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Mercury CT60 Manual

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Identification Record
Please record the following information:
System serial number (located on TIM bracket)
Bow thruster serial number
Hull identification number (HIN)
Boat manufacturer
The serial numbers are the manufacturer's keys to numerous engineering details that apply to your
Mercury MerCruiser® power package. When contacting your authorized Mercury MerCruiser dealer
about service, always specify model and serial numbers.
The descriptions and specifications contained herein were in effect at the time this guide was
approved for printing. Mercury Marine reserves the right to discontinue models at any time or to
change specifications or designs without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.
©2009, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision
Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Bravo Two, Pro
Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, Total
Command, VesselView, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all
registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered
service mark of Brunswick Corporation.
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous
design features to assure operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using this product for many boating
seasons. To obtain maximum performance and carefree use, we ask that you thoroughly read this
manual.
The Operation, Maintenance and Warranty Manual contains specific instructions for using and
maintaining your product. We suggest that this manual remain with the product for ready reference
whenever you are on the water.
Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating
will be pleasant.
Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the terms of
the warranty are set forth in the Warranty Sections of this manual. The warranty statement contains
a description of what is covered, what is not covered, the duration of coverage, how to best obtain
warranty coverage, important disclaimers and limitations of damages and other related
information. Please review this important information.
Transom thruster serial number
Boat model
Purchase date
Software calibration version
Engine model
Length

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Summary of Contents for Mercury CT60

  • Page 1 The descriptions and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation.
  • Page 2 At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use. In addition, random Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations.
  • Page 3 Operator Warnings WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 - Warranty Total Command Warranty........2 Mercury MerCruiser Limited Warranty (Total Warranty Registration: United States and Command System Only) .........3 Canada.............2 Transfer of Warranty........4 Warranty Registration: Outside the United States and Canada............2 Section 2 - Getting to Know Your Power Package Total Command............8...
  • Page 6 Owner Service Assistance........38 Parts and Accessories Inquiries....38 Local Repair Service........38 Resolving a Problem........39 Service Away From Home.......38 Mercury Marine Service Offices.......39 Stolen Power Package........38 Ordering Literature..........40 Attention Required after Submersion....38 United States and Canada......40 Replacement Service Parts......
  • Page 7 Section 1 - Warranty Section 1 - Warranty Table of Contents Total Command Warranty........2 Mercury MerCruiser Limited Warranty (Total Warranty Registration: United States and Command System Only) ........3 Canada............2 Transfer of Warranty........4 Warranty Registration: Outside the United States and Canada.........2...

  • Page 8: Total Command Warranty

    All warranty questions can be directed to the address listed below. You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax to Mercury MerCruiser’s warranty registration department with your name, old address, new address, and engine serial number.

  • Page 9: Mercury Mercruiser Limited Warranty (Total Command System Only)

    Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the pre‑delivery inspection process specified by Mercury Marine is completed and documented.

  • Page 10: Transfer Of Warranty

    Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine. Mercury Marine will then arrange for the inspection and any covered repair.
  • Page 11 Mississauga, Canada, L5N 7W6 Fax 1-800-663-8334 Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the distributor closest to you.
  • Page 12 Section 1 - Warranty Notes: Page 6 90-899883210 APRIL 2008...
  • Page 13 Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Total Command............ 8 Switchpad ............9 Joystick ............8 90-899883210 APRIL 2008 Page 7...

  • Page 14: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Total Command The Total Command system controls and coordinates the bow thruster, stern thruster, transmissions, and speed of the engines to provide precise joystick control of the vessel. Total Command also offers an auxiliary switchpad that operates only the thrusters.

  • Page 15: Switchpad

    Section 2 - Getting to Know Your Power Package The vessel response is proportional fore and aft, as well as rotationally, to the joystick input. The farther the joystick is pushed from the center, the more force is going to be produced forward or backward. For example, pushing forward slightly will put the main engines in gear, continuing to the push the joystick farther forward will incrementally throttle the engines and make the vessel move faster.
  • Page 16 Section 2 - Getting to Know Your Power Package The switchpad controls the bow and stern thrusters. It contains four switches to control individual thrusters, a switch to activate and deactivate Total Command, and three status indicator lights. 33495 Callout Control Function Starboard bow thruster button...

  • Page 17: Section 3 - On The Water

    Section 3 - On the Water Section 3 - On the Water Table of Contents Operation Chart—Total Command..... 12 Status Indicator ........14 Total Command Operation......... 12 Capacity Indicator ........15 Overview............12 Fault Indicator ........15 System Start Up..........12 Status Indicator Flashing versus Capacity Basic System Information......13 Indicator Flashing or Solid ......

  • Page 18: Operation Chart-Total Command

    Section 3 - On the Water Operation Chart—Total Command Start Engine Enable Total Command Operate Total Command Disable and Shut Down Turn on all battery Move the joystick the Press the system Steer the rudders to switches and direction that you want the activation switch the straight back converters.

  • Page 19: Basic System Information

    Section 3 - On the Water Basic System Information To engage the Total Command joystick, activate the Total Command system using the steps found in System Start Up. The green status indicator light will remain solidly lit when the system is ready for use. 24704 Joystick (Typical) The joystick controls vessel movement and rotation.

  • Page 20: Advanced System Information

    Section 3 - On the Water Advanced System Information The Total Command system can be engaged any time the engines are keyed on. Once engaged, pressing the system activation switch at any time will immediately deactivate the system. The system will also become inactive if it is idle for more than 15 minutes.

  • Page 21: Capacity Indicator

    Total Command switchpad. If a fault occurs, reset the system by pressing the activation button or turning the engine keys off and on. If the fault persists, contact your Mercury MerCruiser or Cummins MerCruiser Diesel dealer or distributor. 34450...

  • Page 22: Status Indicator Flashing Versus Capacity Indicator Flashing Or Solid

    Section 3 - On the Water Status Indicator Flashing versus Capacity Indicator Flashing or Solid If the Total Command system is active but any of the conditions of operation are not met, the joystick will be disabled and the green status indicator will flash. This is different from the capacity light flashing, in that full operational control resumes and the green light is solid as soon as the operational conditions are met.
  • Page 23 Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves forward 25928 34457 Boat moves aft 25927 34458 Boat moves to starboard without rotating 25929 34459 Boat moves to port without rotating 25931 34460 90-899883210 APRIL 2008...
  • Page 24 Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat rotates clockwise 25921 34461 Boat rotates counterclockwise 25920 34462 Boat moves clockwise around its bow 33912 34463 Boat moves counterclockwise around its bow 25918 34034 Page 18...
  • Page 25 Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves clockwise around its stern 33914 34035 Boat moves aft to the starboard 33913 34036 Boat moves forward to the starboard 34763 34534 Boat moves forward to the port...

  • Page 26: Maneuvering With The Switchpad

    Section 3 - On the Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves aft to the port 34537 34765 Boat moves counterclockwise around its stern 34538 34766 Maneuvering with the Switchpad WARNING A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
  • Page 27 Section 3 - On the Water Movement Switchpad Input Boat Response (shown from light gray to dark gray) Boat moves to port without rotating 33905 25931 Boat rotates clockwise 33906 25921 Boat rotates counterclockwise 33907 25920 Boat rotates clockwise around its bow 33908 33912 Boat rotates counterclockwise around its bow...
  • Page 28 Section 3 - On the Water Movement Switchpad Input Boat Response (shown from light gray to dark gray) Boat rotates counterclockwise around its stern 33910 33913 Boat rotates clockwise around its stern 33911 33914 Page 22 90-899883210 APRIL 2008...
  • Page 29 Section 4 - Specifications Section 4 - Specifications Table of Contents Batteries.............. 24 Thrusters............. 24 Fuses..............24 90-899883210 APRIL 2008 Page 23...

  • Page 30: Batteries

    BCI group size Group 31 Manufacturer Odyssey Manufacturer's part number PC2150 Fuses Thruster Series Voltage Fuse CT60/24V 24 V 200 Amp ANL fuse CT80/24V 24 V 200 Amp ANL fuse CT125/24V 24 V 300 Amp ANL fuse CT165/24V 24 V...

  • Page 31: Section 5 - Maintenance

    Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner and Operator Responsibilities....26 Thruster Motor Maintenance....... 27 Maintenance Schedule........26 General Maintenance ........27 System Maintenance.......... 26 Relays ............28 Electrical Tests and Measurements....26 Brushes ............28 Joystick and Switchpad.........27 Thruster Maintenance.........

  • Page 32: Owner And Operator Responsibilities

    It is the operator's responsibility to ensure the performance of all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation, and to return the vessel to a Mercury MerCruiser dealer or Cummins MerCruiser Diesel authorized repair facility for a periodic checkup. If you have any questions about how to perform these checks, consult your dealer or distributor for additional information.

  • Page 33: Joystick And Switchpad

    To avoid harming the surface finishes and rubber material, do not use a harsh or corrosive solvent to clean the joystick or switchpad. If cracks or tears in the boot or covering appear, contact your authorized Mercury MerCruiser or Cummins MerCruiser distributor repair facility immediately.

  • Page 34: Relays

    Section 5 - Maintenance The electric motor must be kept dry and ventilated. Relays Check the relay contact surfaces, and replace if necessary. Brushes Remove the motor and clean out the dust from the motor brushes with compressed air. While inspecting and blowing the dust out of the motor, inspect the brushes. Replace the brushes if found to be worn by more than 70% of their original length.

  • Page 35: Thruster Leg Maintenance

    Section 5 - Maintenance 5. Remove the propeller pin from the propeller shaft. Propeller pin Propeller shaft Stainless steel seal cover Drive leg 34042 Thruster Leg Maintenance The composite drive leg is lubricated for life. The oil does not need to be changed. The drive leg must not be disassembled, even partially.
  • Page 36 Fixing screw Propeller hub 34045 Description lb‑in. lb‑ft Thruster models CT60, CT80, and CT125 – Thruster models CT165 and CT225 – CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.
  • Page 37 Section 6 - Storage Section 6 - Storage Table of Contents Total Command System Storage......32 Battery..............32 90-899883210 APRIL 2008 Page 31...

  • Page 38: Total Command System Storage

    Section 6 - Storage Total Command System Storage Refer to the vessel owners and operator's manual for details about boat preparations for long‑term storage information, and refer to the appropriate engine and powertrain owners and operator's manual for engine and transmission storage information. Battery Follow the battery manufacturer's instructions for storage.
  • Page 39 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Troubleshooting Guide........34 Controls Not Responding as Expected....34 Total Command Not Operating......34 Capacity Light is On..........35 Thruster Not Operating........34 Fault Light is On ..........35 90-899883210 APRIL 2008 Page 33...

  • Page 40: Troubleshooting Guide

    Total Command does not respond • Check the capacity and fault lights. If neither is on, see your authorized Mercury MerCruiser or Cummins MerCruiser Diesel dealer or distributor. • Place ERC levers in neutral. Total Command does not respond, and the •...

  • Page 41: Capacity Light Is On

    Turn off the keyswitches, and then turn them back on. The fault indicator light stays on after key • Have the system checked by an authorized Mercury MerCruiser or Cummins off‑key on procedure MerCruiser dealer or distributor. 90-899883210 APRIL 2008...
  • Page 42 Section 7 - Troubleshooting Notes: Page 36 90-899883210 APRIL 2008...

  • Page 43: Section 8 - Customer Assistance Information

    Parts and Accessories Inquiries ..... 38 Local Repair Service ........38 Resolving a Problem ........39 Service Away From Home ......38 Mercury Marine Service Offices ....39 Stolen Power Package ......... 38 Ordering Literature..........40 Attention Required after Submersion ... 38 United States and Canada ......

  • Page 44: Owner Service Assistance

    States and Canada, contact the nearest Marine Power International Service Center. Stolen Power Package If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

  • Page 45: Mercury Marine Service Offices

    Section 8 - Customer Assistance Information Resolving a Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership.

  • Page 46: Ordering Literature

    • Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P.O. Box 1939...

This manual is also suitable for:

Ct125Ct165Ct225Ct80Total command

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