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Manual Introduction
The purpose of this document is to guide the design and integration of the Cat® C9 ACERT® marine
propulsion engine with the Zeus Pod Drive System into a new pleasure craft. It is required to
review the standard Caterpillar A&I Guides released on Power Net and the ZF A&I Guide Manual in
addition to the list of information provided.

Table of Contents:

1) Zeus Pod Drive System Powered by Cat C9 ACERT Attachments

1.1 Cat C9 ACERT Attachments Overview .....................................................Page 3
1.2 Caterpillar Supplied Attachments ...............................................................Page 4-5
1.2.1 Installed on Engine
1.2.2 Shipped Loose
1.3 Dealer/OEM Responsibility........................................................................Page 6

2) Engine Installation
2.1 Mounting and Engine Location ..................................................................Page 7-8
2.2 Engine Rear Housing Group Cover/Guard .................................................Page 9
2.3 24-inch Drive Shaft Installation..................................................................Page 9
2.4 Drive Shaft Engine Side Bolt-Hole Pattern ................................................Page 10
2.5 Drive Shaft Zeus® Pod Drive System Side Bolt-Hole Pattern....................Page 11
2.6 Zeus® Pod Drive System Side Drive Shaft Guard ......................................Page 11
2.7 Engine Rear Housing Group Cover/Guard Installation ..............................Page 12
2.8 Drive Shaft Entanglement Guard................................................................Page 13

3) Exhaust System
3.1 Exhaust Overview.......................................................................................Page 14
3.2 Exhaust Elbow Group P/N 338-1865 .........................................................Page 15
3.3 Exhaust Installation.....................................................................................Page 15-17
3.4 Exhaust Elbow Height ................................................................................Page 18

4) Seawater Cooling Connections .................................................................................Page 19

5) Zeus® Pod Drive System Gear and Oil Connections ..............................................Page 20-23

6) Electrical Connections
6.1 Engine Monitoring System Connection......................................................Page 24
6.2 J1939 Display Connections.........................................................................Page 25

7) Installation Drawings ................................................................................................Page 26-29

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1 Zeus Pod Drive System Powered by Cat C9 ACERT Attachments:

1.1 Cat C9 ACERT Attachments Overview

The Zeus Pod Drive System powered by the Cat C9 ACERT engine consists of components added
and supplied by Caterpillar in addition to components added by the dealer/OEM. Below is the list of
items required to complete the package; the following pages will show the breakdown of the source
of each item needed. Engine TVA was validated with the listed components attached to the engine.

1. Engine Housing Group — Rear

2. Engine Guard Group for Coupling
3. Shaft Group — Main Drive 609.6-mm (24-inch Shaft) Adjustable
4. Coupling Group — Torsional
5. Guard Group (Zeus Pod Drive System)
6. Fitting Group (Oil Lines) Zeus Pod Drive System
7. Power Steering/Transmission Dual Oil Cooler
8. Engine Mounts
9. Gear Oil Filters
10. Bulk Hose for Sea Water (Zeus Pod Drive System Cooling)
11. Hydraulic Hose Lines for Zeus Pod Drive System Pod Oil Connections.
12. Elbow Group — Exhaust
13. Down Pipe — Exhaust
14. Zeus Pod Drive System Side Exhaust Elbow
15. Exhaust Lift Muffler
16. 51-mm (2-inch) Seacock
17. MPD/CMPD/MMPD for Engine Diagnostics Display
18. Plug & Play Harness
19. Software
20. Installation Diagram
21. Zeus Pod Drive System

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 1.2 Caterpillar Supplied Attachments:

1.2.1 Installed on Engine:

• Engine Housing Group — Rear

• Guard Group — Coupling
• Coupling Group — Torsional
• Engine Mount Brackets
• Gear Cooler/Power Steering Cooler (mandatory attachment when Zeus Pod Drive System is
selected on the price list)

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 1.2.2 Shipped Loose:

• Insulated Exhaust Riser

• Hump Hoses and Attachments
• Exhaust Down Pipe with a 101.6-mm (4-inch) primary bypass connection to a lift muffler
• Exhaust Zeus Pod Drive System Elbow with a 38.1-mm (1.5-inch) secondary bypass to be
connected to the Zeus Pod Drive System
• Shaft Group — Main Drive 609.6-mm (24-inch) shaft
• Guard Group (Zeus Pod Drive System)
• Plug & Play Harness
• Isolation Engine Mounts

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 1.3 Dealer/OEM Responsibility

• Provide and install Zeus Pod Drive System oil cooling hydraulic lines per Caterpillar
cleanliness guideline
• Provide and install fitting group (oil lines) for both engine and Zeus Pod Drive System
• Provide and install raw-water cooling lines.
• Seawater strainer
• Provide and install drive shaft entanglement and equipment protection guard
• Provide and install water lift muffler, secondary bypass to Zeus Pod Drive System
• Order engine display and harness
• Order and install Zeus Pod Drive System

Entanglement guard: prevents fingers, hands, or other items from becoming caught
in something such as a rotating shaft.

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2. Engine Installation

2.1 Mounting and Engine location

• With the order of Zeus Pod Drive System powered by C9 ACERT attachments option off
the price list, the Housing Group — Rear will be installed on the engine, the front and rear
bracket supports P/N 226-2294 will be shipped assembled on the engine; however, the engine
mounts P/N 1391502 will ship loose.

Refer to standard LEBW4971 A&I installation guidelines for mount installation and specs.

• Attention: The bottom four bolts on the front housing represent the horizontal layout for
mounting.
• 01 is the centerline of the crankshaft.

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 • Engine location and relevance to Zeus Pod Drive System installation is covered on the
installation drawings (339-9479) 1-4. Available on TMI.
• Engine installation angles are restrictive to the Zeus Pod Drive System installation and drive
shaft arrangement.

Note: This is a reference drawing only; for the latest drawings please refer to TMI/X Ref.

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 2.2 Engine Rear Housing Group Cover/Guard

• Caterpillar ships the rear housing coupling cover installed on the engine; however, it will
need to be removed in order to install the 609.6-mm (24-inch) shaft to the engine.
(Reinstallation at the end of this section)

2.3 24-inch Drive Shaft Installation

• The shaft length limit is 609.6 to 685.8 mm (24 to 27 inch) for installation design, with a
+/- 12.7 mm (0.5 inch) tolerance during actual installation.
• Nominal installation angle of the drive shaft is 2 degrees +/- 1.
• Both ends of the shaft are coupled to the engine and Zeus Pod Drive System side with a
3/8 –24" fine thread bolts which would require a torque of 50 +/- 10 N•m.
• Bolts on shaft to be painted after installation and service replacement to prevent corrosion.
• Shaft maintenance will consist of a slip joint re-lubrication using Cat Advanced 3Moly
Grease every 250 hours and a spider bearing service kit for the shaft service no sooner to
mid-life of engine (2500 hours). Based on the max load factor of 30% of the E-Rating.
• Ideally, the two joint angles of the driveshaft should be identical or opposite, as angle is
introduced into each joint and must be on the same plane.

Same Working Angle

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 2.4 Drive Shaft Engine Side Bolt Hole Pattern

Eight drive shaft bolt holes on the coupler.

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 2.5 Drive Shaft Zeus Pod Drive System Side Bolt Hole Pattern

• Spicer 1610 Flange is an

eight-bolt hole pattern
that the drive shaft
connects to.
• Use the 3/8" –24 fine
thread bolts and nut
provided. These bolts
would require a torque of
50 +/- 10 N•m.

“Failure to properly install guards may result in entanglement hazard.”

2.6 Zeus Pod Drive System Side Drive Shaft Guard

• Five M10X1.5 bolts torque to 55+/- 10 N•m

to hold the 2 guard pieces on to the Zeus
Pod Drive System side.
• Two M6X1 bolts torque to 12 +/- N•m to
hold the two pieces together.
• Mounting location on Zeus Pod Drive
System side drive shaft guard for dealer/OEM
provided entanglement drive shaft guard.
(M8X1 threaded boss: one on each side)

“Failure to properly install guards may result in entanglement hazard.”

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 2.7 Engine Rear Housing Group Cover/Guard Installation

• Five 3/8"-16 bolts.

Torque to 47
+/- 9 N•m to hold
the lower guard
piece onto the
engine side.
• Six 7/16"-14 bolts.
Torque to 70+/-
15 N•m to hold the
top guard piece onto
the engine side.
• Four 3/8"-16 bolts.
Torque to 47 +/-
9 N•m.

• Mounting location on engine side drive shaft guard for dealer/OEM provided
entanglement/protection drive shaft guard. (M8X1 clearance holes: one on each side)

“Failure to properly install guards may result in entanglement hazard.”

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 2.8 Drive Shaft Entanglement Guard

It is the responsibility of the OEM to install a shaft guard once installed in the final
installation to protect against an entanglement hazard, which can cause personal
injury or death, and to protect or prevent equipment damage due to shaft failures.

• Depending on the shaft guard installed, an additional deck plate might be necessary to be
installed between the guard and bottom deck.
• Dimensional location of the available optional bolt holes for mounting the guard can be
retrieved from the installation Auto Cad drawings.
• Max weight of the entanglement guard is no more than 10.9 kg (24 lb).

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3. Exhaust System:

3.1 Exhaust Overview

It is a Zeus Pod Drive System design that requires the engine exhaust to be directed to the Zeus
Pod Drive System exhaust inlet. A standard conventional exhaust will not work, as blocking the
exhaust inlet port on the Zeus Pod Drive System will damage the seals on the Zeus Pod Drive
System as the design helps the exhaust to be sucked out through the propeller hub.

The current exhaust system supplied has been proven and validated not to exceed the recommended
Caterpillar exhaust backpressure of 10.0 kPa (40.2 in H2O) on the C9 ACERT engine with
609.6-mm (24-inch) shaft applications.

The engine exhaust path is through the riser elbow, which is then sprayed and mixed with the return
seawater from the engine via the showerhead connection on the riser; down the 6-inch down pipe
into the Zeus Pod Drive System side exhaust elbow, then the exhaust and seawater is funneled
through the Zeus Pod Drive System housing and exits through the propeller hub.

Additional bypasses are installed to the system to handle the higher backpressure experienced during
idle running conditions — a 101.6-mm (4-inch diameter) main bypass, which would need to be
connected to a water lift muffler installed on the main down pipe, and a smaller 38.1-mm (1.5-inch
diameter) bypass, which would need to be connected to the Zeus Pod Drive System end.

Exhaust path through the Zeus Pod Drive System

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 3.2 Exhaust Elbow Group P/N 338-1865

• Elbow assembly — exhaust [water cooled 152.4-mm (6-inch) riser] P/N 336-9931 includes
the exhaust seal gasket
• Tube exhaust 152.4 mm (6 in O.D.) with a 101.6-mm (4-inch diameter) bypass connection
P/N 3369932
• Elbow assembly — exhaust [152.4-mm (6-inch inlet), 127-mm (5-inch outlet)] Zeus Pod
Drive System side elbow P/N 336-9936
• Hump hoses P/N 338-0679
• Zeus Pod Drive System side exhaust flange P/N 338-1862
• Seal — O-ring

3.3 Exhaust Installation

• The OEM will be responsible to provide support to the exhaust system by utilizing the bolt
hole provided on the riser and the flywheel housing.
– Clearance hole size on the riser is 11.5 mm +/- 0.5
– Bolt hole size on the flywheel housing is M10 X 1.5
• Install Zeus Pod Drive System side exhaust elbow O-ring on the Zeus Pod Drive System
side exhaust connection.
• Install Zeus Pod Drive System side exhaust elbow; ensure that the bypass connection is no
more than 45 degrees in the down angle.
• Connect hump hoses on both ends of the exhaust down pipe.
• Connect raw water outlet from aftercooler to showerhead.
– Showerhead hole size is 44.5 mm.
• Connect the 1.5" secondary bypass on the Zeus Pod Drive System side exhaust elbow to the
Zeus Pod Drive System engine seawater discharge port. (The installed discharge valve
must stay open during operation)
• Exhaust down pipe primary bypass size: 101.6 mm (4 inch) OD
• At this time, it is the OEM’s responsibility to size and install an exhaust water lift
muffler in addition to the Caterpillar supplied exhaust components, in addition to
connecting the smaller secondary bypass to the Zeus Pod Drive System drive.
• Refer to LEBW4970 Exhaust System A&I Guide for lift muffler information.
• Refer to engine TMI for exhaust backpressure limits on the engine.

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Page 16 of 30
Bolt Torque Values:
• Riser: (M10X1.5) X4 55+/- 10 N•m
• Zeus Pod Drive System Side Exhaust Elbow: Bolt & Nut (M8 X 1.25) X6 28+/- 7 N•m
• Hose Clamps for Hump Hoses: 11+/- 1 N•m

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 3.4 Exhaust Elbow Height

• Verify that the distance from the water line to bottom of the exhaust riser is no less than
254 mm (10 in) after the boat has been fully loaded. (Standard Cat engine exhaust riser
minimum height requirement is 560 mm (22 in).

• This limit is verified only on the Caterpillar Supplied main exhaust system; it can be different
using main exhaust systems from other suppliers.

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4. Seawater Cooling Connections:

Raw water is drawn from the Zeus Pod Drive System seawater supply connection to the inlet of the
auxiliary water pump via the seawater strainer, then flows through the fuel cooler before the
auxiliary water pump inlet (if the engine is equipped with the optional fuel cooler). Then the raw
water is pumped to the aftercooler, through the hydraulic oil cooler installed on the engine, then to
the jacket water heat exchanger, and to the exhaust water elbow showerhead connection. The raw
water mixes with the engine exhaust after it flows through the showerhead.

Since there is no strainer build in the Zeus Pod Drive System, it is the responsibility of the OEM to
install a seawater strainer with a max mesh basket of no more than 2 mm, which is a requirement for
this application.

Joint connection sizes and recommendation:

Refer to LEBW4978 Cooling Systems –A&I Guide for additional information on seawater hose
connections and water flow value specifications.

Specifications:

• Zeus Pod Drive System side raw water inlet connection: 51-mm (2-inch) seacock
required by OEM if not already supplied by ZF
• Raw water strainer sized for at least 237 L/M (65 GPM) of raw water flow, with a mesh
basket size of no more than 2 mm
• Engine raw water pump inlet connection: 52.5 mm (2.07 in) OD
• Heat exchanger raw water outlet connection: 44.5 mm (1-¾ in)
• Showerhead raw water inlet connection: 44.5 mm (1-¾ in)

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5. Zeus Pod Drive System Gear and Oil Connections

• Caterpillar recommends using a -10 (15.9 mm ID.) Cat 716 hose. The fitting sizes for
the four connections on the power steering/transmission oil cooler are: ½ - 14 NPT
THD.
• Fitting group and adapters (335-4135) can be ordered from Morton.
• Although the fitting and adapters will be shipped from Caterpillar if ordered, it is the
responsibility of the dealer/OEM to size and install the hydraulic oil lines.

It is the dealer/OEM’s responsibility to follow the cleanliness guidelines when installing the
hydraulic oil line in order to prevent contaminants from entering the Zeus Pod Drive System
side transmission or power steering components.

“Contaminants are measured in units called microns. One micron is equivalent to one-millionth of a meter. A

grain of salt is about 100 microns in diameter, a human hair, around 80. We can’t see particles smaller than 40 microns,

yet a 5-micron particle damages earthmoving equipment systems.

Most manufacturers, including Caterpillar, assess the cleanliness of fluid systems by counting and measuring

the particles present in the oil and comparing those results to an International Standards Organization (ISO) code. An

ISO contaminant code contains two numbers. The first refers to the number of 5-micron and larger particles in a one-

millimeter oil sample. The second indicates the quantity of 15-micron and larger particles in that same sample. A rating

of 21/17 rating, for example, means that one millimeter of oil contains up to 221 (about two million) particles five

microns and larger, as well as 217 (130,000) particles 15 microns and larger. A one-millimeter oil sample that earns a

21/17 rating is equivalent to a 55-gallon drum of oil contaminated with half a teaspoon of very fine dust.

Although that sounds pretty clean, if your machine meets the 21/17 standard – and the hydraulic pumps operate

at 32 gallons per minute, 8 hours a day, 200 days per year – you’re actually running more than 625 pounds of dirt

through the hydraulic system annually. By improving cleanliness to 18/15, you can reduce the amount of dirt in your

system to about 80 pounds per year. Achieve a 16/13 rating, and the number drops to 20 pounds.

Use foam and plastic packaging, rather than cardboard, to reduce paper contamination.

Filter oil repeatedly prior to filling new machine systems.

Use particle-counting technology to verify cleanliness before shipping.”

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 • Always ensure that the hoses are sealed until actually connected to the system. If there is any
suspicion that the hydraulic hose cleanliness has been compromised in any way, always
follow Caterpillar guidelines in using the available hose cleaning tools released on
NEHS0643.

• Ensure that the oil inlet and outlet connections are marked before actual installation;
install one oil line at a time to ensure no misplacement occurs as it can lead to
component failure.

• Ensure that standard hydraulic line installation is followed and stay as close as possible along
the edge of the stringer per the following example.

• Ensure that the Zeus Pod Drive System power steering and transmission gear reservoirs are
topped off after starting the package, depending on the oil line length installed.

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Above is a presentation on a typical installation.

Zeus Pod Drive System Side P1 = Power Steering OUT (to eng cooler) Engine Side P1 = Power Steering IN (from Zeus Pod Drive System P.S.)
Zeus Pod Drive System Side P2 = Power Steering IN (from eng cooler) Engine Side P2 = Power Steering OUT (to Zeus Pod Drive System P.S.)
Zeus Pod Drive System Side P3 = Transmission Gear OUT (to eng cooler) Engine Side P3 = Transmission Gear IN (from Zeus Pod Drive System T.G.)
Zeus Pod Drive System Side P4 = Transmission Gear IN (from eng cooler) Engine Side P4 = Transmission Gear OUT (to Zeus Pod Drive System T.G.)

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Page 23 of 30
6. Electrical Connections

Plug & Play harness will be shipped with the engine; the current connections are:

H-C1 Zeus Pod Drive System Connector

H-C2 Customer Connector
H-C3 VIP Connector

6.1 Engine Monitoring System Connection

The plug & play harness will be updated to accommodate connecting Cat Engine Monitoring
Systems (MPD, MMPD, CMPD, and MAPD).
Only the load factor gauge currently released with the MAPD will not be compatible with the Zeus
Pod Drive System arrangement.

It is important to ensure that the engine voltage is communicated to ZF prior to ordering the
Zeus Pod Drive System.

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 6.2 J1939 Display Connections

The Zeus Pod Drive System controller uses the J1939 connection on the 70-pin customer
connector. This connection should not be modified.

Use the 6-pin connector on the engine harness to connect a J1939 display device such as an MPD,
Mini MPD, Color MPD, or MAPD. Standard Cat cabling can be ordered on the OFFBOARDM price
list. (See the diagram to topology)

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7. Installation Drawings:

339-9479 A

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 339-9479 B

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 339-9479 C

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 339-9479 D

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 Information contained in this publication may be considered confidential.
Discretion is recommended when distributing.
Materials and specifications are subject to change without notice.
CAT, CATERPILLAR, their respective logos, ACERT, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate
and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

LEGM0002-00
Page 30 of 30(7/09) 2009 Caterpillar
All rights reserved.