
beyond the VIP. The extension harness comes in multiple lengths. Check with CMD for specific
length availability.
Main Station Extension Harness ‑ The main station extension harness extends the CAN bus,
power, ground, and switched power from the VIP to the helm. This allows control interfaces to
interact with the rest of the system in the engine compartment.
HELM COMPONENTS
Zeus Twin Engine Helm Harness ‑ The Zeus twin engine helm harness contains all the
connectors to connect all control interfaces to the control system. The specific connections are
listed below.
HELM CONNECTIONS
• CAN X Termination Resistor (both PORT and STBD)
• PORT and STBD CCM
• Switched Load (for accessories)
• PORT and STBD Main Power Relay STBD
• Clean Power / STBD Power Disconnect
• PORT and STBD Lever 3 (not used)
• PORT and STBD key switches (only at main station)
• Start/Stop Panel (required at second station)
• Steering Motor (Electronic feedback steering column)
• Control Head
90-866927070 SEPTEMBER 2007 Page 9 / 70

• Joystick
• Smart Junction Box
Command and Control Module (CCM) ‑ The CCM processes inputs created by vessel controls
(joystick, steering wheel, electronic remote control) and sends these commands to the necessary
system components. The CCM interacts with navigation system components, and also contains
data that is used for auto pilot functionality.
Smart Junction Box – The Smart junction box provides LED indication of key switch and CAN
bus activity, and a single connection point for both port and starboard control systems and other
components. There are also connections available for CAN V devices, VesselView, System
Tachometer / Speedometer.
Standard Junction Box – A standard junction box allows multiple SmartCraft components to
connect to the SmartCraft network in one box. These components include but are not limited to
Precision Pilot, IMU/GPS, DTS track pad, and Tab SMUX. The Standard Junction Box also serves
as an additional multi‑ignition SmartCraft component connection point.
SmartCraft Data Harness – The SmartCraft data harness is a yellow cable with a 10 pin connector
on each end that connects the Smart Junction Box to the Standard Junction Box. This allows
components that are connected to the Standard Junction Box to share data with the rest of the
control system, and serves as an additional multi‑ignition SmartCraft component connection point.
Electronic Remote Control (ERC) – The electronic remote control provides engine throttle and
shift input to the control system, and houses the DTS track pad.
DTS Track Pad – The DTS Track Pad, which is mounted in the control head, allows the user to
control certain system features. These features are Troll, Engine Synchronization, Docking Mode,
Throttle Only, Helm Control Transfer, and Single‑Lever Mode. The track pad contains buttons
corresponding to these functions.
Electronic Steering – Electronic steering is a motor, sensor, and actuator assembly that mates
with a steering wheel to provide directional input to the control system. This direction input is
translated into commands and sent to the TVM on the pods.
Joystick – The joystick provides directional input to the control system, which in turn commands
the pods. This control is provided on three axes; fore to aft, side to side, and yaw (twisting the
joystick).
Trim Tab Panel – The Trim Tab Panel consists of three switches which interlock to form a small
panel. These switches are port bow (up/down), starboard bow (up/down), and auto tab enable.
The switches allow for manually setting/adjusting the starboard trim tab and port trim tab, and
enabling the auto tab function that controls the trim tabs automatically.
Trim Tab Smart Multiplex Module (SMM) – The Trim Tab Smart Multiplex Module (SMM) reads
the switch settings from the Trim Tab Panel and converts these inputs to data that can be read by
the SmartCraft network.
Tab SMM Harness ‑ The Tab SMM harness connects the Tab SMM to the Trim Tab Panel and
to the standard junction box.
Key Switch – The key switch provides switched power to the control system, and can be used to
start and/or stop an engine. There will be one key switch for each engine, and they are only
installed at one helm. For a boat that is equipped with two helms, the main helm will have the key
switches, the other helm will only have a Start/Stop Panel.
Key Switch Extension Harness – In the event that the key switch is not located close to the helm
harness, a key switch extension harness can be used. However, when using a Key Switch
Extension Harness a Start/Stop Panel will be required at the main station. This is because the Key
Switch Extension Harness removes the crank circuit from the key switches.
Start/Stop Panel – The Start/Stop Panel allows the operator to start and/or stop the engines with
the press of a single button. Each engine is controlled independently. For the Start/Stop Panel to
function, the key switch must be in the ON position. This is an optional component at the main
station, if key switches are installed within the operators reach. Otherwise, this is a mandatory
component on secondary stations where no key switches are installed (i.e. second station).
Page 10 / 70 90-866927070 SEPTEMBER 2007

Precision Pilot Track Pad – Using the Precision Pilot Track Pad, the user is able to enter
waypoints along a desired path and the boat will navigate itself along this path. Skyhook is another
feature of the Precision Pilot Track Pad. By enabling Skyhook, the control system uses a set of
coordinates (longitude and latitude) read from the GPS and holds the boat at this approximate
location. The Precision Pilot Track Pad is also used for heading control.
Inertial Measurement Unit (IMU) – The Inertial Measurement Unit (IMU) is a solid state, rate gyro
electronic compass that detects the direction of the earth’s magnetic field using solid state
magnetometers and indicates the vessel heading relative to magnetic north. Additionally, solid
state accelerometers and angular rate sensors indicate the vessel’s attitude and rate of turn.
Global Positioning System (GPS) – Global Positioning System (GPS) is a device that provides
the location, speed, and direction of the vessel. This information comes from satellites that transmit
radio signals to the GPS unit.
Navigation System Extension Harness – The Navigation System Extension Harness allows the
Navigation System components such as the GPS and IMU to be mounted in remote locations with
regards to the helm harness.
Navigation System Y-Harness – The Navigation System Y‑Harness connects the Inertial
Measurement Unit and the Global Positioning Sensor to the SmartCraft Network, through a
standard junction box. This allows the data from the guidance components to be read by the control
system. The control system uses this data for the Precision Pilot, joystick docking, auto tab, and
more.
E-Stop Switch – The E‑Stop Switch offers a redundant emergency shutdown method in the event
that the key switch fails. The E‑Stop Switch is mounted at the helm, and connects to the helm
harness.
Starboard Clean Power Harness – The Starboard Clean Power Harness provides clean battery
power to the helm harness.
VesselView – The VesselView is a SmartCraft based digital display. Some of the data displayed
by the VesselView is engine information, trim tab position, drive position, tank levels, and
navigational information (if connected to GPS). When ordered as an option the VesselView comes
with an interface harness, bezel, sun cover, temperature sensor, operation manual, installation
manual, USB extension harness, NMEA 0183 extension harness, port ignition jumper harness,
and installation hardware. One important aspect of the VesselView is that it is required for fault
reporting and alarm annunciation.
VesselView Harness ‑ The VesselView harness connects the VesselView display unit to the
Smart Junction Box for displaying data and configuring the control system. There are connection
points on the harness for NMEA 0183, air temperature sensor, SmartCraft link gauges, alarm horn,
and Smart Junction Box.
CAN V COMPONENTS
CAN V Genset Adaptor Harness – The CAN V Adaptor Harness interfaces with SmartCraft
compatible generator sets, and allows generator data to be broadcast over the CAN V data bus.
CAN V Termination Harness – The CAN V Termination Harness provides a termination resistor
for one end to the CAN V data bus.
CAN V Terminator ‑ The CAN V Terminator is a short harness that provides a termination resistor
for one end of the CAN V data bus.
CAN V Extension Harness – The CAN V Extension Harness extends the CAN V data bus beyond
the Smart Junction Box to a SmartCraft compatible CAN V device. The CAN V Extension Harness
connects between the CAN V Termination Harnesses, located on each end of the CAN V bus.
Vessel Interface Panels (VIP)

VIPs are engine‑specific. Care should be taken to keep port and starboard continuity through the
harness connections. By this point the engine connections should be made. Refer to the chart
printed on the front of the VIP for the proper connections.
90-866927070 SEPTEMBER 2007 Page 11 / 70

1. Connect the station extension harness to the T‑harness that already connects the drive to the
VIP.
2. Confirm the following port and starboard harness connections:
Appropriate vessel sensor harness
Appropriate engine harness
Appropriate 14 pin T‑harness
Power supply harness
a b c d e
26174
Port shown, starboard similar

a - Vessel sensor harness d - Not used in this application
b - Engine harness e - Unswitched power harness
c - T‑harness
Main Station Extension Harness

The main station extension harness extends the CAN bus data, power, ground, and switched
power from the T‑Harness on the VIP to the helm. It comes in various lengths to facilitate
installation.
One main station extension harness is required per engine, per station.
31330
Not to scale
Installation
1. Connect the main station extension harness to the remaining connection on the 14 pin
T‑harness at the VIP. Tighten the connector collars. Ensure connector collars are fully
engaged and secure.
2. Route the main station extension harness to the helm. The station extension harness will
connect to the helm harness, covered later.
3. If a second helm is being installed, install the second helm to the station extension harness
with a T‑harness.
Helm Harness
The helm harness contains all the connectors to connect all control interfaces to the control system.
The specific connections are listed below.
One helm harness is required per station.
Page 12 / 70 90-866927070 SEPTEMBER 2007

Installation
NOTE: Ensure the helm components are laid out with respect to the helm harness breakouts.
Some breakouts are extremely short, and require components to be mounted in close proximity
with each other.
31058
1. Connect the 14 pin connector on the helm harness labeled "PORT" to the port engine Station
Extension Harness. Ensure connector collars are fully engaged and secure.
2. Connect the 14 pin connector on the helm harness labeled "STARBOARD" to the starboard
Station Extension Harness. Ensure connector collars are fully engaged and secure.
Helm Connections
The following connections will be made to the helm harness.
• CAN X termination resistor (both PORT and STBD)
• PORT and STBD CCM
• Switched load (for accessories)
• PORT and STBD main power relay
• STBD clean power and STBD power disconnect
• PORT and STBD Lever 3 (not used)
• PORT and STBD key switches (only at main station)
• Start and stop panel (required at second station)
• Steering motor (Electronic feedback steering column)
• Control head
• Joystick
• Smart junction box
• Tilt actuator (future feature)
• Tilt position (future feature)
Command and Control Module (CCM)

The command and control module processes inputs created by vessel controls (joystick, steering
wheel, electronic remote control) and sends these commands to the necessary system
components.
• One CCM required for PORT
• One CCM required for STBD
90-866927070 SEPTEMBER 2007 Page 13 / 70

• Software is side specific
31059
Installation
One set of CCMs (port and starboard) are required for each helm. If installing two helms, install
the second helm first.
NOTE: To minimize vibration, mount the command module with the supplied rubber grommets /
bushings according to the following guidelines and template:
• Mount in an area that is accessible
• Mount in an area where the wiring connections will not be stepped on or disturbed
• Mount in an area that stays relatively dry.
• Fasten the harness to prevent flexing at the CCM connection.
• Do not over torque mounting screws.
• Use standoffs as required to avoid bending the module
Do this for both port and starboard CCMs.
NOTE: Due to the breakouts on the helm harness, the CCMs are required to be mounted within
a certain distance of the helm harness and Smart Junction Box.
Page 14 / 70 90-866927070 SEPTEMBER 2007

SINGLE OR MAIN HELM INSTALLATION

1. Mount the CCMs to the predetermined location using the dimensions provided.
31066
Template is NOT to scale. Top units are in millimeters, bottom units are in inches.
2. Plug connectors A and B, on the helm harness, into the appropriate CCM. Do this for both
port and starboard CCMs.
3. Connect the 14 pin Deutsch connector on the helm 1 harness marked "PORT" to the port
engine station extension harness, or dual helm T‑harness if equipped with a second helm.
4. Connect the 14 pin Deutsch connector on the helm 1 harness marked "STARBOARD" to the
starboard engine station extension harness, or dual helm T‑harness if equipped with a second
helm.
90-866927070 SEPTEMBER 2007 Page 15 / 70

SECOND HELM INSTALLATION, IF EQUIPPED

1. Mount the CCMs to the predetermined location using the dimensions provided.
31066
Template is NOT to scale. Top units are in millimeters, bottom units are in inches.
2. Plug connectors A and B, on the helm harness, into the appropriate CCM. Do this for both
port and starboard CCMs.
3. Connect one T‑harness to each main station extension harness coming from the engine.
engine T‑harness.
starboard engine T‑harness.
6. Remove the CAN‑X terminator resistor from the helm 1 harness. Seal the unused connectors
with weather caps.
7. Connect the "ENGINE" end of a second data harness to each T‑harness, and route the station
extension harnesses to the second helm.
station extension harness.
station extension data harness.
10. Ensure the CAN‑X connectors at helm 2 have terminator resistors installed.
Page 16 / 70 90-866927070 SEPTEMBER 2007

Standard 6‑way Junction‑box

A standard junction box works as a breakout point for additional SmartCraft components to connect
to the multi‑ignition input from the Smart Junction Box. The Standard Junction Box serves as the
connection point for the Tab Smart Multiplex Module, Inertial Measurement Unit, Global Position
Sensor, Precision Pilot, and DTS Track Pad to the Smart Junction Box.
31075
Installation
IMPORTANT: Careful considerations must be made when deciding where to mount the Standard
Junction Box.
• Unobstructed access of about 4 inches needs to be available to all connections on the junction
box
• The mounting location needs to be free of excessive moisture and heat.
• The Standard Junction Box should be mounted in the same general area as the Smart
Junction Box.
NOTE: The Standard Junction Box must be mounted near the remainder of the helm components
to allow harness connections.
1. Using the dimensions provided, mark and drill the holes necessary to install the Standard
Junction Box.
163.8 mm
(6.45 in.)
146.5 mm
(5.75 in.)
7.44 mm
(0.29 in.)
84.33 mm
(3.32 in.)
44.5 mm
(1.75 in.)
31076
Not to scale
2. Mount the Standard Junction Box to the predetermined location. Do not over torque the
mounting screws.
90-866927070 SEPTEMBER 2007 Page 17 / 70

Smart Junction Box

The Smart junction box provides LED indication of key switch and CAN bus activity, and a single
connection point for both port and starboard control systems and other components. There are
also connections available for CAN V devices, VesselView, System Tachometer / Speedometer.
31070
The Smart Junction Box has 10 positions for single helm applications. Unlike the 6‑position J‑box,
the connections on the Smart Junction Box are input specific. The appropriate input is marked on
the cover of the J‑box.
Smart Junction Box Connections

• "Port SmartCraft Display" – Broadcasts engine data with port key switch enable
• "SmartCraft Display Multi‑Ignition" – Used to add more components to the SmartCraft network
via a standard junction box. Contains all key switches (powers up on any key switch enable)
• "Starboard SmartCraft Display" – Broadcasts engine data with starboard key switch enable
• "Port Engine" – Connects to port CCM through the helm harness. Communication to / from
the port engine is transmitted through this connector.
• "Multi‑Ignition" – Contains multiple key switch circuits for additional devices, or another
VesselView
• "CAN V" – This allows data from SmartCraft compatible CAN V devices to be displayed on
SmartCraft display devices. Generator sets are connected to the SmartCraft network through
this connection point.
• "Vessel View Multi‑Ignition" – This connector allows the VesselView to be powered ON via
multiple key switches independently.
• "Starboard Engine" – Connects to starboard CCM through the helm harness. Communication
to / from the starboard engine is transmitted through this connector.
Installation
IMPORTANT: Due to the importance of the Smart Junction Box to the overall functionality of the
control system:
• Careful considerations must be made when deciding where to mount the component.
• Unobstructed access of about 4 inches needs to be available to all connections on the junction
box
• The mounting location needs to be free of excessive moisture and heat.
• The Smart Junction Box should be mounted as far from EMI sources as practical to your
installation.
• Do not over torque the mounting screws.
Page 18 / 70 90-866927070 SEPTEMBER 2007

NOTE: Due to the breakouts on the helm harness, the Smart Junction Box is required to be
mounted within a certain distance of the helm harness and CCMs.
1. Using the dimensions provided, mark and drill the holes necessary to install the Smart Junction
Box.
31074
2. Mount the Smart Junction Box to the predetermined location. Do not over torque the 4
mounting screws.
3. The Helm Harness has a breakout labeled "STARBOARD JUNCTION BOX". The connector
is keyed so that it will only fit into the appropriate connector on the Smart Junction Box.
Connect this breakout to the connector labeled "STARBOARD ENGINE" on the Smart
Junction Box.
4. The Helm Harness has a breakout labeled "PORT JUNCTION BOX". The connector is keyed
so that it will only fit into the appropriate connector on the Smart Junction Box. Connect this
breakout to the connector labeled "PORT ENGINE" on the Smart Junction Box.
5. Ensure that each unused connector is properly covered with a weathercap.
SmartCraft Data Extension Harness

The SmartCraft data extension harness is a yellow cable with a 10 pin connector on each end that
connects the Smart Junction Box to the Standard Junction Box. This allows components that are
connected to the Standard Junction Box to share data with the rest of the SmartCraft Network. It
is available in various lengths.
31080
Not to scale
1. Connect one end of the data extension harness to the Smart Junction Box connector labeled
"SmartCraft Display Multi‑Ignition."
90-866927070 SEPTEMBER 2007 Page 19 / 70

2. Connect the other end of the data extension harness to the standard junction box, on any
unused connector.
Dual‑Handle Electronic Remote Control

Locating and Drilling Mounting Area for Dual‑Handle Electronic Remote Control
The electronic remote control provides engine throttle and shift input to the control system, and
houses the DTS Track Pad.
NOTE: Refer to the supplied kit instructions for templates and other mounting instructions.
1. Locate area of boat where the remote control is to be mounted. Allow sufficient clearance for
handle movement and clearance for the wiring.
2. Select the correct template for mounting application.
3. Place the template over the mounting area. Cut and drill as instructed on the template.
IMPORTANT: After cutting mounting area, remove any sharp edges.
3508
a - Template
Page 20 / 70 90-866927070 SEPTEMBER 2007

Dual‑Handle Electronic Remote Control Cut‑Out Template
55.88 mm
(2.20 in.)
6.35 mm
(0.250 in.)
19.00 mm
(0.750 in.)
98.42 mm
(3.875 in.)
53.18 mm
(2.094 in.)
89.00 mm
(3.50 in.)
69.85 mm
(2.750 in.)
19.00 mm
(0.750 in.)
9.50 mm
(0.375 in.)
3593
a - Front of boat
NOTE: Due to variances in the printing process, this image may not be to scale. Verify the accuracy
of the template, using the remote control mounting bracket, before cutting the mounting holes.
Installing the Dual‑Handle Electronic Remote Control with DTS Trackpad
1. Ensure the opening is free of sharp edges.
90-866927070 SEPTEMBER 2007 Page 21 / 70

2. Route the wiring for the ERC through the opening.
31333
3. Match the colors on the harness to the colors on the ERC to assure proper orientation. Connect
the lever connectors on the harness to the levers on the ERC's.
c
a b
28083
a- For starboard engine harness

b- For port engine harness
c- DTS trackpad connection
d- Bracket with holes for bayonet ends
4. Insert the bayonet ends of the two lever harnesses into the bracket holes to prevent
disconnection.
5. Connect the Digital Throttle and Shift (DTS) trackpad connector to the standard 6‑way junction
box.
IMPORTANT: Allow some slack in the trim button harness going to the control handle. This
harness will flex and move during movement of the control handle.
Page 22 / 70 90-866927070 SEPTEMBER 2007

6. Place the remote control over the opening.
28093
7. Securely fasten the remote control with four M6 × 40 screws, washers, and self‑locking nuts.
! CAUTION
Overtightening the detent tension adjustment screw can damage the control module. Do not turn
this screw more than 11 turns from the initial point of hex head contact with bracket.
8. Set the control handle tension adjustment screw to increase or decrease the overall effort to
move the control handle through its range of motion. Proper adjustment will help prevent
unwanted handle motion in rough water. Turn the screw clockwise for more tension, or
counterclockwise for less tension.
9. Set the handle detent tension adjustment screw to increase or decrease the overall effort
needed to move the control handle out of its detent positions. Proper adjustment will help
prevent the handles from moving out of their detents until desired. Turn the screw clockwise
for more resistance, or counterclockwise for less resistance.
a b
28087
a - Detent tension adjustment (Marked "De")

b - Control handle tension adjustment (Marked "Fr")
90-866927070 SEPTEMBER 2007 Page 23 / 70

10. Install the side covers with attaching screws. Ensure ears on side covers are hooked under
the main shell before tightening screws.
b b
28084
Starboard shown, port similar

a - Side cover (2)
b - Attaching screws (4) M4 x 20
Electronic Steering Column

Manual Tilt Steering Column Installation
The electronic steering column is a motor sensor and actuator assembly that mates with a steering
wheel to provide directional input into the control system. This directional input is translated into
commands and sent to the TVM on the drives by the CCM.
STEERING COLUMN LOCATION
1. Identify the desired mounting location on the dash for the steering wheel. Ensure that there is
sufficient clearance behind the dash for all components and wiring. Consult the Zeus
Application Manual for dimensions and clearances.
24499
a - Mounting location for the steering wheel
2. The steering mechanism can be mounted on horizontal or vertical surfaces. See the
appropriate horizontal or vertical mount template on the following pages for proper hole
location.
DRILLING STEERING COLUMN HOLES USING THE SPECIAL TOOL
1. Drill the 7.4 cm (2‑7/8in.) center hole with a hole saw at the center of where the steering wheel
will be located.
2. Insert the special tool into the hole and orient the tool with the center bolt hole down for vertical
mounting or with the center bolt hole up for horizontal mounting.
Page 24 / 70 90-866927070 SEPTEMBER 2007

Steering wheel special tool Part number not available at time of printing
3. Place a level on the flat surface of the tool and make the tool parallel to a level surface on the
boat.
a c
24501
Vertical mounting shown

a - Special tool
b - Level (digital shown)
c - Drill guide holes
4. Drill the 10 mm (0.4 in.) mounting holes through the three guide holes.
5. Remove the tool.
b
24503

a - 7.4 cm ( 2‑7/8 in.) diameter
b - 10 mm (0.4 in.)
90-866927070 SEPTEMBER 2007 Page 25 / 70

DRILLING STEERING COLUMN HOLES USING THE TEMPLATE

1. Locate the appropriate template for the chosen location of the steering wheel.
b
a
g d
e 24756
Not to scale–for use with horizontal mounting

a- 12.8 cm (5.0 in.) diameter overall dimension
b- 10mm (0.4 in.) diameter ×3 holes
c- 4.75 cm (1.9 in.)
d- 10.2cm (4.0 in.) minimum
e- Underside of decking
f- 9.5 cm (3.74 in.)
g- 7.4 cm ( 2‑7/8 in.) diameter
Page 26 / 70 90-866927070 SEPTEMBER 2007

a
b
d 24757
Not to scale–for use with vertical mounting

a- 12.8 cm (5.0 in.) diameter overall dimension
b- 7.4 cm ( 2‑7/8 in.) diameter
c- 10.2cm (4.0 in.) minimum
d- 9.5 cm (3‑75 in.)
e- 4.75 cm (1.9 in.)
f- 10mm (0.4 in.) diameter ×3 holes
g- Underside of decking
2. Drill the three 10 mm (0.4 in.) holes and one 7.4 cm ( 2‑7/8 in.) hole in the appropriate locations
for vertical or horizontal mounting.
b
24503

a - 7.4 cm ( 2‑7/8 in.) diameter
b - 10 mm (0.4 in.) diameter
90-866927070 SEPTEMBER 2007 Page 27 / 70

INSTALLING THE STEERING COLUMN

1. Install the base mount and gasket to the dashboard using the three M8×45 bolts, washers and
self‑locking nuts. Tighten securely.
24504
Gasket not visible between mount and dashboard

a - M8 × 45 bolts
NOTE: The actuator can be rotated in 45° increments to allow proper clearance for the motor.
2. Insert the steering mechanism from the back of the mount plate. The space must be large
enough to fit the steering mechanism, wire lead, and motor. Note that the motor can be rotated
in 45° increments to ease installation.
d c
24779
Rear view with the motor in the right‑hand horizontal position

a - 4.33 cm (1.69 in.) d - 3.94 cm (1.55 in.)
b - 6.58 cm (2.6 in.) e - Wire lead
c - 17.10 cm (6.73 in.) f - 8 mounting positions possible in 45°
increments
Page 28 / 70 90-866927070 SEPTEMBER 2007

3. Attach the steering mechanism to the base mount using four M8 × 55 bolts and self‑locking
nuts. Torque the bolts.
c
a
d
24505
a - Base mount c - Motor

b - M8 × 55 bolts and self‑locking nuts d - Steering actuator
Description Nm lb. ft.

Bolts 30‑35 22‑26
4. Insert the four plugs into the unused steering actuator holes.
24506
a - Plugs b - M8 × 55 Bolts
5. Rotate the steering shaft to allow access to the set screws in the universal joint. Loosen the
set screws.
24507
a - Set screws
6. Align and link the universal joint in the tilt mechanism to the steering shaft of the steering
actuator.
90-866927070 SEPTEMBER 2007 Page 29 / 70

7. Orient the tilt mechanism so that the manual tilt lever is on the bottom of the unit. Fasten the
tilt mechanism to the base using four each M6 × 15 recessed head bolts. Torque bolts.
a a
b
24508
a - M6 × 15 recessed head bolts b - Manual tilt lever
Description Nm lb. in.

M6 × 15 recessed head bolts 6 43
.
8. Torque the two set screws in the universal joint.
24512
a - Large set screw (M6)

b - Small set screw (M4)
Description Nm lb. in.

Small set screw (M4 × 30) 2.5‑3 22‑26
Large set screw (M6 × 30) 7‑7.5 61‑65
Page 30 / 70 90-866927070 SEPTEMBER 2007

9. Align the cutout on the fixed covering to the tilt lever and mount the fixed covering to the tilt
mechanism using two self tapping (ST) 3.5 × 25 screws.
a a
24509
a - 3.5 × 25 self tapping screws
10. Align the movable cover to the tilt mechanism mounting holes and secure with three ST 3.5 ×
16 screws.
24510
a - 3.5 × 16 self tapping screws
11. Install the gasket with the smaller interior groove of the gasket mating with the ridge on the
fixed cover.
24511
a - Larger groove
b - Smaller groove
12. Connect the steering mechanism connector to the helm harness connector marked "Steering
Motor."
90-866927070 SEPTEMBER 2007 Page 31 / 70

Steering Wheel Installation

1. Insert the woodruff key into the steering wheel shaft of the tilt mechanism.
a
b
25413
a - Woodruff key
b - Steering wheel shaft
2. Align the keyway of the steering wheel to the woodruff key. Ensure that the woodruff key is in
place after fully seating the steering wheel.
3. Secure the steering wheel using a flat washer and the M12 stop nut. Tighten securely.
a b
25414
Typical steering wheel shown

a - Flat washer
b - M12 stop nut
4. Install the center trim plate or cover, if equipped.

5. Ensure that the steering wheel turns freely and that the tilt operates fully.
Electronic Steering Helm Connections
1. Ensure the appropriate steering connector on the helm harness is connected to the electronic
steering helm.
2. Ensure the appropriate power tilt pigtail on the helm harness is covered by a weather cap.
Joystick
Joystick Location Requirements
The joystick provides directional input to the control system, which in turn commands the pods.
This control is provided on three axes; fore to aft, side to side, and yaw (rotating the joystick cap).
NOTE: Do not mount the VHF radio near the joystick.
• The preferred location is to mount the joystick starboard of the steering wheel and aft so that
it can be comfortably actuated while sitting or standing.
Page 32 / 70 90-866927070 SEPTEMBER 2007

• If possible, an arm rest should be located behind the joystick for comfortable operation while
sitting.
• Mount the mount plate of the joystick as horizontally as possible. The maximum incline is
approximately 10°, because anything greater introduces control error.
• The mounting surface should ideally be higher than the mounting surface of the electronic
remote control (ERC). The joystick knob will then be at a height similar to the ERC control
lever handles. Otherwise, the joystick may be too low and uncomfortable to reach while
standing.
• Locate the joystick aft of the ERC shift control, but ensure enough spacing for the operator to
place the ERC shift levers in full reverse without impacting the joystick.
• Do not place in an area which may cause unwanted interaction.
• Identify the mounting location on the dash for the joystick. Allow enough space for the joystick
to operate with a hand around it without interference in any direction.
28194
Typical joystick mounting location

a - Joystick
• Refer to the appropriate joystick mount dimensions or use the joystick mount cover for surface
area requirements
a
f b
e c
24488
Not to scale–Joystick mount dimensions
a - 5.72cm ( 2‑1/4 in.) d - 8.255cm (3‑1/4 in.)
b - 4 × 8mm (5/16 in.) diameter e - 4.128cm (1‑5/8 in.)
c - 6.0cm (2‑3/8 in.) diameter f - 2.858 cm (1‑1/8 in.)
90-866927070 SEPTEMBER 2007 Page 33 / 70

• Allow a minimum of 15.25 mm (6 in.) of clearance underneath the entire mounting area for
the joystick body and wiring.
Joystick Installation
1. Identify the location on the dash for the joystick.
2. Use to the appropriate joystick mount template to locate and mark the required holes
a
f b
e c
24488
Not to scale–Joystick mounting dimensions
a - 5.72cm ( 2‑1/4 in.) d - 8.255cm (3‑1/4 in.)
b - 4 × 8mm (5/16 in.) Diameter e - 4.128cm (1‑5/8 in.)
c - 6.0cm (2‑3/8 in.) Diameter f - 2.858 cm (1‑1/8 in.)
3. Drill the four 8mm (5/16 in.) holes and one 6.0cm (2‑3/8 in.) hole in the appropriate locations.
24493
a - 8 mm (5/16 in.) holes

b - 60 mm (2‑3/8 in.) hole
Page 34 / 70 90-866927070 SEPTEMBER 2007

4. Insert the gasket and joystick with mount plate in the dash.
b
a
24485
a - Gasket
b - Joystick with mount plate
5. Ensure that the "Front" mark on the mount plate is facing the bow of the boat. If the "Front"
mark cannot be located, another method is to ensure the wire harness breakout, coming from
the joystick, is mounted toward the port side of the boat. Secure the mount plate to the dash
using four bolts, washers, and self‑locking nuts. Torque the nuts.
24484
a - Front mark

Self‑locking nuts 0.9‑1.4 8‑12 –
6. Carefully snap the mount plate cover to the mount plate.
24494
a - Mount plate cover
7. Connect the joystick connector to the appropriate connector on the helm harness.
90-866927070 SEPTEMBER 2007 Page 35 / 70

Trim Tab
Trim Tab Panel
The Trim Tab Panel consists of three switches which interlock to form a small panel. These
switches are port bow (up/down), starboard bow (up/down), and auto tab enable. The switches
allow for manually setting/adjusting the starboard trim tab and port trim tab, and enabling the
auto‑tab function that controls the trim tabs automatically.
The port/starboard trim tab control switches will also be able to make tab adjustments when in
automatic trim control mode. The tabs can be adjusted independently to allow for external
conditions or personal preferences.
The trim tab panel, when used, should be mounted on the helm within easy reach of the operator.
Manual trim tab control overrides the automatic system.
The manual trim tab control also makes offset adjustments when the boat is in automatic trim
control mode. Tabs can be adjusted independently.
a b c
31081
Typical
a - Port trim switch
b - Starboard trim switch
c - Automatic trim override
Use the panel available through the Zeus accessories guide.

1. Cut the mounting hole for the trim tab panel using the dimensions provided.
77.48 mm
(3.05 In.)
58.42 mm 48.514 mm (1.91 in)

(2.3 in.)
31092
Cutout dimensions
2. Snap the trim tab panel into the mounting hole.
Page 36 / 70 90-866927070 SEPTEMBER 2007

3. Connect the trim tab panel harness to the SMM harness.
31701
Trim tab SMM harness

4. Connect the SMM harness to the standard 6‑way J‑box or junction box.
5. If using a trim tab panel other than that provided, contact a CMD distributor applications
engineer for wiring diagrams to properly connect all wires to the harness.
Trim Tab Smart Multiplex Module (SMM)
The Trim Tab Smart Multiplex Module reads the switch settings from the Trim Tab Panel and
converts them to data that can be read by the SmartCraft Network.
INSTALLATION
1. Using the dimensions below, carefully locate a mounting location for the SMM.
45mm
(1.77 in) 6 mm (0.024 in) X 3
135 mm (5.31 in)
90 mm (3.54 in)
31999
2. Insert the supplied rubber grommets into each of the feet of the SMM.
3. Insert the supplied metal standoffs into the rubber grommets.
4. Mount the SMM to the predetermined location, being careful to not over tighten the mounting
screws.
5. Connect the Trim Tab SMM Harness to the SMM. Ensure the connectors are securely seated.
90-866927070 SEPTEMBER 2007 Page 37 / 70

Key Switch
The key switch provides switched power to the control system, and can be used to start and/or
stop an engine. There will be one key switch for each engine, and they are only installed at the
main station. For a boat that is equipped with two stations the main station will have the key
switches, the other station will have a Start/Stop Panel. In the event that a Key Switch Extension
Harness is used, a Start/Stop panel will have to be used at the main station due to the crank circuit
being absent from the Key Switch Extension Harness.
31093
Preparation
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product
damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine
starting. Always disconnect the battery cables from the battery before maintaining, servicing,
installing, or removing engine or drive components.
1. Ensure battery cables are disconnected.
! CAUTION
Avoid injury or product damage. Obstructions, such as braces and wiring, may be unseen when
looking at the front of the dashboard. Before drilling or cutting any holes in the dashboard, check
the area behind the dashboard for obstructions. Do not drill or cut when obstructions are present.
IMPORTANT: To ensure that water does not collect at the key switch and drains from the housing,
install the key switch a minimum of 10° from vertical.
2. Select a location for the key switch on the dashboard that meets the following requirements:
• unobstructed behind the dashboard
• within harness length limits
• able to orient the switch a minimum of 10° from a vertical position
• adequate clearance between the components to install bezels, if equipped
3. If the dashboard is fiberglass, prevent the dashboard from chipping by applying masking tape
to the area that is to be drilled or cut.
4. If the dashboard is vinyl covered, keep the vinyl from tearing by removing the vinyl from the
area to be drilled or cut.
5. The keyswitches can also be mounted in a remote panel, such as in the salon, using optional
extension harnesses available from CMD. Follow the instructions included with your key
switch.
Page 38 / 70 90-866927070 SEPTEMBER 2007

Standard Mounting ‑ With Housing

1. Cut or drill a 54 mm (2‑1/8 in.) diameter hole through the dashboard at the selected location.
2 -1/8 in.
(54mm)
4316
2. Install the key switch housing assembly onto the key switch assembly.
IMPORTANT: Ensure the drain opening notch, with the white plastic showing, points down for
proper draining after installation.
3. Align the upper notch of the key switch assembly and housing. Ensure the drain opening notch,
with the white plastic showing, points down for proper draining after installation.
4693
a - Drain opening notch with white plastic showing
4. Install and torque the key switch nut.

Key switch nut 2.2 20 –
5. Install the cover and the bezel onto the key switch housing.
6. Install the gasket onto the key switch housing.
b
a
4403
a - Gasket
b - Key switch housing
90-866927070 SEPTEMBER 2007 Page 39 / 70

7. Insert the key switch electrical connector, wiring, and key switch housing through the dash
opening.
4058
a - Key switch housing
NOTE: The ring mounting nut is threaded so that it can be installed to fit a thick or thin dashboard.
8. Install the ring mounting nut, depending on dash thickness, so that the most threads are
engaged when threaded onto the key switch housing.
a 3893
a - Thin dashboard
b - Ring mounting nut orientation
a
3894
a - Thick dashboard
b - Ring mounting nut orientation
9. Position the key switch properly in the dash.

NOTE: The ring mounting nut must be tight so the assembly will not rotate during use.
10. Tighten the ring mounting nut securely.
11. Connect the key switch electrical connector to the appropriate port / starboard key switch
connectors on the helm harness.
Page 40 / 70 90-866927070 SEPTEMBER 2007

Optional Mounting ‑ Without Housing

1. Cut a 22.5 mm (7/8 in.) oblong shaped hole that matches the key switch assembly threaded
end with the opposing top and bottom flat surfaces. This hole shape will keep the assembly
from rotating during use.
a a
4734
a - Distance between the flat surfaces ‑ b - Diameter of the hole ‑ 22.5 mm (7/8 in.)
20 mm (25/32 in.)
2. Install one nut onto the key switch assembly with the flat flange of the nut toward the key end
of the switch. Thread this nut on as needed until the key switch will extend through the
dashboard with enough threads exposed for the second nut to be installed.
IMPORTANT: There are two notches in the key switch assembly. The notch with white plastic
showing is a drain opening. To properly drain the key switch, this notch must point down when
installed.
3. Install the key switch assembly into the dashboard oblong hole. Ensure the drain opening
notch, with the white plastic showing, points down for proper draining after installation.
4693
a - Drain opening notch with white plastic showing
4. Install and torque the remaining key switch nut.

Key switch nut 2.2 20
5. Connect the key switch electrical connector to the command module harness.
Key Switch Extension Harness
In the event that the key switch is not located close to the helm harness, a key switch extension
harness can be used. This harness extends the key switch circuits in various lengths. However,
when using a Key Switch Extension Harness a Start/Stop Panel will be required to operate the
engine. This is because the Key Switch Extension Harness removes the crank circuit from the key
switches.
31095
90-866927070 SEPTEMBER 2007 Page 41 / 70

INSTALLATION
1. Connect one end of the Key Switch Extension Harness to the appropriate key switch connector
on the Helm Harness.
2. Connect the other end of the Key Switch Extension Harness to the appropriate key switch.
Start/Stop Panel
The Start/Stop Panel allows the operator to start and/or stop the engines with the press of a single
button. Each engine is controlled independently. For the Start/Stop Panel to function, the key
switch must be in the ON position. This is an optional component at the main station, if key switches
are installed within the operators reach. Otherwise, this is a mandatory component on secondary
stations where no key switches are installed (i.e. second station).
28082
Preparation
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product
damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine
starting. Always disconnect the battery cables from the battery before maintaining, servicing,
installing, or removing engine or drive components.
1. 1. Ensure battery cables are disconnected.
! CAUTION
Avoid injury or product damage. Obstructions, such as braces and wiring, may be unseen when
looking at the front of the dashboard. Before drilling or cutting any holes in the dashboard, check
the area behind the dashboard for obstructions. Do not drill or cut when obstructions are present.
2. Select a location for the Start/Stop Panel on the dashboard that meets the following
requirements:
• Unobstructed access behind the dashboard.
• Within harness length limits.
• With enough clearance between the components to install bezels, if equipped.
3. If the dashboard is fiberglass, prevent the dashboard from cracking by applying masking tape
to the area that is to be drilled or cut.
4. If the dashboard is vinyl covered, keep the vinyl from tearing by removing the vinyl from the
area to be drilled or cut.
Page 42 / 70 90-866927070 SEPTEMBER 2007

Installation
1. Using the dimensions below, cut or drill a 54 mm (2‑1/8 in.) diameter hole through the
dashboard at the selected location.
2 -1/8 in.
(54mm)
4316
2. Insert the Start/Stop Panel electrical connector, wiring, and Start/Stop Panel housing through
the dash opening.
b
31096
Behind the dashboard or panel

a - Port connector
b - Starboard connector
c - Back of switch housing
NOTE: The ring mounting nut is threaded so that it can be installed to fit a thick or thin dashboard.
3. Install the ring mounting nut so that most threads are engaged when threaded onto the key
switch housing. The amount of engaged threads will depend on the thickness of the dash.
4. Position the Start/Stop Panel in the correct orientation on the dash.
NOTE: The ring mounting nut must be tight so the assembly will not rotate during use.
5. Tighten the ring mounting nut securely.
6. Connect the Start/Stop Panel electrical connectors to the respective "START/STOP"
connections on the helm harness.
Precision Pilot Track Pad

Using the Precision Pilot Track Pad, the operator is able to use waypoints, tracking along a desired
path and the boat will navigate itself along this path. Skyhook is another feature of the Precision
Pilot Track Pad.
90-866927070 SEPTEMBER 2007 Page 43 / 70

Installation with Supplied Nut

NOTE: There are two different ways to secure the Precision Pilot Track Pad assembly to the helm.
With the nut supplied with the kit, or with four screws (not supplied with this kit). For helms with a
thickness below 5 mm (0.197 in.), secure the Precision Pilot Track Pad with four screws. Review
the installation instructions to determine which mounting is best suited for your application.
1. Use the dimensions provided to identify a suitable location for the Precision Pilot Track Pad.
Ensure the area behind the selected location is clear of obstructions and wires.
2. Using the dimension provided, mark and drill the 54mm center mounting hole.
3. Install the gasket onto the Precision Pilot Track Pad assembly.
4. Insert the assembly into the helm cutout.
5. Ensure the Precision Pilot Track Pad is correctly orientated. Thread the supplied nut onto the
assembly and tighten the nut securely.
6. Install the bezel cover onto the Precision Pilot Track Pad. The bezel cover will snap into place.
7. Connect the Precision Pilot Track Pad connector to the Standard Junction Box.
b
c
31098
Template not to scale

a - 54 mm (2.125 in.)54mm Center Hole
b - 5.2 mm (0.2 in.) Mounting Hole (x4)
c - Bezel Cover Locating Hole
Installation with Four Mounting Screws

1. Use the provided dimensions to identify a suitable location for the Precision Pilot Track Pad
assembly. Ensure the area behind the selected location is clear of obstructions and wires.
2. Mark the center location of the 63.5 mm (2.5 in.) hole onto the helm with a marker or awl. Mark
the center location of the four mounting screws onto the helm with a marker or awl.
NOTE: The four mounting screws are not included with this kit. Use an appropriate size drill bit for
the mounting hardware used.
3. Drill out the 63.5 mm (2.5 in.) hole with a hole saw.
4. Drill the four mounting screw holes with an appropriate size drill bit for the mounting hardware
used.
Page 44 / 70 90-866927070 SEPTEMBER 2007

NOTE: Do not use screws with a diameter greater than 5 mm.

5. Install the gasket onto the Precision Pilot Track Pad assembly.
6. Insert the assembly into the helm cutout.
7. Ensure the Precision Pilot Track Pad is correctly orientated. Align the screw holes and secure
the assembly to the helm with four screws. Do not over torque the screws. Do not use screws
with a diameter larger than 5mm.
8. Install the bezel cover onto the assembly. The bezel cover will snap into position.
31100
9. Connect the Precision Pilot Track Pad connector to the Standard Junction Box.
Guidance Equipment Installation

Inertial Measurement Unit (IMU)
The Inertial Measurement Unit (IMU) is a solid state, rate gyro electronic compass that detects the
direction of the earth’s magnetic field using solid state magnetometers and indicates the vessel
heading relative to magnetic north. Additionally, solid state accelerometers and angular rate
sensors indicate the vessel’s attitude and rate of turn.
31110
IMU MOUNTING CONSIDERATIONS

The selection of a suitable mounting location is important for the optimal performance of the IMU.
The mounting location and orientation of the IMU should be:
• Level with the earth’s horizontal plane – Although the IMU can be calibrated in the vessel
to compensate for pitch and roll installation‑offset, it is best to mount the compass as level as
possible to maximize its pitch and roll operational range.
• Oriented with arrow pointing to bow parallel to vessel centerline – Although the IMU can
be calibrated in the vessel to compensate for heading installation‑offset, it is best to mount
the compass pointed towards the bow and parallel to the vessel centerline. The unit can be
mounted in other orientations, although this requires additional configuration step.
90-866927070 SEPTEMBER 2007 Page 45 / 70

• Near the Center of Gravity (CG) of the vessel – The compass experiences the least amount
of movement when located at the CG, which allows the most accurate readings. This is similar
to a traditional card/needle compass, where the farther the compass is from the CG, the more
the fluid sloshes around, making accurate readings more difficult.
• Away from structures containing ferrous metals – The earth’s lines of magnetic flux tend
to become distorted in the vicinity of ferrous metals, which can potentially cause errors in the
compass’s indicated heading. The IMU can be calibrated to compensate for these errors, but
it is best to minimize the errors by placing the compass as far from ferrous metals as practical.
• Away from magnetic field sources – Power or ignition cables, electric motors, and other
electronic equipment can create magnetic fields. The earth’s lines of magnetic flux tend to
become distorted in the vicinity of magnetic fields sources, which can potentially cause errors
in the compass’s indicated heading. The magnetic fields tend to come and go as power is
switched on and off, which makes compensation impractical. Therefore, you should try to
mount the IMU as far away as possible from these magnetic field sources (doubling the
distance between the magnetic field source and the compass will reduce the field strength by
a factor of approximately 8).
• Minimal vibration – Although the IMU is more tolerant of vibration than a fluxgate compass,
it is best to mount the compass in a location free of vibration as opposed to a location with
vibration.
INSTALLATION
NOTE: The IMU must be calibrated for proper functioning. Refer to the installation instructions
included with the unit.
The IMU can be mounted to a horizontal surface such as a floor or a deck, or it can be mounted
to a vertical surface such as a wall or bulkhead.
HORIZONTAL SURFACE
The usual way of mounting the IMU to a horizontal surface is to mount it to the top of the surface;
however, it may be mounted upside down to the underside of a surface provided that the IMU is
programmed to recognize that it is mounted this way.
1. Using the dimensions provided, mark and drill the holes necessary to mount the IMU to a
horizontal surface.
98.3mm
(3.97 in.)
36.1mm
(1.4 in.) a
b c 31111
Template is not to scale

a - Bow of boat
b - 5 Pin SmartCraft
c - 9 Pin NMEA 0183
2. Attach the mounting brackets to the bottom of the IMU using the provided brass flat head
screws. Do not over torque.
Page 46 / 70 90-866927070 SEPTEMBER 2007

3. Attach the IMU to the horizontal surface using the four mounting screws provided with the unit.
31112
a- Mounting screws
b- IMU
c- Mounting brackets
d- Brass flat head screws
4. Connect the Navigation System Extension Harness to the IMU 5 pin connector.
VERTICAL SURFACE
The usual way of mounting the IMU to a vertical surface is attaching the unit to the forward side
of a vertical surface, so that the side of the compass with the connectors is facing the bow of the
boat; however, it may be mounted to the astern side of a vertical surface, so the side of the
compass with the connectors is facing the stern of the boat, provided that the IMU is programmed
to recognize that it is mounted in this way.
1. Using the dimensions provided, mark and drill the holes necessary to mount the IMU to a
vertical surface.
31113
Template is not to scale

2. Attach the mounting brackets to the side of the IMU using the provided brass flat head screws.
90-866927070 SEPTEMBER 2007 Page 47 / 70

3. Attach the IMU to the vertical surface using the four mounting screws provided with the unit.
Refer to the figure below. Do not over torque the mounting screws.
a
b
c
d
31114
a- Brass flat head screws

b- Mounting brackets
c- Mounting screws
d- IMU
Global Positioning Sensor (GPS)

Global Positioning Sensor (GPS) is a device that provides the location, speed, and direction of the
vessel.
GPS MOUNTING CONSIDERATIONS
The selection of a suitable mounting location is important for the optimal performance of the GPS
unit. The mounting location and orientation of the GPS should be:
1. Level with the earth’s horizontal plane – This gives the GPS antenna the optimal view of
satellites from all directions.
2. High enough to have a clear view of the sky to the horizon in all directions unblocked by masts
or antennas – The GPS provides the best readings when it has access to as many satellites
as possible.
3. As far as possible from VHF, satellite, or radar antennas – Radio frequency transmissions
from these antennas can interfere with the proper reception of the GPS satellite signals.
INSTALLATION
The GPS antenna should be located in clear view of the sky. Hardtop or radar arch mounting is
typical. The antenna can be mounted either flush to the surface or on a 25.4 mm (1.0 in.) 14 threads
per inch standard marine pole mount.
Page 48 / 70 90-866927070 SEPTEMBER 2007

HORIZONTAL SURFACE
1. Using the dimensions provided, mark and drill the necessary holes for mounting the GPS to
a horizontal surface.
a
b
31115
View from bottom. Template is not to scale

a - Connector for harness
b - Holes for fasteners (3×)
2. Attach the GPS to the horizontal surface using the included brass mounting screws and lock
washers.
b
c
d
e
31116
a - GPS antenna d - Screw

b - 25.4 mm (1 in.) hole e - Harness
c - Washer
MARINE POLE MOUNT

1. Screw the included GPS antenna mount base to the standard marine mount pole.
2. Thread the Navigation System Extension Harness through the standard marine mount and
the antenna mount base from the bottom to the top.
3. Connect the Navigation System Extension Harness to the GPS connector.
90-866927070 SEPTEMBER 2007 Page 49 / 70

4. Attach the GPS to the antenna mount base using the included brass mounting screws and
lock washers.
a
b
c
d
e
f
31118
a - GPS Antenna d - Lock washer

b - Harness e - Screw
c - Bracket f - Pole
NAVIGATION SYSTEM EXTENSION HARNESS

The Navigation System Extension Harness allows the Navigation System components such as
the GPS and IMU to be mounted in remote locations with regards to the helm harness.
Extension harnesses for the IMU and GPS are available from CMD.
31700
Navigation system extension harness

INSTALLATION
IMPORTANT: Observe the following guidelines:
• Do not route harness near sharp edges, hot surfaces, or moving parts. Fasten cables away
from and sharp edges, fasteners, or objects that could wear into the harness.
• Avoid sharp bends in the harness.
• Fasten and support the harness with clamps or cable ties along the routing path at least every
45.7 cm (18 in.).
• Do not modify harness.
• Hand‑tighten barrel nut connectors.
IMU CONNECTION
NOTE: The Navigation System Extension Harness comes in three lengths. The shortest length is
intended for the IMU. The other two are used for the GPS. The Navigation System Extension
Harnesses used for the GPS can be "daisy chained" together to form a longer length.
Page 50 / 70 90-866927070 SEPTEMBER 2007

Connect the Navigation System Extension Harness to the 5 pin circular connector on the IMU.
The other end of the Navigation System Extension Harness will connect to the Navigation System
Y‑Harness.
31119
IMU 5 pin connection

GPS CONNECTION
Connect the Navigation System Extension Harness to the 5 pin circular connector on the GPS.
The other end of the Navigation System Extension Harness will connect to the Navigation System
Y‑Harness.
b
31122
a - Screw mounting holes b - 5 pin connection
Navigation System Y‑Harness

The Navigation System Y‑Harness connects the IMU and the GPS to the SmartCraft Network,
through a standard junction box. This allows the data from the guidance components to be read
by the control system.
31123
INSTALLATION
1. Connect one end of the Navigation System Y‑Harness to the Navigation System Extension
Harness going to the IMU.
2. Connect the other end of the Navigation System Y‑Harness to the Navigation System
Extension Harness going to the GPS.
3. Connect the 10 pin connector on the Navigation System Y‑Harness to the Standard Junction
Box.
90-866927070 SEPTEMBER 2007 Page 51 / 70

E‑Stop Switch
The E‑Stop Switch offers a redundant emergency shutdown method if the key switch fails. The
E‑Stop Switch is mounted at the helm, and connects to the helm harness. The switch itself is a
normally open, single‑pole single‑throw rocker switch.
31992
Installation
INSTALLATION RECOMMENDATIONS:
Install the E‑stop switch in a place that is easy to access, but where it will not be accidentally
activated.
1. Install the E‑Stop switch in the dash using the dimensions provided below.
36.83 mm
(1.45 in.)
21.08mm
(0.83 in.)
31994
2. Connect the 2‑pin connector on the E‑Stop Switch harness labeled "STBD HELM" to the
connector on the helm harness labeled "STBD E‑STOP."
3. Connect the 2‑pin connector on the E‑Stop Switch harness labeled "PORT" to the connector
on the helm harness labeled "PORT E‑STOP."
Starboard Helm Clean Power Harness

The Starboard Helm Clean Power Harness provides clean battery power for the main power relay
on the Helm Harness.
31276
Starboard Helm Clean Power Harness
Page 52 / 70 90-866927070 SEPTEMBER 2007

Installation
NOTE: The Starboard Helm Clean Power Harness is not terminated on the battery end and no
circuit protection is provided. It is up to the OEM to provide the necessary terminals for connecting
the harness to the battery, and adding an in‑line 20 amp fuse or circuit breaker to the positive side.
1. Install a 20 amp circuit protection device in the positive side of the Starboard Helm Clean
Power Harness, close to the battery terminal.
2. Install the appropriate wire terminals to the ends of the Starboard Helm Clean Power Harness.
3. Find the connector on the Helm Harness labeled "Starboard Power Disconnect". If this
connector is plugged into another connector on the helm harness disconnect the connectors.
4. Connect the Starboard Clean Power Harness to the Helm Harness connector labeled "STBD
ECU Main Power Disconnect". Place a weather cap on the connector labeled "STBD 14‑Pin
Main Power Disconnect."
5. Connect the positive side of the Starboard Helm Clean Power Harness to the load side of a
battery switch or terminal strip connected to the positive side of the battery.
6. Connect the negative side of the Starboard Helm Clean Power Harness to a negative (–)
terminal strip or bus bar connected to the negative side of the battery.
VesselView Installation
VesselView
Refer to the installation manual provided with the product for installation requirements and
instructions.
VesselView Harness Connection
1. Connect the the VesselView harness to the starboard display connector on the Smart J‑box.
See Wiring Connections for diagrams.
2. Connect the VesselView harness to the VesselView unit.
3. VesselView harness assembly has an 8‑plug connector that plugs into the "VesselView
Multi‑Ignition" port.
4. If the back of the VesselView is hard to get to, the USB extension harness can be used.
a. Remove and retain the USB (universal serial bus) port cover.
b. Connect the USB extension harness to the appropriate port on the back of the
VesselView display. Mount the other end so that it can be accessed from the dashboard.
c. Use the USB cover from the back of the VesselView display to cover the USB port.
5. Ensure that the VesselView unit receives power when any key switch is in the "ON" position.
CAN V Components
CAN V Genset Adaptor Harness
The CAN V Genset Adaptor Harness interfaces with SmartCraft compatible generator sets, and
allows generator data to be broadcast over the CAN V data bus. The CAN Adaptor Harness is
required on SmartCraft version 1 Onan e‑QD generator sets.
INSTALLATION
1. Attach the connector with the label "To Genset" to the generator. Ensure connector is fully
seated.
2. The connector labeled "To Ext Harn" will either attach to the CAN V Termination Harness, or
to the CAN V Extension Harness.
3. Connect +12V key switch, or enable, supply to the wake signal input on the adaptor harness.
90-866927070 SEPTEMBER 2007 Page 53 / 70

CAN V Termination Harness

The CAN V Termination Harness provides a termination resistor for one end of the CAN V data
bus. A termination resistor is required at each end of the CAN V data bus to ensure proper
communication.
31133
CAN V termination harness

INSTALLATION OF THE CAN V DEVICE
NOTE: If this is a SmartCarft Version 1 Onan generator set, the CAN V Adaptor Harness will be
installed. Connect the CAN V Termination Harness female connector to the CAN V Adaptor
Harness labeled "To Ext Harn".
If this is the last device on the CAN V data bus, plug the CAN V device into the CAN V Termination
Harness. If not, then plug into the CAN V Extension Harness (covered next).
CAN V TERMINATOR
The CAN V Terminator is a short 2‑wire harness that contains a termination resistor for CAN V.
SMART JUNCTION BOX
Connect the CAN V Termination Harness female connector to the Smart Junction Box connector
labeled "CAN V".
CAN V Extension Harness
The CAN V Extension Harness extends the CAN V data bus beyond the Smart Junction Box to a
SmartCraft compatible CAN V device. The CAN V Extension Harness connects between the CAN
V Termination Harnesses, located on each end of the CAN V bus.
31135
1. Connect the connector labeled "To Terminator Harness" to the CAN V Termination Harness
connector labeled "CAN V Extension Harness". Ensure connectors are fully seated.
2. Route the CAN V Extension Harness to the Smart Junction Box, at the helm.
3. Connect the connector labeled "To J‑Box" to the CAN V Termination Harness connector
labeled "CAN V Extension Harness".
Page 54 / 70 90-866927070 SEPTEMBER 2007

Pre‑Calibration Requirements
Several actions need to be taken before initial power‑up and calibration to avoid damage to the
engines or equipment, and to avoid improper calibration. Carefully complete these steps before
starting calibration.
1. Align both drives to the straight back position. Use the drive‑to‑drive parallelism alignment
tool, if available, or the steps for initial alignment as described in the drive alignment procedure
in this section of the manual.
2. Align the steering wheel to the straight forward position. Use the steps for initial alignment as
described in the steering wheel alignment procedure in this section of the manual.
3. Check all the fluid levels. Additional mounting and operation information is available in the
installation manuals provided with each component.
4. Prime the fuel in all engines including the generator, if equipped. Refer to the appropriate
installation and owners manuals for the proper priming procedure.
5. Open the appropriate seacocks or have adequate cooling water available before starting each
engine.
Initial Configuration of VesselView and Steering

Initial VesselView Configuration
START-UP
The first time VesselView is started, a wizard will guide you through the initial set‑up of the unit.
To begin the wizard, key on all connected engines, and then press the RIGHT arrow on
VesselView. For more information on the calibration process, refer to the VesselView Installation
and Operators Manual, provided with the unit.
ENGINE SETUP
Select the type of engine.
1. To select the type of engine, press the Select button to allow access to the engine type box.
2. Wait until an engine type appears.
3. Press the LEFT or RIGHT arrows to scroll through available engine types.
4. Select Diesel Inboard–no troll.
5. To confirm your selection, press the ✔ button.
NUMBER OF ENGINES
Select the number of engines
1. Press the DOWN arrow on the arrow trackpad to select the Number of Engines box.
2. Press the Select button to access the box.
3. Press the LEFT or RIGHT arrows to change from 1(the default). Select the number of engines
as Two (2).
4. To confirm your selection, press the ✔ button. Press the RIGHT arrow to continue.
HOW ENGINES ARE DISPLAYED
Configure how engines are displayed on VesselView. Typically, the engines are displayed left to
right in the same order as their physical locations, port to starboard.
1. On the Display Setup screen, press the Select button to access options.
2. Choose where to display for each engine configuration
3. Press the ✔ button to confirm your selection
4. Press the RIGHT arrow to continue.
90-866927070 SEPTEMBER 2007 Page 55 / 70

VESSELVIEW DEVICE SETUP

A typical VesselView installation is one VesselView unit per helm. Each VesselView has a unique
identification, which differentiates the VesselView unit from all other installed SmartCraft items
such as other VesselView units, generator sets, or SmartCraft gauges. If VesselView is the only
SmartCraft item installed, leave the unique VesselView identification at 1.
NOTE: If a SmartCraft speedometer and tachometer are used along with the VesselView, the
VesselView's unique ID will have to be changed to a number other than one, or VesselView will
collide data with the gauges.
The helm identification identifies whether the VesselView is at the primary (1) or secondary (2)
unit.
Go back with the LEFT arrow to change the setting.
When finished, select the Saving Settings Box and restart.
To make a a correction after restarting, return to the VesselConfig:
1. Press Menu
2. Press Menu
3. Select Calibrate VesselConfig to redo the Wizard settings
CALIBRATING TANKS
1. Press Menu
2. Press Menu
3. Select Calibrate
4. Select Tanks
5.
Choose which engine
6.
Choose which tank
7.
Press ✔
8.
Choose type of tank
9.
Enter size of tank (holding the arrow down increases speed)
10.
Choose location (defaults to S1) S1, S2, S3, PF (port forward), PA (port aft), CF(center
forward), CA, (center aft) etc. (will display proper tank depending on engine & tank)
11. Press ✔
12. Select calibration method. (Default assumes square tank)
MANUAL CALIBRATION (FUEL TANKS ONLY)
Manual calibration of the fuel tanks is recommended for best accuracy.
1. Confirm tank is empty. Press ✔.
2. Screen will prompt to fill to 25%. For example of a tank with 100 gallons capacity, add 25
gallons. Press ✔.
3. Screen will prompt to fill to 50%. For example of a tank with 100 gallons capacity, add 25 more
gallons for a total of 50 gallons. Press ✔.
4. Screen will prompt to fill to 75%. For example of a tank with 100 gallons capacity, add 25 more
gallons for a total of 75 gallons. Press ✔.
5. Finish adding to 100%. Press ✔. (Note: If tank sender is nonstandard, go to Settings>Offsets
and set tank offset.)
GENERATOR
VesselView automatically detects the generator manufacturer. VesselView supports Kohler and
Onan. It will not display either logo by default. When generator data is detected on the bus, the
logo will appear.
NOTE: Kohler does not have an oil pressure sensor, so the oil pressure box is not filled with data.
The box displays a dash. Onan does have a sensor for oil pressure and does display data in the
OP box.
Diesel P1 will display fuel flow instead of water pressure
Page 56 / 70 90-866927070 SEPTEMBER 2007

ENVIRONMENT OR DEPTH ALARM

In Environment, depths under 100 ft. show three digits with a decimal. Depths over 100 ft show
no decimal.
TROLL LIMITS
To set Troll Limits
1. Put the engine in gear and at idle.
2. Choose the parameter to edit.
3. Use RIGHT and LEFT arrows to adjust troll.
CRUISE LIMITS
RPM, Status (off or enabled), speed, RPM set point are controlled through the screen. Adjust
during use, if necessary.
Engine will not exceed the RPM set point while enabled. Cruise Control allows you to set a
maximum RPM level for your vessel to maintain while Cruise Control is engaged and the remote
control is set at WOT.
If your VesselView unit is equipped with a Cruise option, follow these steps to set a maximum
cruising RPM.
1. Open the Cruise screen to display current RPM, cruise status, speed, and the RPM set point.
2. Press the < or > button to edit the RPM set point to the desired level.
3. Select Enabled to set Cruise Control.
4. Move the remote control to the WOT position. The vessel will not exceed the RPM set point
while cruise in enabled. You may adjust the RPM set point up or down by using the < or >
button.
FACTORY RESET
Reset the Setting Directory
Reset the sensor to add or remove a component, or to reset a sensor.
Vessel Configuration
Initial Out of the Water Drive Alignment
This procedure sets the drives parallel to each other and approximately true to the boat.
1. Remove the rear propellers, if installed. Refer to Propellers.
2. Hand‑thread a drive alignment tool onto the port and starboard drive inner (rear) propeller
shaft until the tool is snug against the propeller shaft thrust surface.

Drive alignment tool 8M0029055
3. Rotate the tools and propeller shafts until the tools are horizontal and the roll pins on the drive
alignment tools are below the propeller shafts.
90-866927070 SEPTEMBER 2007 Page 57 / 70

4. Place a locally obtained straight edge (or carpenter's level) between the drives and on top of
the roll pins.
c
a
b
28032
a - Drive alignment tool c - Straight edge

b - Pins
5. At the helm, turn the port and starboard key switches to the on position. Do not start the
engines.
6. Select the VesselView screen — Manual Drive Alignment
7. Follow the directions on the screen to unlock the drives.
29754
8. From under the boat, rotate the drives by hand until the the straight edge contacts squarely
(is parallel) along the 152 mm (6 in.) long alignment surface of both of the tools.
c
a
28033
Port drive shown, same at starboard
a - Tool alignment surface c - Parallel
b - Straight edge
9. After the straight edge is parallel and square against both tools, the drives should now be
aligned perpendicular to the boat and parallel with each other.
Page 58 / 70 90-866927070 SEPTEMBER 2007

10. Return to the helm and set the VesselView selection to "Locked."
11. Turn the port and starboard key switches to the OFF position.
12. Remove the straight edge and drive alignment tools from the prop shafts and install the
propellers. Refer to Propellers.
IMPORTANT: After the alignment procedures are completed and during the initial sea trials with
the boat underway, the boat should be operated on a straight course and the software activated
to set the steering wheel to the straight ahead position.
Vessel Configuration (VesselConfig)
VesselConfig is a separate application designed to allow calibration of the Zeus modules and
drives from the VesselView display. This function will reside within VesselView for the purpose of
calibrating the drives and controls. Access to this function is limited to trained technicians.
The technician should get the special key sequence from their application engineer or service
manager so that they can calibrate the controls.
Accessing VesselConfig
1. Press and hold the top two buttons ( "✔, "X") and the bottom two buttons ("Brightness/Alarm",
"Menu") for a period of about 10 seconds.
2. Select VesselConfig and press the check (" ✔") button.
32001
3. Upon selecting VesselConfig, the VesselView display will restart into vessel configuration
mode.
90-866927070 SEPTEMBER 2007 Page 59 / 70

Main Menu
The Main Menu contains four calibration options.
a
b
c
d
e
29749
Figure 1
a- Vessel Personality List
b- Factory Configuration
c- Sea Trial
d- Vessel Calibration (not available at this time)
e- Import/Export
Vessel Calibration is not available at this time.

Use the cursor button to highlight the desired function and press ✔ to select.
• Select Vessel Personality List to check the modules and their respective software levels.
Software that does not match will be highlighted in red.
• Select Factory Configuration to configure the steering wheel and ERC levers, and to unlock
the drives for alignment.
• Select Sea Trial to realign the drive while on the water.
• Ignore Vessel Calibration. It is not used at this time.
• Select Import/Export to download settings directly into the boat, (for example, if a boat with
the same attributes was calibrated before and the settings were saved.)
Go to the respective procedure in this section for additional information and instructions on each
selection. To return to the Main Menu from any submenu, press the X key.
Page 60 / 70 90-866927070 SEPTEMBER 2007

VESSEL PERSONALITY LIST

Selecting Vessel Personality List from the Main Menu will open the Vessel Personality List
submenu. The Vessel Personality List identifies each module and its respective software level.
Modules that are not compatible are highlighted in red.
a b
31376
a - List of modules
b - Module software level
c - Incompatible modules (Indicated by the color red)
1. Verify that the latest software is being used in each module, and that the software is compatible
with each other. Contact your CMD Applications Engineer if any are not compatible.
FACTORY CONFIGURATION
Selecting the Factory Configuration selection from the Main Menu will open to the Factory
Configuration submenu.
The submenu has four available options.
a
b
c
d
e
31363
Factory Configuration submenu

a- Lever Configuration
b- Steering Configuration
c- Manual Drive Alignment
d- Unlock Feature Upgrade
e- Calibrate Maretron Compass
90-866927070 SEPTEMBER 2007 Page 61 / 70

Lever Configuration: Configures and calibrates the Zeus DTS electronic remote controls.
1. On the Lever Adapt screen, set the number of engines as 2.
2. Input the helm number. The main helm is recognized as Helm 1.
3. Select the installed lever type in the boat.
4. Confirm Shadow Mode to "NO"
29922
5. Follow the instructions on the screen to calibrate the electronic remote controls.
29752
a - Lever position Indicator
6. If the step fails, a message that the lever calibration has failed will appear.
7. A message will appear to indicate when the calibration has been successfully completed.
Page 62 / 70 90-866927070 SEPTEMBER 2007

Steering Wheel Configuration: Allows the technician to modify and store the straight ahead
forward position of the electronic steering wheel.
29753
1. Follow the instructions on the screen to calibrate the straight ahead forward position of the
steering wheel.
2. A pop‑up menu will appear if a step fails.
3. A pop‑up will appear when the calibration has been successfully completed.
Manual Drive Alignment: Unlocks the drives so the OEM can manually align the drives.
29754
1. The keys need to be ON throughout this procedure.

2. Follow the instructions on the screen to align the drives using the special alignment tool, as
described in Initial Out of Water Drive Alignment found later in this section.
3. When completed, re‑lock the drives to store the new drive adjustments to memory.
4. A pop‑up will appear when the process has been successfully completed and saved.
Unlock Feature Upgrades: allows the technician to add features (for example, Skyhook
purchased separately) to the VesselView product.
UNLOCK FEATURE UPGRADES
Selecting the Unlock Feature Upgrades selection from the Main Menu will open the Unlock
Feature Upgrades submenu. This menu allows the technician to add features that are purchased
separately (like Skyhook) to the VesselView display.
90-866927070 SEPTEMBER 2007 Page 63 / 70

NOTE: A 40‑character E‑Key is required to activate any optional feature upgrades.
32002
1. Press the check (" ✔") button to enter the 40‑character E‑key activation code.
32003
Sample E‑Key entry

2. After inputting the E‑Key, scroll to the "done" option on the screen and press the check (" ✔")
button.
3. The successful completion of an upgrade will be indicated.
CALIBRATE MARETRON COMPASS
Selecting the Calibrate Maretron Compass selection from the Main Menu will open the Calibrate
Maretron Compass submenu. This menu allows the technician to configure and calibrate the
electronic compass.
32005
Follow the instructions on the screen to calibrate the electronic compass.
Page 64 / 70 90-866927070 SEPTEMBER 2007

1. Find an open area in calm water.
32005
2. Start turning in slow circles when safe to do so.
32006
3. Mapping the offset correction is part of the compass calibration process.
32008
4. A pop‑up will appear when the calibration has been successfully completed.
LOAD LIBRARIES
Selecting the Load Libraries selection from the Main Menu will open the Load Libraries
submenu. This menu allows the technician to load necessary software libraries into the
VesselConfig Application.
1. From the VesselConfig Main Menu, highlight Load Libraries and press the check(" ✔") button.
90-866927070 SEPTEMBER 2007 Page 65 / 70

2. Follow the instructions on the screen to load libraries. Ensure the library file is in the root
directory of the USB drive. The Library
32009
3. A message will indicated when the libraries have been successfully loaded, and the
VesselView will restart.
32010
SEA TRIAL
Selecting Sea Trial from the Main Menu will navigate the user to the Sea Trail submenu.
The boat needs to be in a clear area of water, free of obstacles and other boats, and where the
water and wind are calm.
a
b
29755
a - Drive Initialization
b - Drive Alignment
Drive Initialization: Selecting Drive Initialization starts an automatic sequence that calibrates the
drives and tabs to their factory default positions.
Page 66 / 70 90-866927070 SEPTEMBER 2007

Drive Alignment: Selecting Drive Alignment starts an automatic sequence that calibrates the
drives to track straight, taking into account individual hull characteristics.
DRIVE INITIALIZATION
1. Use the cursor button to highlight Drive Initialization, and press ✔ to select.
2. Follow the instructions on the screen to restore the drives to their original alignment.
3. Stand clear of drives if boat is out of the water, as drives will be moving. A warning will appear
on the screen.
4. A pop‑up will appear at the end of the procedure indicating whether the process was
successful or not.
DRIVE ALIGNMENT
1. Use the cursor button to highlight Drive Alignment, and press ✔ to select.
2. Follow the instructions on the screen to calibrate the drives to track straight, taking into account
individual hull characteristics.
31356
3. Drive Alignment must be done while underway in an open area with little wind and calm water.
31358
90-866927070 SEPTEMBER 2007 Page 67 / 70

4. Use the left and right buttons to adjust the direction of travel until the boat runs straight. Record
the results for future reference.
b c
31359
Alignment reference number_________________

a - Reference number c - Right turn button
b - Left turn button
5. Save and close alignment screen.
31357
IMPORT/EXPORT
Import/Export allows the technician who is going to have to configure several boats with identical
attributes, or "personality," to save the personality from one boat, once it has been calibrated
(Export), and install them on others (Import), bypassing much of the configuration process.
When exporting the file, the record is initially saved as "vesselconfig" and the day's date. (Example:
vesselconfig5_15_07.xxx)
The technician then needs to rename the file on another PC before importing it to the next boat.
This is done in the same manner as changing the name of any file on the computer or drive.
Page 68 / 70 90-866927070 SEPTEMBER 2007

The file needs be renamed to fit the boat's personality. (For example, Boat1_45Conv_2008.xxx
for a 45 ft convertible built in 2008). When the file is imported to subsequent boats, the name of
the file will appear on the Vessel Personality List. The new name will help the technician know if
the correct personality was loaded.
a
b
c
31366
a - Import
b - Export
c - Load Libraries
a
b
29803
a - Import
b - Export
1. From the VesselConfig Main Menu, (Figure 1) highlight Import/Export and press ✔.
2. Connect a memory device (computer, thumb drive, etc.) to the USB port on the back of the
VesselView unit.
3. Highlight Import or Export, as appropriate, and press ✔.
4. A pop‑up will appear at the end of the procedure.
90-866927070 SEPTEMBER 2007 Page 69 / 70

NOTES:
Page 70 / 70 90-866927070 SEPTEMBER 2007

SECTION - 7 PREDELIVERY PREPARATION AND STORAGE
SECTION 7 - PREDELIVERY PREPARATION AND

STORAGE
Table of Contents
Predelivery Preparation........................................................................................................................................... 2
Coolant Level....................................................................................................................................................2
Drive Gear Lube...................................................................................................................................................... 2
Checking...........................................................................................................................................................3
Filling.................................................................................................................................................................4
Transmission Fluid.................................................................................................................................................. 5
Checking...........................................................................................................................................................5
Filling.................................................................................................................................................................7
Steering Actuator and Trim Fluid............................................................................................................................. 8
Checking...........................................................................................................................................................8
Data System Wiring................................................................................................................................................. 9
Data Cable ....................................................................................................................................................... 9
Smart Junction box ........................................................................................................................................... 9
Non‑Mercury Supplied Ignition Key Switch ...................................................................................................... 9
VesselView Harness ........................................................................................................................................ 9
Propeller Installation.............................................................................................................................................. 10
Battery Connections.............................................................................................................................................. 12
Operational Tests.................................................................................................................................................. 14
Operational Tests of the Engine and Drive.....................................................................................................14
Preparation .............................................................................................................................................. 14 7
System Calibration ................................................................................................................................... 15
Operation Test ......................................................................................................................................... 15
Steering Wheel Operational Tests..................................................................................................................16
Boat in the Water Tests...................................................................................................................................16
Wide Open Throttle Test .......................................................................................................................... 16
Dual‑Handle Electronic Remote Control (ERC) with DTS Trackpad Features and Operation........................16
Operation ................................................................................................................................................. 16
Helm Transfer.................................................................................................................................................. 18
Synchronizing Helms Prior To Transfer ................................................................................................... 18
Synchronizing Engines....................................................................................................................................18
Basic Joystick Operation.................................................................................................................................19
Trim Tab System.............................................................................................................................................19
Trim Tab Control Operational Tests................................................................................................................19
Freezing‑Weather Storage and Seasonal Storage............................................................................................... 20
Storage Descriptions.......................................................................................................................................20
Freezing‑Weather Storage Instructions........................................................................................................... 21
Seasonal Storage Instructions........................................................................................................................21
Predelivery Inspection Checklist—Zeus Drive...................................................................................................... 22
90-866927070 SEPTEMBER 2007 Page 1 / 22

PREDELIVERY PREPARATION AND STORAGE SECTION - 7
Lubricant, Sealant, Adhesives

Exposed electrical terminals and
connections
25 Liquid Neoprene 92-25711-3
Exposed electrical terminals and
connections
34 Special Lubricant 101 Propeller shaft splines 92-802865Q02
87 High Performance Gear Lube Gear lube monitor 92-858064K01
94 Anti-Corrosion Grease Propeller shaft splines 92-802867Q 1
95 2-4-C Marine Lubricant with Teflon Propeller shaft splines 92-802859A1
Special Tools
Propeller Nut Tool 91‑805457T 1
Aids in the removal and installation of the front propeller nut.
10677
Predelivery Preparation
NOTICE
Before starting the Predelivery procedures, read this manual thoroughly. If you do not understand
any portion of the manual, contact your local distributor of Cummins MerCruiser Diesel products.
Take the following final steps to prepare the power package for delivery to the customer after the
power package installation is complete. It is the boat manufacturer's responsibility to perform these
procedures or to have the dealer complete these procedures.
Coolant Level
1. Refer to the appropriate QSB or QSC Operation and Maintenance Manual and check the
engine coolant level. Add the specified coolant, if necessary.
Description Where Used Part Number

Fleetguard Compleat with
Fleetguard Part Number: CC2825
DCA4 Closed cooling system
Obtain Locally
2. Recheck the coolant level after the first WOT boat test and add the specified coolant, if
necessary.
Drive Gear Lube

NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment 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 recycling of waste, and
contain and dispose of fluids as required.
Page 2 / 22 90-866927070 SEPTEMBER 2007

Checking
IMPORTANT: The gear lube level in the gear lube monitor rises and falls during drive operation.
Check the gear lube level when the drive is cool and the engine is off.
NOTE: After the drive has been operated and the gear lube is hot, the fluid expands and may be
up to the "MAX OPERATING LEVEL" (hot full line).
To check the drive gear lube with the drive cover installed:
1. Remove the access cover from the drive cover.
2. Remove the cap from the gear lube monitor.
c
b
25878
a - Access cover
b - Cap
c - Gear lube monitor
3. Inspect the gear lube level in the gear lube monitor. The gear lube level should be at the "COLD
FILL LEVEL" (cold full line).
a
c
27837
Shown with drive cover removed
a - Cap
b - "COLD FILL LEVEL" line
c - "MAX OPERATING LEVEL" line
4. If the level is low, see Filling.

5. If the level is correct, install the access cover.
To check the drive gear lube with the drive cover removed:
1. Remove the drive cover. See Removing the Drive Cover.
90-866927070 SEPTEMBER 2007 Page 3 / 22

2. Inspect the gear lube level in the gear lube monitor. The gear lube level should be at the "COLD
FILL LEVEL" (cold full line) when the drive and fluid are cold.
b
a
27853
a - "COLD FILL LEVEL" line
b - Gear lube level
IMPORTANT: If any water is visible at the bottom of the gear lube monitor or appears at the fill
and drain plug hole, or if the gear lube appears discolored, contact your Cummins MerCruiser
Diesel Authorized Repair Facility immediately. Both conditions may indicate a water leak in the
drive.
4. If the level is correct, install the drive cover. See Installing the Drive Cover.
Filling
IMPORTANT: If more than 59 mL (2 fl. oz.) of High Performance Gear Lube is required to fill the
gear lube monitor, a seal may be leaking. Lack of lubrication will damage the drive. Contact your
Cummins MerCruiser Diesel Authorized Repair Facility .
If the gear lube level is below the "COLD FILL LEVEL" line, add the specified gear lube.
1. Remove the cap from the gear lube monitor.
2. Fill the gear lube monitor with the specified gear lube so that the gear lube is level with the
"COLD FILL LEVEL" line (cold full line). Do not overfill.
b
a
27853
Shown with drive cover removed
a - "COLD FILL LEVEL" line
b - Gear lube level

87 High Performance Gear Lube Gear lube monitor 92-858064K01
Page 4 / 22 90-866927070 SEPTEMBER 2007

NOTE: After the drive has been operated and the gear lube is hot, the fluid expands and may be
up to the "MAX OPERATING LEVEL" line (hot full line).
a
c
27837
a - Cap
b - "COLD FILL LEVEL" line
c - "MAX OPERATING LEVEL" line
3. Ensure that the rubber gasket is inside the cap for the gear lube monitor and install the cap.
Do not overtighten.
b
a
27851
a - Gear lube monitor
b - Cap
Transmission Fluid
Checking
You can check the transmission fluid level through the access cover on the drive cover or with the
drive cover removed.
1. If the drive cover is removed, go to step 3.
90-866927070 SEPTEMBER 2007 Page 5 / 22

2. If the drive cover is installed, remove the access cover from the drive cover; then, go to step
3.
a
b
c
25914
a - Access cover
b - Transmission
c - Transmission dipstick
3. Remove the dipstick. Wipe the dipstick with a clean, lint‑free cloth.
4. Insert the dipstick, resting it on the top of the threaded hole.
5. Remove the dipstick and check the fluid level indicated. The fluid level should be between the
maximum and minimum marks on the dipstick.
NOTE: Fluid from the transmission fluid cooler and hoses may drain into the transmission, causing
a fluid level slightly above the maximum mark.
a
c b
28080
Checking—dipstick rested on top of threaded hole
a- Maximum mark
b- Minimum mark
c- Top of threaded hole
d- Dipstick
6. If the level is correct, install the dipstick.

7. If the fluid level is low, add the specified transmission fluid through the dipstick threaded hole
to bring the level up to the maximum mark on the dipstick.
Description Fluid Type Fluid Part Number

Synthetic Power Steering Fluid SAE
Transmission and drop box 92‑858077K01
0W‑30
NOTE: If the transmission fluid level is extremely low, see your local Cummins MerCruiser Diesel
Authorized Repair Facility.
Page 6 / 22 90-866927070 SEPTEMBER 2007

IMPORTANT: For a more accurate measurement, operate the engine at 1500 RPM for three
minutes immediately before checking the fluid level.
8. Start the engine and operate at 1500 RPM for three minutes to fill all the hydraulic circuits.
9. Stop the engine and quickly check the fluid level.
10. If the fluid level is low, add the specified transmission fluid to bring the level up to the maximum
mark on the dipstick.
11. Install the dipstick.
12. Install the access cover onto the drive cover if it was removed.
13. Install the drive cover if it was removed. See Installing the Drive Cover.
Filling
You can fill the transmission with fluid through the access cover on the drive cover or with the drive
cover removed.
1. Remove the drive cover to fill the transmission with the drive cover removed. See Removing
the Drive Cover, then go to step 3.
2. Remove the access cover from the drive cover, if filling with the drive cover installed. Go to
step 3.
3. Remove the dipstick. Wipe the dipstick with a clean, lint‑free cloth. Check the fluid level as
outlined in Checking.
a
b
c
25914
a - Access cover
b - Transmission
c - Transmission dipstick
4. Add the specified transmission fluid through the dipstick threaded hole to bring the level up to
the maximum mark on the dipstick.
Description Fluid Capacity Fluid Type Fluid Part Number

Transmission and drop Synthetic Power
5‑¼ liters (5‑½ quarts)
box Steering Fluid SAE 92‑858077K01
Transmission only 4 liters (4‑¼ quarts) 0W‑30
IMPORTANT: For a more accurate measurement, operate the engine at 1500 RPM for three
minutes immediately before checking the fluid level.
5. Start the engine and operate at 1500 RPM for three minutes to fill all the hydraulic circuits.
6. Stop the engine. Quickly unscrew and remove the dipstick.
90-866927070 SEPTEMBER 2007 Page 7 / 22

7. Check the fluid level as outlined in Checking.
a
c b
28080
a- Maximum mark
b- Minimum mark
c- Top of threaded hole
d- Dipstick
8. If the fluid level is low, add the specified transmission fluid to bring the level up to the maximum
mark on the dipstick.
9. Install the dipstick.
10. Install the access cover onto the drive cover if it was removed.
11. Install the drive cover if it was removed. See Installing the Drive Cover.
Steering Actuator and Trim Fluid

The steering actuator and trim system use a common hydraulic pump and fluid storage reservoir
for the combined lubrication and hydraulic fluid.
Checking
1. Using a clean, lint‑free cloth, wipe the dirt and debris away from the cap and exterior of the
steering actuator and trim fluid reservoir.
2. Remove the cap.
3. Inspect the fluid level, which should be 25 mm (1 in.) below the bottom of the filler neck of the
reservoir.
c d
a
27857
a- Correct fluid level
b- Reservoir
c- Bottom of filler neck
d- Cap
Page 8 / 22 90-866927070 SEPTEMBER 2007

Filling
1. Using a clean, lint‑free cloth, wipe the dirt and debris away from the cap and exterior of the
steering actuator and trim fluid reservoir.
2. Remove the cap.
3. Fill the reservoir with the specified fluid until the fluid is 25 mm (1 in.) below the bottom of the
filler neck of the reservoir. Do not overfill.
4. Install the cap.
c d
a
27857
a- Correct fluid level
b- Reservoir
c- Bottom of filler neck
d- Cap
Description Fluid Capacity Fluid Type Fluid Part Number

Steering actuator and
Synthetic Power
trim system 5‑3/4 to 6 liters
Steering Fluid SAE 92‑858077K01
(approximate total (6 to 6‑1/3 quarts)
0W‑30
capacity)
Data System Wiring

Data Cable
1. Verify that the data harness has a terminator/resistor connected at the engine end.
2. Verify that the data harness is not routed near sharp edges, hot surfaces or moving parts.
3. Verify that the data harness is not routed near ignition components (coils, spark plugs, spark
plug leads.
4. Verify that the harness is fastened and supported along the routing path.
Smart Junction box

1. Verify that all connectors are locked in their receptacle.
2. Check to make sure are harness connections are fastened within 25.4 cm (10 in.) of the
junction box.
3. Verify that all not used receptacles are covered with a weather cap (859318T‑2).
Non‑Mercury Supplied Ignition Key Switch

1. If a non‑Mercury Marine ignition key switch in used, check with the manufacturer to verify that
it passes the ingress protection testing per IEC IP66 specification minimum. Ignition switches
must pass this specification.
VesselView Harness
1. Verify that all connectors are properly inserted and locked in their receptacles (remote control,
key switch, VesselView, air temperature sensor, lanyard stop switch and junction box.
90-866927070 SEPTEMBER 2007 Page 9 / 22

2. Verify that the harness to the remote control handle has unobstructed freedom of movement
during control handle movement (full forward and full reverse).
3. Verify that the lanyard switch is wired into the system correctly.
4. Verify that all engine battery cables are connected to the correct terminals.
5. Verify that the power harness leads are connected to the starting battery.
6. Verify that the harness is fastened along the routing path.
Propeller Installation
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water
with a propeller installed. Before installing or removing a propeller, remove the key from the key
switch, place the drive in neutral, and engage the E‑stop switch to prevent the engine from
starting.
1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.
NOTE: Anti‑corrosion grease is for saltwater applications only.

34 Special Lubricant 101 Propeller shaft splines 92-802865Q02
2-4-C Marine Lubricant with

95 Propeller shaft splines 92-802859A1
Teflon
94 Anti-Corrosion Grease Propeller shaft splines 92-802867Q 1
24029
Lubricating the propeller shaft splines

IMPORTANT: Check that both the front and aft propeller part numbers match for port and
starboard drives.
2. Slide the front thrust hub onto the propeller shaft with the tapered side toward the propeller
hub.
3. Align the splines and place the front propeller on the propeller shaft. The propeller must fit
freely on the propeller shaft splines.
Page 10 / 22 90-866927070 SEPTEMBER 2007

4. Install the front propeller nut.
a
24031
a - Front propeller
b - Nut
5. Place a block of wood between the trim tab and the propeller.
6. Torque the front propeller nut using the propeller nut tool.
c 24035
a - Block of wood
b - Trim tab
c - Propeller nut tool
Propeller Nut Tool 91‑805457T 1

Front propeller nut 136 – 100
7. Check the propeller for rotation. The propeller must not contact the lower drive housing.
NOTE: The drives require an alignment procedure to make them parallel. This procedure must be
performed with the aft propellers either not mounted or removed. Depending upon your
manufacturing processes, you may delay installation of the aft propellers until after the alignment
of the drives. Refer to Section 6—Initial Drive and Steering Wheel Alignment and
Calibration.
8. Slide the rear thrust hub onto the propeller shaft with the tapered side toward the propeller
hub.
9. Align the splines and place the rear propeller on the propeller shaft. The propeller must fit
freely on the propeller shaft splines.
90-866927070 SEPTEMBER 2007 Page 11 / 22

10. Install the rear propeller nut.

11. Place a block of wood between the trim tab and the propeller.
12. Torque the rear propeller nut.
b
a
24037
a - Block of wood
b - Trim tab
f
a
c b
d
e 25876
Zeus drive propeller assembly

a - Front thrust hub d - Rear thrust hub
b - Front propeller e - Rear propeller
c - Front propeller nut f - Rear propeller nut

Rear propeller nut 81 – 60
Battery Connections
1. At the VIP. Attach the connector of the unswitched power harness to the VIP receptacle
labeled "POWER".
2. At the battery, battery bus or battery switch.
a. Connect the unswitched power harness wire (usually red) with the 30 A fuse to positive
(+) terminal.
b. Connect the other wire (usually black) to the negative (–) terminal.
3. At the engine. Attach the connector of the unswitched power harness to the appropriate
engine connector.
4. At the battery, battery bus or battery switch.
Page 12 / 22 90-866927070 SEPTEMBER 2007

a. Connect the unswitched power harness wire (usually red) with the 30 A fuse to positive
(+) terminal.
b. Connect the other wire (usually black) to the negative (–) terminal.
g b
f c
e d
29881
Battery connection shown, similar with battery bus or battery switch connection
a - Unswitched power harness e - Unswitched power harness connector
connector at VIP at engine
b - 30 A fuse f - Negative terminal
c - Positive terminal g - Battery, battery bus bar, or battery
d - 30 A fuse switch connection
5.
IMPORTANT: The power supply for the MerCathode controller wire must be connected directly
to the battery positive (+) terminal. Do not connect it to a switched positive (+) circuit. The
MerCathode system must function continuously for proper corrosion protection.
NOTE: To ensure that the MerCathode system always remains energized in the event that the
battery switch (if equipped) is turned off, the MerCathode system positive (+) battery lead and
negative battery lead should be connected directly to the battery with an in‑line 20A fuse.
6. Remove the cable tie on the bundled harness wires from the MerCathode controller.
7. Connect the ring terminal of the red/purple wire (with the in‑line 20 A fuse) from the
MerCathode controller assembly to the battery positive (+) terminal or using a circuit breaker
to an unswitched positive (+) DC bus bar.
8. Connect the ring terminal of the black wire from the MerCathode controller assembly to the
battery negative (–) terminal or an unswitched negative DC bus bar.
29384
a - Cable tie
b - Bundled wire with ring terminal
c - Positive (+) terminal wire with in‑line 20 A fuse
90-866927070 SEPTEMBER 2007 Page 13 / 22

e f a
d
b
c
29037
a - MerCathode controller d - Anode wire
b - Reference wire e - Positive (+) terminal wire
c - Negative (–) terminal wire f - Continuity wire (–) to bonding stud
9. Apply a thin layer of Quicksilver liquid neoprene sealant to all exposed electrical connections.

Exposed electrical terminals
and connections
10. Connect the backup hydraulic steering pump clean power harnesses from the port and
starboard drive to the appropriate clean power wiring (provided by the OEM and equipped
with 35 A circuit breakers).
11. Refer to the manufacturer's instructions and connect the integrated auxiliary units (such as
the genset, air conditioning, and so on) in the bilge to the appropriate battery.
12. Torque the battery terminal connections.

Battery stud 8–11 71–97 –
13. Apply sealant to the exposed terminals and electrical connections.

Exposed electrical terminals
and connections
Operational Tests
Operational Tests of the Engine and Drive
PREPARATION
NOTE: Refer to appropriate QSB or QSC Operation and Maintenance Manual for engine operating
specifications and engine fluid capacity information. Refer to the appropriate Cummins MerCruiser
Diesel Operation, Maintenance, and Warranty Manual for drive related fluid capacity information.
1. check for the proper installation of cooling system drain plugs, drain valves and hoses.
2. Check the closed cooling system fluid level.
3. Check the engine oil level.
NOTE: The fluid level may be somewhat over the maximum mark, as some of the fluid from the
transmission fluid cooler and hoses may have drained back into the transmission.
4. Verify the following fluids are at the proper level:
• Coolant level
• Steering actuator and trim pump fluid level
• Drive unit gear lube monitor
• Transmission fluid level
Page 14 / 22 90-866927070 SEPTEMBER 2007

SYSTEM CALIBRATION
1. complete the calibration procedures outlined in Section 6 before proceeding to the operational
tests.
2. Test the on‑board electronics and warning systems in accordance with instructions provided
by the manufacturer of the equipment.
OPERATION TEST
1. If the engine and drive are to be tested with the boat out of the water, water must be supplied
to the seawater pickup pump as indicated in the following steps.
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water
with a propeller installed. Before installing or removing a propeller, remove the key from the key
switch, place the drive in neutral, and engage the E‑stop switch to prevent the engine from
starting.
! WARNING
Performing tests with the engine running may cause the propeller to rotate and result in serious
injury or death. Use caution when performing a test that requires the engine running, and remove
the propeller to avoid injury.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the
water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of
the water and without sufficient cooling water supply.
a. Install a flushing attachment to the seawater inlet hose.

b. Connect a hose between the flushing attachment and a water source.
2. If testing the engine and drive with the boat in the water, open the seawater inlet seacock and
ensure a sufficient supply of cooling water to the seawater pickup pump.
3. If testing auxiliary units in the bilge, open the accessory seawater inlet seacock (tested with
the boat in the water) or ensure sufficient cooling water is supplied to the seawater inlet hose
of the auxiliary units (tested with the boat out of the water).
4. Open the seawater outlet seacock.
! WARNING
Leaving the helm unattended while performing tests with the boat in the water may result in loss
of boat control causing serious injury or death. Ensure someone is at the helm at all times, unless
the boat is secured to a dock.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the
water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of
the water and without sufficient cooling water supply.
5. Place the remote control in the neutral, idle position..
6. Refer to the Marine Recreational High Output Propulsion Units QSB and QSC Operation
and Maintenance Manual and start the engine according to the manufacturer's instructions.
7. Watch all gauges for normal readings.
8. Inspect the engine compartment for water, oil, fuel and exhaust leaks.
9. Turn the key switch OFF. Remove the key from the key switch.
90-866927070 SEPTEMBER 2007 Page 15 / 22

10. If the engine does not turn off with the key switch, use the emergency stop switch on the VIP
panel. Identify the problem and correct.
Steering Wheel Operational Tests
With the electrical system is in the on position, the steering wheel should turn freely to the end
stops in both directions. Ensure that the wheel turns and stops as expected in all tilt positions.
1. Observe that the steering wheel turns the drives in the appropriate directions.
a. Out of the water. With the key switch in the on position, observe that the drives turn in
the appropriate direction when the steering wheel is turned.
b. In the water. With the boat properly secured to the dock and the engines operating,
observe that the thrust moves in the appropriate direction when the steering wheel is
turned.
Boat in the Water Tests
WIDE OPEN THROTTLE TEST
IMPORTANT: To operate engine at full throttle before the break‑in period is complete:
1. Place the remote control in the neutral, idle position..
2. Refer to the Marine Recreational High Output Propulsion Units QSB or QSC Operation
and Maintenance Manual available from the engine manufacturer and start the engine
according to the manufacturer's instructions.
3. Slowly advance the throttle until the engine reaches 1300 RPM (+/‑100 RPM).
4. Watch all gauges for normal readings.
5. When engines reaches normal operating temperature, run the boat up on plane.
6. Advance engine RPM (in 200 RPM increments) until engine reaches its maximum rated RPM.
7. Test if propellers with the correct pitch have been installed. Operate the boat (with a maximum
load on board) at wide open throttle (WOT) and check the RPM. Engine RPM must not be
less than the rated RPM. If engine speed is too high, replace the propellers with propellers of
higher pitch. If engine speed is too low, replace the propellers with propellers of lower pitch .
Dual‑Handle Electronic Remote Control (ERC) with DTS Trackpad Features and
Operation
OPERATION
The electronic remote control (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 the control handle from the forward position to the neutral position
to decrease speed and eventually stop. Pull the control handle back from neutral to the first detent
for reverse gear. Continue pulling the handle back to increase speed in reverse.
Page 16 / 22 90-866927070 SEPTEMBER 2007

NOTE: In certain modes, gear position is determined by the position of the shift valves on the
transmission, not the position of the ERC levers. When using the joystick or while in Skyhook, the
computer moves the transmission in and out of gear even though the handles are in neutral.
c b
28086
a- Neutral
b- Forward
c- Reverse
d- Bow of boat
The amount of force needed to move the ERC handles and to move the ERC handles through the
detents is adjustable to help prevent unwanted motion of the handle in rough water.
To adjust ERC handle tension:
1. Remove the side cover.
2. Turn the screw clockwise to increase tension on the control handle and counter‑clockwise to
decrease tension.
3. Adjust to tension desired.
To adjust ERC handle detent tension:
1. Remove the side cover.
2. Turn the screw clockwise to increase tension on the control handle and counter‑clockwise to
decrease tension.
3. Adjust to tension desired.
a b
28087
Starboard side with side cover removed.

a - ERC handle tension screw
b - ERC handle detent tension screw
90-866927070 SEPTEMBER 2007 Page 17 / 22

Helm Transfer
! WARNING
Avoid serious injury or death from loss of boat control. The boat operator should never leave the
active station while engine is in gear. Helm transfer should only be attempted while both stations
are manned. One‑person helm transfer should only be performed while engine is in neutral.
NOTE: Neutral position is preferred when doing a station transfer. If conditions do not allow the
remote control to be placed in the neutral position, a helm transfer can be done while in gear.
The helm transfer function allows the boat operator to select which helm is in control of engine
operation. Pressing the "TRANSFER" button two times allows engine control to be transferred to
a new helm. When a helm transfer is initiated, the control will automatically start adjusting engine
RPM and gear position to match the control handle setting at the new helm. Adjust the control
handles to the desired throttle and gear position.
Once the "TRANSFER" button is pressed, the transfer LED will light up and one beep will sound.
Press the "TRANSFER" button again to complete the helm transformation. When helm
transformation is complete, another beep will sound and the transfer LED will turn off.
NOTE: Helm transfer must be completed in 10‑seconds or less. If the helm transfer is not
completed, the action will be canceled and a beep will sound twice. Pressing the "TRANSFER"
button again will initiate a helm transfer again.
NEUTRAL
TROLL
- +
SYNC TRANSFER
1 LEVER THROTTLE DOCK

ONLY
22593
SYNCHRONIZING HELMS PRIOR TO TRANSFER

Pressing the "TRANSFER" button allows the boat operator 10 seconds to match up the control
handle settings at the new helm with the handle settings that are at the old (to be inactive) helm.
If the handles are not matched, the neutral lights will flash. The light blinks faster as the handles
are nearing match position. When the light stays on continuously, the handles are matched and
the button can be pressed again to complete the transfer. The new station now has control.
Synchronizing Engines
The auto‑synchronizing feature, when engaged, will automatically adjust all engine speeds to
match the speed of the starboard engine.
Press the "SYNC" button on the DTS trackpad to turn auto‑synchronization on or off. When the
sync LED is yellow, the "SYNC" button has been pressed, but the conditions are not right for auto
synchronization to engage. When the sync LED turns red, engine synchronization has been
engaged. The engines will remain synchronized as long as engine speed is over 900 RPM for two
seconds, remote control handles are positioned within 10% of each other, and the engines are
below 95% throttle opening.
To disengage the auto synchronization feature, press the "SYNC" button.
NEUTRAL
TROLL
- +
SYNC TRANSFER
1 LEVER THROTTLE DOCK

ONLY
22590
Page 18 / 22 90-866927070 SEPTEMBER 2007

Basic Joystick Operation

The joystick offers precise, intuitive control of your boat during low speed and docking maneuvers.
The joystick translates the movement of the joystick into similar movement in the boat. Engine
speed is limited in this mode to prevent unacceptable boat dynamics during maneuvers.
While operation with the joystick is easy to 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 recommend that you occasionally practice
maneuvering in the traditional way to maintain your traditional drive docking skills in case joystick
control is temporarily not available.
Trim Tab System
The trim tabs on the Zeus drive are fully integrated into the drive. There are no additional systems
to bolt on. The trim tabs are usually automatically controlled for optimum performance. Manual
trim tab control will override the automatic system when conditions or personal preferences
require.
The maximum trim tab angle is 16° down. The trim tab width is 50.8 cm (20 inches).
Interchangeable camber plates will be available to fine‑tune the trim of the vessel by increasing
lift. Contact your Cummins MerCruiser Diesel Applications Engineer if your application needs
additional lift.
a
b
25570
Typical trim tab cutaway side view

a - Length of trim tab
b - Camber plate height
Trim Tab Control Operational Tests

When auto tab control is activated, the tabs move to a trim position based on boat speed and
engine RPM. The manual switches can be activated when in auto mode to compensate for
conditions such as additional passengers to one side causing a list.
Manual offsets are held until changed again through the panel, or until the electronic remote
controls are moved into the neutral position, returning the trim tabs to their default factory settings.
The following tests should take place in a clear and open water area without obstructions or other
boats.
90-866927070 SEPTEMBER 2007 Page 19 / 22

1. From a stop, start the boat moving in a straight line and operate the trim tabs while moving
onto plane. Observe that the boat responds appropriately to the inputs. Push the forward end
of the rockers to bring the tabs down. Push on the aft end of the rockers to bring the tabs up.
a b c
25578
a - Port rocker
b - Starboard Rocker
c - Manual/automatic selector
2. After the boat is on plane, adjust the trim tabs for proper visibility from the helm, but not so
much that the boat speed or engine RPM is lowered.
Freezing‑Weather Storage and Seasonal Storage

Storage Descriptions
IMPORTANT: We strongly recommend that this service be performed by a Cummins MerCruiser
Diesel Authorized Repair Facility. Damage caused by freezing is not covered by the Cummins
MerCruiser Diesel Limited Warranty.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze
damage. Drain the seawater section of the cooling system immediately after operation or before
any length of storage in cold weather. 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 seacock, leave the water inlet hose disconnected and plugged.
NOTE: As a precaution, attach a tag to the key switch or steering wheel of the boat to remind the
operator to open the seacock or unplug and reconnect the water inlet hose before starting the
engine.
The power package must be protected from freeze damage, corrosion damage, or both types of
damage during storage. Storage is any length of time the product is not operated. Based on the
length of storage certain precautions and procedures must be observed to protect the power
package.
Freeze damage can happen when water trapped in the seawater cooling system freezes. For
example, after operating the boat, exposure to freezing temperatures for even a brief period of
time 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 engine's cooling system
for even a brief storage time; drain and flush the seawater cooling system after each outing.
Freezing‑weather (freezing temperature) operation refers to operating the boat whenever freezing
temperatures are possible. Likewise, freezing‑weather storage refers to whenever the boat is not
being operated and freezing temperatures are possible. In such cases, the seawater section of
the cooling system must be completely drained immediately after operation.
Page 20 / 22 90-866927070 SEPTEMBER 2007

Seasonal storage refers to when the boat is not being operated for one month or more. The
duration varies according to the geographic location. Seasonal storage precautions and
procedures include all the steps for freezing‑weather storage and some additional steps that must
be taken when storage will last longer than the short time of freezing‑weather storage.
Freezing‑Weather Storage Instructions
IMPORTANT: We recommend the use of propylene glycol antifreeze in the seawater section of
the cooling system for freezing‑weather (freezing temperatures), seasonal storage, or extended
storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is
recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's
recommendations.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze
damage. Drain the seawater section of the cooling system immediately after operation or before
any length of storage in cold weather. 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 seacock, leave the water inlet hose disconnected and plugged.
NOTE: As a precaution, attach a tag to the key switch or steering wheel of the boat to remind the
operator to open the seacocks before starting the engine.
1. Close all seacocks.
2. Read all precautions and perform all procedures found in the QSB or QSC Operation and
Maintenance Manual supplied by the engine manufacturer including the following.
a. Drain all the water separating fuel filters.
b. Drain the seawater section of the cooling system, including the water lift mufflers.
c. Remove the hoses from the seawater strainer and drain the hoses completely.
d. Drain and empty the seawater strainer according to the manufacturer's instructions.
e. Reconnect the hoses to the seawater strainer and tighten the hose clamps securely.
3. Place a caution tag at the helm advising the operator to open the seacocks before operating
the boat.
4. For additional assurance against freezing and corrosion fill the heat exchanger with a solution
of propylene glycol antifreeze and tap water mixed to protect the power package to the lowest
temperature to which it will be exposed during storage. Refer to the QSB or QSC Operation
and Maintenance Manual supplied by the engine manufacturer.
5. Follow the battery manufacturer's instructions for battery storage.
Seasonal Storage Instructions
1. Read all precautions and perform all procedures found in the Cold Weather (Freezing
Temperature) Storage section.
2. Refer to the QSB or QSC Operation and Maintenance Manual supplied by the engine
manufacturer and fill the heat exchanger with a solution of propylene glycol antifreeze and tap
water mixed to protect the power package to the lowest temperature to which it will be exposed
during storage.
3. Follow the battery manufacturer's instructions for battery storage.
90-866927070 SEPTEMBER 2007 Page 21 / 22

Predelivery Inspection Checklist—Zeus Drive

Check / Check /
Not Applicable CHECK BEFORE RUNNING Not Applicable ON THE WATER TEST
Adjust Adjust
ENGINE CHECKS ENGINE CHECKS
⃞ ⃞ Engine mounts tight ⃞ ⃞ Driveshaft alignment
⃞ ⃞ Engine alignment ⃞ ⃞ Fuel leaks
⃞ ⃞ Alternator belt tension ⃞ ⃞ Fluid and oil leaks
⃞ ⃞ Closed cooling level ⃞ ⃞ Seawater leaks
⃞ ⃞ All fuel connections tight ⃞ ⃞ Coolant leaks
⃞ ⃞ All electrical connections secure ⃞ ⃞ Exhaust leaks
Idle________ RPM, within
⃞ ⃞ Exhaust system hose clamps tight ⃞ ⃞
specifications
⃞ ⃞ Engine oil level ⃞ ⃞ Acceleration from idle RPM
WOT________ RPM within
⃞ ⃞ Seawater pickup pump belt tension ⃞ ⃞
specifications (in forward gear)
DRIVE CHECKS DRIVE CHECKS
Steering operation throughout
⃞ ⃞ All electrical connections secure ⃞ ⃞
range
Instruments and VesselView
⃞ ⃞ Battery fully charged and secured ⃞ ⃞
panel operation
Forward ‑ Neutral ‑ Reverse gear
⃞ ⃞ Audio warning system operation ⃞ ⃞
operation
Throttle, shift and steering system
⃞ ⃞ controls—properly mounted and ⃞ ⃞ Trim tab operation and settings
connected
⃞ ⃞ Steering and trim fluid level ⃞ ⃞ Boat handling and docking
⃞ ⃞ Drive lube level ⃞ ⃞ Lubricant, oil and fluid leaks
⃞ ⃞ Transmission fluid level AFTER ON WATER TEST
Fuel, oil, coolant, seawater,
⃞ ⃞ Drive mounting fasteners torqued ⃞ ⃞
lubricant, and fluid leaks
⃞ ⃞ Seacocks open ⃞ ⃞ Oil and fluid levels
Correct propellers (installed and Apply Quicksilver Corrosion
⃞ ⃞ ⃞ ⃞
torqued) Guard to power package
Page 22 / 22 90-866927070 SEPTEMBER 2007

Zeus Installation Manual

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Zeus Installation Manual

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Cummins MerCruiser Diesel

QSB AND QSC DIESEL ZEUS DRIVE MODELS

Notice to the Boat Manufacturer and Installer

Page i © 2007 Mercury Marine 90-866927070 SEPTEMBER 2007

IMPORTANT: Identifies information essential to the successful completion of the task.

SECTION 1 - IMPORTANT INFORMATION 1

90-866927070 SEPTEMBER 2007 Page 1 / 6

Typical engine mount fixture tool

Engine Mount Fixture

ENGINE-TO-DRIVE ALIGNMENT TOOL

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Description Cummins Part Number

Drive Serial Number and Decal Placement

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Anodes and MerCathode System Locations

Trim tab anode

Anode kit (if

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Reference Electrode Wire of the MerCathode System

Painting the Boat

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SECTION 2 - BOAT CONSTRUCTION

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Typical hull underside

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a - Hull and surrounding area

a- Interface ring with stainless steel studs

Models with a Fabricated (Molded‑In) Tunnel Opening

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Models with a Tunnel Cut‑out Opening

Description Part Number

CUTTING OUT THE TUNNEL OPENING

Drill Point Alignment

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3. Drill the front hole for the locating bar.

Typical hull tunnel

Front locating hole

Top plate alignment specifications

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Typical hull tunnel with locating bar in place

Front locating hole

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c. Install the two wing‑nuts on the fixture bolts.

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a - Cut‑out fixture on bottom of boat

Interface ring mounting

Router bit specifications

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14. Remove and discard the cut‑out fiberglass.

Dimensions of a tunnel cut‑out opening

Final dimensions of hull around the tunnel opening

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Engine Foundation Design

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Drop Box and Engine Installed Height

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Page 14 / 14 90-866927070 SEPTEMBER 2007

SECTION 3 - EXHAUST SYSTEM

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Exhaust System Description—Flange‑Type Connection