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Zeus Mechanical and Hydraulic

Systems
 Upon completion of this lesson the student will be
able to:
 Identify Zeus Mechanical Components
 Explain available Zeus Gear Ratios
 Identify Zeus Hydraulic Components
 Explain the operation of the Zeus Hydraulic System
 Interpret Zeus Hydraulic schematics
 Perform mechanical and hydraulic component
identification
 Identify the function of mechanical and hydraulic
components

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Zeus Technician Classroom Qualification
Hull Design

Tunnel design
Zeus Mechanical System

crash_test_video.wmv

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Zeus Technician Classroom Qualification
Hull Design

Training_rick_davis.wmv

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Zeus Technician Classroom Qualification
Hull Design

 ..\..\Orginal Zeus
Documents\instructor_guide_classroom\documents\
Zeus_Installation_Manual.pdf
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Zeus Technician Classroom Qualification
Hull Design

Allowing for
perpendicular
pod
installation

integrated tunnel recess

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Zeus Technician Classroom Qualification
Hull Design

Hull Design:
• must incline the installed
engine at 0° ± 1° fore and aft
with boat at rest in the water.
• the engine aligned to the
center of the drive input shaft
and parallel to the vessel
centerline.

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Zeus Technician Classroom Qualification
Hull Design

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Zeus Technician Classroom Qualification
Hull Design

Rob_Mirman_Engine_Compartment.wmv

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Zeus Technician Classroom Qualification
Zeus Mechanical System

 Similar to Bravo 3 Nomenclature


 Heavier construction and components for increased
drive loads
 PWM Clutch for smooth engagement and operation
of joystick

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Zeus Technician Classroom Qualification
Zeus Mechanical System

Hydraulic Clutch Packs

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Zeus Technician Classroom Qualification
Zeus Mechanical System

a - input flange b - dropbox (if equipped) c - input speed sensor d - output speed
sensor e - Forward solenoid f - oil temperature sensor g - Reverse solenoid h -
Trolling valve solenoid i - oil pressure sensor
Zeus Mechanical System

Input Shaft with oil


galleries

Oil Gallery

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Zeus Technician Classroom Qualification
Zeus Mechanical System

Transfer Gear Box

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Zeus Technician Classroom Qualification
Zeus Mechanical System

 Table 4 illustrates the relationship between the


overall ratio and available drop box ratios.

To technical package
Marine Application Bulletin

HYDRAULICS FOR ZEUS

Introduction - 19
March 14, 2008
Zeus Technician Classroom Qualification
Zeus Hydraulic System

Day Two - 20
1/22/2010
Zeus Technician Classroom Qualification
Zeus Hydraulic System
Gen 1

Hydraulic Pump Electrical


Components
1. Hydraulic pump
2 Pump pressure control valve
3 Swash plate position sensor,
Zeus Hydraulic System
Gen 2 1 - Reservoir (tank)
2 - Return oil (low pressure)
3 - Pump case drain
4 - Oil supply
5 - Fluid cooler
6 - Case drain hose
7 - Return oil low-pressure circuit
8 - Steering control valve
9 - Trim control valve
10 - Trim-down circuit
11 - Trim-up circuit
12 - Trim tab cylinder
13 - Trim tab
14 - Check valve for trim tab—Pilot operated
15 - Dashed-line indicates steering and trim
manifold
16 - Supply oil high-pressure circuit
17 - High-pressure filter
18 - Hydraulic oil pump and control valve
19 - Direction of propeller thrust
20 - Steering actuator
Zeus Hydraulic System Gen 1

Electronically – controlled
variable displacement piston
pump
Zeus Hydraulic System Gen 2

Mechanically – controlled
variable displacement,
pressure compensated pump.
Zeus Hydraulic System Gen 1

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Zeus Technician Classroom Qualification
Zeus Hydraulic System Gen 1

B
A

Select

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Zeus Technician Classroom Qualification
Zeus Hydraulic System

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Zeus Technician Classroom Qualification
Zeus Hydraulic System

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Zeus Technician Classroom Qualification
Zeus Hydraulic System Gen 1

• An emergency steering backup pump


• Allows for centering the pod

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Zeus Technician Classroom Qualification
Zeus Hydraulic System Gen 1

Steering Backup Pump


Circuit

a - Return hose (if


equipped)
b - Backup pump
c - Up line connection
d - Down line
connection
e - Steering hydraulic
manifold
Zeus Hydraulic System Gen 1

The Zeus drive includes integrated


hydraulically actuated electronically
controlled trim tabs
Zeus Hydraulic System Gen2

Manual override buttons for steering and trim, including


relocation of the trim hydraulic control valves to the steering
manifold

Front of manifold
a - Steer-to-starboard control valve
b - Trim-down control valve
c - Manifold
Zeus Hydraulic System Gen2

Rear of manifold
a - Manifold
b - Trim-up control valve
c - Steer-to-port control valve
Zeus Hydraulic System

 Hydraulic Schematic_cropped.pdf

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Zeus Technician Classroom Qualification
Designing a Zeus Equipped Vessel

 Each vessel is unique


 Ordering the correct components for the Zeus
Architecture for original installation or repair
 Using the Zeus (SmartCraft 2.1) System
Architecture & Option Overview Diagram will ensure
that the components you order are correct for the
vessel you are working on

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Activity 2

Activity 2 Activity 2
Worksheet A Worksheet B
On Zeus Simulator At Seats

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Activity 2
Worksheet A Review
Component Description Name Tag Letter/Number
This component is required on Zeus
vessels equipped with QSC 3800 Drop Box
Engines to reduce torque to the pod.

This component converts


electrical signals into hydraulic Steering Manifold
actions for the steering system.

This hydraulic component helps Power Trim Actuator


the Zeus system to quickly get
the vessel on plane.

In the event of a hydraulic


Backup Pump
failure of the primary system
this component will center the
Zeus pod.

Day Two - 38
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Zeus Technician Classroom Qualification
Activity 2
Worksheet A Review
Component Description Name Tag Letter/Number
Helps remove contaminants
from the hydraulic system. Hydraulic Filter

Cools the hydraulic fluid for the


steering system. Hydraulic cooler

Cools the oil for the Drop Box.


Drop Box Cooler

Holds the oil for the steering


Hydraulic Reservoir
and power trim systems.

Uses multiple pistons to power


the Zeus hydraulic system. Hydraulic Pump

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Activity 2
Worksheet A Review
Component Description Name Tag Letter/Number
Enables the Pod gear lube to be Upper gear lube
changed with the vessel in the
water. drain/fill

Allows for the adjustment of the Detent Tension


detent tension on the ERC. Adjustment Screws

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Zeus Technician Classroom Qualification
Activity 2 Worksheet A

Tag # Description
1. Hydraulic pump Pressure Sensor
2. Steer A Coil
12. Back up Pump
13. Primary Drive Position
27. Trim Tab A Pressure
29. Trim Tab B Pressure
14. Steer B Coil
3. Hydraulic Tank Pressure Sensor
28. Trim Tab B Coil
4. Steer B Pressure Sensor
15. Steering Select Coil

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Zeus Technician Classroom Qualification
Activity 2 Worksheet A

Tag # Description
8. Transmission Output Speed Sensor (TOSS)
9. Forward Gear Solenoid
19. Hydraulic Oil Level Sensor
5. Secondary Drive Position Sensor
23. Transmission Oil Temperature
6. Water in Drive Sensor
7. Transmission Input Speed Sensor (TISS)
18. Hydraulic Oil Temperature Sensor
20. Transmission Pump Pressure Sensor
21. Trolling Valve Solenoid
10. Pump Pressure Control Coil
11. Low Gear Lube Level Switch

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Zeus Technician Classroom Qualification
Activity 2 Worksheet A

Tag # Description
16. Steer A Pressure
17. Trim Tab A Coil
22. Reverse Gear Solenoid
24. Swash Plate Position Sensor
25. Engine Exhaust Temperature Sensor
26. Trim Tab Position

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Zeus Technician Classroom Qualification
Activity 2 Worksheet B
1. What component provides smooth transmission engagement during Joystick operations?
Trolling Clutch
2. Where can you look to find the transmission and drop box ratio for a Zeus pod?
Transmission and Pod ID tags (Etiquetas)
3. A vessel is brought in with a Tab Spool Stuck Fault. Answer the following questions about this
fault.
A. What will cause this fault? Tab hydraulic spool stuck – actual vs. commanded tab
position deviation excessive
B. What mode fault is this? Sticky
C. What Guardian Strategy will be implemented? Tab Disabled
4. A vessel is brought in with a High Hydraulic Oil Temp Fault. Answer the following questions
about this fault.
A. What will cause this fault? Critical High Hydraulic Oil Temperature Warning
B. What mode fault is this? Non-Sticky
C. What Guardian Strategy will be implemented? Standby Mode
D. You measure the resistance of the Hydraulic Oil Temperature Sensor when the hydraulic
oil is at 77 F and find the resistance to be 96Ω. Is this within acceptable limits? No

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Zeus Technician Classroom Qualification
Activity 2 Worksheet B
5. How does the pressure control valve modify hydraulic pressure in the steering system? By
bleeding pressure off of the pump output circuit
6. A vessel is brought to you that has had an engine compartment fire. You need to order an
Engine and VIP unswitched power harness that is 8 foot in length. What part number should
you use? EA8238
7. What is the part number for the Helm Bundle Kit? EA8236
8. A customer wants a 2nd VesselView display added to his vessel. What harness must be
ordered and what is the part number? VesselView Display Kit EG 8051
9. A customer orders a Cummins Onan generator for his vessel. What extension harnesses
must also be ordered for installation? Can V Extension Harness EA 8252
10. What device is used to reduce exhaust vibration when the vessel is idling? Water Lift Muffler
11. After installing a Zeus system into a vessel you need to perform an exhaust backpressure
test. The vessel has a QSC engine. At rated rpm you find backpressure to be 4.0 in. Hg. Is
this within specifications? No

List the actions that can be taken if backpressure is too high


A. Reduce exhaust system length
B. Eliminate sharp bends
C. Increase exhaust diameter size
D. Reduce muffle restriction
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Zeus Technician Classroom Qualification
Activity 2 Worksheet B
12. If a Zeus pod is going to be installed in a vessel where the hull has been cut out, answer the
following questions.
A. What is the minimum thickness of the hull around the opening? 30.98 mm (1.22 in)
B. What is the maximum thickness of the hull around the opening? 38.1 mm (1.50 in)
C. What is the nominal thickness of the hull around the opening? 31.75 mm (1.25 in)
13. What is the preferred angle of inclination of the driveshaft on a Zeus equipped vessel? 2°
14. Where must the power supply for the MerCathode controller be connected to provide proper
corrosion protection? To the battery positive terminal

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Zeus Technician Classroom Qualification