Entrenamiento Sistema de Control SMARTCRAFT

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
Day Two - 1
1/22/2010
Zeus Technician Classroom Qualification
Hull Design
Tunnel design
Zeus Mechanical System
crash_test_video.wmv
Day Two - 4
1/22/2010
Hull Design
Training_rick_davis.wmv
Day Two - 5
1/22/2010
Hull Design
 ..\..\Orginal Zeus
Documents\instructor_guide_classroom\documents\
Zeus_Installation_Manual.pdf
Day One - 6
1/22/2010
Hull Design
Allowing for
perpendicular
pod
installation
integrated tunnel recess
Day One - 7
1/22/2010
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.
Day One - 8
1/22/2010
Hull Design
Day One - 9
1/22/2010
Hull Design
Rob_Mirman_Engine_Compartment.wmv
Day One - 10
1/22/2010
 Similar to Bravo 3 Nomenclature

 Heavier construction and components for increased
drive loads
 PWM Clutch for smooth engagement and operation
of joystick
Day Two - 12
1/22/2010
Hydraulic Clutch Packs
Day Two - 13
1/22/2010
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
Input Shaft with oil

galleries
Oil Gallery
Day Two - 15
1/22/2010
Transfer Gear Box
Day Two - 16
1/22/2010
 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 Hydraulic System
Day Two - 20
1/22/2010
Gen 1
Hydraulic Pump Electrical

Components
1. Hydraulic pump
2 Pump pressure control valve
3 Swash plate position sensor,
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
Mechanically – controlled
variable displacement,
pressure compensated pump.
Day Two - 25
1/22/2010
B
A
Select
Day Two - 27
1/22/2010
Day Two - 28
1/22/2010
Day Two - 29
1/22/2010
• An emergency steering backup pump

• Allows for centering the pod
Day Two - 30
1/22/2010
Steering Backup Pump

Circuit
a - Return hose (if

equipped)
b - Backup pump
c - Up line connection
d - Down line
connection
e - Steering hydraulic
manifold
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
 Hydraulic Schematic_cropped.pdf
Day Two - 35
1/22/2010
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
Day Two - 36
1/22/2010
Activity 2
Activity 2 Activity 2
Worksheet A Worksheet B
On Zeus Simulator At Seats
Day One - 37
1/22/2010
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
1/22/2010
Activity 2
Worksheet A Review
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
Day Two - 39
1/22/2010
Activity 2
Worksheet A Review
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
Day Two - 40
1/22/2010
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
Day Two - 41
1/22/2010
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
Day Two - 42
1/22/2010
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
Day Two - 43
1/22/2010
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
Day Two - 44
1/22/2010
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
Day Two - 45
1/22/2010
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
Day Two - 46
1/22/2010

Entrenamiento Sistema de Control SMARTCRAFT

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Zeus Mechanical and Hydraulic

integrated tunnel recess

 Similar to Bravo 3 Nomenclature

Hydraulic Clutch Packs

Input Shaft with oil

Transfer Gear Box

 Table 4 illustrates the relationship between the

HYDRAULICS FOR ZEUS

Hydraulic Pump Electrical

• An emergency steering backup pump

Steering Backup Pump

a - Return hose (if

The Zeus drive includes integrated

Manual override buttons for steering and trim, including

 Each vessel is unique

This component converts

This hydraulic component helps Power Trim Actuator

In the event of a hydraulic

Cools the hydraulic fluid for the

Cools the oil for the Drop Box.

Holds the oil for the steering

Uses multiple pistons to power

Allows for the adjustment of the Detent Tension

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

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