Section 5 - Maintenance
Page 26 90-899883210 APRIL 2008
Owner and Operator Responsibilities
This manual only covers the Total Command system, and does not address the maintenance of the
engines, transmissions, or other vessel components or systems. For information covering the operation
and maintenance of your engine and transmission, refer to the appropriate engine owners and operators
manual. For all other information, refer to your vessel operations manual.
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. While many owners are capable of performing these checks, it is best to have all checks and
maintenance performed by a trained service technician.
Normal maintenance, service, and replacement parts are the responsibility of the owner or operator and
as such, are not considered defects in workmanship or material within the terms of the warranty. Individual
operating habits and usage contribute to the need for maintenance service.
Proper maintenance and care of your Total Command system will ensure optimum performance and
dependability, and will keep your overall operating expenses at a minimum. See your Mercury MerCruiser
dealer or your Cummins MerCruiser Diesel authorized repair facility for parts and service.
Maintenance Schedule
Maintenance
Task Interval Maintenance to Be Performed
Annually or as
needed;
whenever vessel
is out of the water
• Check for and remove fish line and other obstructions from the propellors and tunnels.
• Clean and paint thruster leg with anti‑fouling paint
Every 100 hours
or annually
(whichever occurs
first)
• Conduct visual checks of the entire system for corrosion, abrasion, or breakage
• Check power and control cables for abrasion and corrosion
• Clean and tighten all the connections
• Check the state of the batteries (Best performed by a trained technician)
• Cover the drive leg seals with silicone grease (Best performed by a trained technician)
Every 200 hours
or 2 years
• Check for oil leakage on the thruster drive leg
• Remove the thruster propeller(s) to check for fishing line or other debris on the propeller shaft (Best
performed by a trained technician)
Every 300 hours
or 3 years
• Check relay contacts for wear or damage (Best performed by a trained technician)
• Check motor brushes for excessive wear or damage (Best performed by a trained technician)
System Maintenance
Electrical Tests and Measurements
A constant drop in voltage is the most frequent cause of rapid deterioration of the relays and motor brushes.
Check the condition of the batteries, connections, and power cables as specified in the Maintenance
Schedule. These checks are best performed by trained technicians with special equipment.
NOTICE
Operating the thrusters out of water for any amount of time can damage the motors or seals. Perform
tests only with the thrusters completely submerged in water to prevent damage.
Conduct all operational tests under normal operating conditions, with the vessel in the water, with fully
charged batteries, with the engines running and the charging system on. Do not operate the system with
the vessel out of the water.
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