Seastar Solutions Optimus 360 Operating Instructions & User Manual
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Seastar Solutions Optimus 360 Operating Instructions & User Manual

Joystick control system for outbord powered vessles
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OPERATION INSTRUCTIONS
AND USER'S MANUAL
61
w w w . s e a s t a r s o l u t i o n s . c o m
S I X T Y O N E
Joystick Control System for
ISO 9001
Outboard Powered Vessels

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Questions and answers

Roger Gaudette
April 28, 2025

My optimus has been taking longer to kick in over the last few years when first engaged. Up to 45 seconds

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1 comments:
Mr. Anderson
May 15, 2025

A delay of up to 45 seconds for the Seastar Solutions Optimus 360 to engage could be caused by a gear case jam or failed component. It is recommended to try manual control of the actuator. If there is no motion, disconnect the shift cable at the engine and check the engine.

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Summary of Contents for Seastar Solutions Optimus 360

  • Page 1 OPERATION INSTRUCTIONS AND USER’S MANUAL w w w . s e a s t a r s o l u t i o n s . c o m S I X T Y O N E Joystick Control System for ISO 9001 Outboard Powered Vessels...
  • Page 2 Yacht Council (http://www.abycinc.org) NMEA 2000 is a registered trademark of the National Marine ® Electronics Association. Optimus, Optimus 360, SeaStar, and BayStar are all trademarks of SeaStar Solutions. Evinrude, Suzuki, Yamaha, and Yanmar are trademarks of their respective holders. California...
  • Page 3 Thank you for choosing an Optimus 360 Joystick Control System by SeaStar Solutions. You have chosen a state of the art vessel control system that will provide years of effortless and trouble free steering performance. About this Book This User’s manual contains the information you need to safely operate and maintain your vessel control system.
  • Page 4 This page left intentionally blank. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 5: Table Of Contents

    3.2 Control Head (EST System) ........3-2 3.3 Joystick ..............3-3 3.4 CANtrak Display ............3-4 3.5 Circuit Breakers for Optimus 360 System and Shift and Throttle Control System ....... 3-4 3.6 Pump Control Module (PCM) ........3-5 3.7 Hydraulic Steering Pumps .......... 3-5 3.8 SmartCylinders ............
  • Page 6 14.1 Statement of Limited Warranty ........ 14-1 14.2 Return Goods Procedure ........14-1 appendIX a – Specifications ..........14-2 appendIX b – Station Select protection ......... b-1 appendIX c – trailering and Storage ........b-2 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 7: Abbreviations

    Power Train Sync Reverse Revolutions Per Minute STBD Starboard (right when facing forward) Switch Trolling Mode Wide Open Throttle Note: Some abbreviations not listed here may be found in their respective sections. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 8 A single handle joystick control device that integrates the steering, the gear shift, and the throttle control for multiple engines into one easy-to-use device to provide docking control of the vessel. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 9: Safety Information

    It IS crItIcaL that you read and underStand aLL the poIntS noted. warnInG the optImuS 360 SyStem muSt onLy be InStaLLed by an authorIzed deaLer or oem. Safe operation of the steering system depends upon proper installation and maintenance of the system, and the common sense, safe judgment, knowledge, and expertise of the operator.
  • Page 10 Optimus component. Use only a damp cloth, or a mild detergent if necessary. maintenance Maintain your Optimus 360 System as directed in Section 11 of this manual. Keep our waters clean for all current and future users. Dispose of all fluids in accordance with your local regulations.

  • Page 11: Safety Labels

    Shown Later In thIS manuaL (See SectIon 3.1) control head Label WARNING PID# 682050 Figure 1-1. Optimus 360 Start-In-Gear advisory decal. hydraulic pump Labels CAUTION Figure 1-2. Hydraulic pump labels. © 2012 SeaStar Solutions...
  • Page 12 Safety Labels (continued) pump control module (pcm) Labels Figure 1-3. PCM labels. Smartcylinder Labels Figure 1-4. SmartCylinder labels. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 13 U.S.C.G. REQUIREMENTS OF 33 CFR PART 183, SUB PART L. BE REQUIRED. CONSULT INSTALLATION MANUAL. 5. KEY OFF IGNITION TO SLOW AND STOP VESSEL. PID# 682048 Figure 1-7. Optimus 360 Actuator decal, PID# 682048. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 14 This page left intentionally blank. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 15: Introduction

    System Overview and the First Time Operation sections. An understanding of the system will assure your safety and help you get the most enjoyment from your Optimus 360 joystick control system. 2.2 Optimus 360 System Overview...

  • Page 16: Optimus 360 System Diagrams

    STARBOARD THROTTLE BY SEASTAR SOLUTIONS ACTUATOR NETWORK SERVICE SERVICE TERMINATOR X 2 VALVE VALVE HYDRAULIC HYDRAULIC HOSE HOSE SMART SMART CYLINDER CYLINDER Figure 2-1. Optimus 360 system diagram, single station. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 17 COMPONENTS NOT SUPPLIED BY SEASTAR SOLUTIONS ACTUATOR NETWORK SERVICE SERVICE TERMINATOR X 2 VALVE VALVE HYDRAULIC HYDRAULIC HOSE HOSE SMART SMART CYLINDER CYLINDER Figure 2-2. Optimus 360 system diagram, dual station. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 18 This page left intentionally blank. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 19: Component Identification

    EPS Front Mount Helm EPS Rear Mount Helm EPS Classic Tilt Helm EPS Sport Plus Tilt Helm Figure 3-1. EPS Helm configurations. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 20: Control Head (Est System)

    The blue Take Command light will come on solid when active. For more detailed control head operation, refer to Section 4.0. Figure 3-2. i6800 Control Head. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 21: Joystick

    The joystick can only take control of the vessel when the shift and throttle control head is at neutral idle. See Section 6.0 for detailed Joystick operation. Figure 3-3. Joystick. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 22: Cantrak Display

    See Section 7.0 for details. Part No. ED1700 Figure 3-4. CANtrak display. 3.5 Circuit Breakers for Optimus 360 System and Shift and Throttle Control System These are supplied by the installer and may be mounted in a variety of locations. Check near the batteries, in the circuit breaker box, or near the pump control modules or hydraulic pumps.

  • Page 23: Pump Control Module (Pcm)

    Note: these pumps look similar to the trim pumps that tilt the engines. They can be distinguished by the decal and the green SeaStar EPS steering fluid. Figure 3-6. Hydraulic steering pump. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 24: Smartcylinders

    Instructions on how to proceed will be supplied on the CANtrak display or in Section 10.2. Figure 3-8. Steering service valve warnInG wear a coaSt Guard-approved perSonaL fLotatIon devIce (pfd) when manuaLLy reaLIGnInG enGIneS. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 25: Shift And Throttle Actuators

    There is a manual override feature on the actuators so the engine can be operated manually in case of a fault. Figure 3-9. Shift and throttle actuator. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 26 This page left intentionally blank. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 27: Steering System Operation

    4.0 stEErINg systEm opErAtIoN The steering portion of the Optimus 360 system provides fingertip steering control of multiple high-powered engines. The system provides both power and the adjustment of a number of parameters so the operator has perfect boat response under all conditions.
  • Page 28 This page left intentionally blank. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 29: Control Head Operation

    The EST Quick Reference Guide provides a summary of the control head operation and should be kept on the vessel at all times. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 30: Identification

    Lamp off – station is inactive Note: If the lamp does not come on when you press take command, Station Protection may be enabled. See Appendix B. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 31 • Press either n button. Both lamps will flash green slowly to indicate that TM is engaged. to dISenGaGe trolling mode: • Move both control levers to forward idle or reverse idle position. • Press either n button. The flashing green lamps will go out to indicate that TM is disengaged. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 32 ShIft detent throttLe Figure 5-3. frIctIon warnInG If a danGer or warnInG IS cauSed by the controL SyStem, the controL head neutraL LIGhtS wILL fLaSh red. See SectIon 10. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 33: Joystick Operation

    Note: The A and C buttons are reserved for future use and not active at this time. notIce While the joystick is active the turning resistance of the steering wheel will increase to remind the user that it is disengaged. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 34: Joystick Fundamentals

    * See section 10 for fault handling information. a and c buttons Reserved for future use. Not active at this time. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 35 If an engine stalls while under joystick control the system will allow only forward and reverse motion. To compensate for the reduced power the system will boost the RPM to the running engine. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 36 – rotate to Steer Figure 6-2. prImary motIon – SIdewayS correctIon – rotate to bIaS headInG Figure 6-3. NEutrAl NEutrAl correctIon – prImary motIon – SIdewayS forward/reverSe to dIaGonaL rEvErsE Figure 6-4. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 37: Joystick Tips

    7. The control head must be active at the helm station with the joystick that will be used and the control handles must be in neutral and idle at that station. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 38: Joystick Operation Examples

    3b. If the boat does not stay centered due to wind or current while holding the joystick to the side, just push or pull the joystick fore/aft to correct. 4. Once close to the dock, return the joystick to the center position. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 39 6.3 Joystick Operation Examples (continued) wind Figure 6-8. Figure 6-9. CURRENT Figure 6-10. Figure 6-11. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 40 3. As the boat approaches the slip pull the joystick backwards to stop the boat in front of the slip. Return the joystick to the home position when the boat stops. Figure 6-12. Figure 6-13. Figure 6-14. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 41 5. Pull the joystick back to move the boat into the slip. 6. A short bump forward on the joystick will stop the boat in position. Figure 6-15. Figure 6-16. Figure 6-17. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 42 This page left intentionally blank. 6-10 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 43: Cantrak Display

    7.0 cANtrak DIsplAy 7.1 Purpose The Optimus 360 CANtrak display has an easy to navigate menu system, adjustable backlighting for night use and includes a cover to protect it from the sun when not in use. Figure 7-1. CANtrak display, All Helms Active screen.

  • Page 44: Cantrak Display Navigation

    Increases the setting of the selected item. Accepts a given statement or condition and advances to the next screen. Returns to previous menu. Save Saves change and returns to previous menu. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 45: Cantrak Display Map - All Helms Active

    Device List – Access product information, such as part number and serial number, for each device on the network. * Menu may be deactivated. Contact your dealer. Figure 7-3. CANtrak display map. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 46: Display Screens

    The All Helms Active screen displays the current system operating conditions. It shows the engine RPM, gear position, and rudder angle. It also allows access to the Diagnostics, Adjustment and Display menu screens. Figure 7-4. All Helms Active screen. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 47: Adjust (Adj) Screen

    It is adjustable between 1 and 100. * May not be available on all installations. Contact your dealer/builder. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 48: Display (Disp) Screen

    Figure 7-6. Change of helm settings with speed. * Some installations may not have this feature accessible. Contact dealer/builder. 7.4.3 Display (DISP) Screen The Display screen allows adjustment of the brightness. Figure 7-7. Display adjustment screen. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 49: First Time Use

    Adjusting Screws Figure 8-1. Control Head lever positions. notIce The detent pressure and drag can be adjusted using the adjusting screws on the front surface of the control head. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 50: Initial Start Up

    Figure 8-3. All Helms Active screen (normal steering mode). warnInG on muLtIpLe heLm StatIon boatS aLL SteerInG heLmS are actIve when the optImuS 360 IS turned on. thIS IS the Same aS you wouLd fInd on a conventIonaL hydrauLIc SteerInG SyStem. © 2012 SeaStar Solutions...
  • Page 51 The joystick now has control of the system and is ready for use. Refer to Sections 4.0, 5.0 and 6.0 for detailed steering, control head and joystick operation. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 52: System Inspection

    Injury and/or death. 1. check steering fluid level in all steering pumps. Each Optimus 360 hydraulic pump has a steering fluid reservoir. Ensure the fluid level is between the MIN and MAX marks on the reservoir as shown in the figure below. Use only SeaStar EPS steering fluid (HA5482) in the Optimus 360 System.
  • Page 53 It IS recommended the fuLL SyStem InSpectIon be revIewed on a reGuLar baSIS to retaIn famILIarIty. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 54: Installation Checks

    Figure 8-5. Engine side view when tilted. 2. Sensor cable – Confirm that the SmartCylinder Sensor Cable is tied securely to the hoses with gradual bends as shown figure 8-6. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 55: Initial Sea Trial

    – Try all the various modes and using both primary and secondary actions. If adjustments to the system are required see Section 7.4.2 for steering adjustments or contact your dealer. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 56 This page left intentionally blank. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 57: System Use

    360 is turned on. The conventional steering portion of the Optimus 360 system is designed to operate much like a conventional hydraulic steering system. The boat can be steered from any helm without requiring additional steps to transfer control.

  • Page 58: Autopilot Operation

    InStructIon compLeteLy before enGaGInG the autopILot mode. The Optimus 360 steering system is designed to interface with many autopilot controllers. See your Autopilot’s documentation for specific model compatibility. On boats with an autopilot the steering effort may be noticeably higher when the autopilot is engaged.

  • Page 59: System Faults & Hazards

    (5 times per second). If the danger fault lies in the Joystick system, the joystick Take Command button light will flash red quickly (5 times per second). 10-1 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 60: Warning

    CANtrak display (see figure 10-6). The buzzer will not sound, but the warning triangle will remain until the problem is corrected. You can view the fault description by selecting Faults from the display menu. 10-2 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 61: System Fault Handling

    Provides detailed instructions on how to proceed. In the case of a danger fault, this will instruct the operator what to do and how to proceed should Limp Home mode be required. 10-3 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 62: Limp Home

    Figure 10-2. Limp home instructions, all steering disabled. 10-4 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 63 ONE of the engines. The CANtrak will instruct the operator to realign the non-responsive engine, tilt it out of the water and proceed home immediately using the responsive engine. Figure 10-3. Limp home instructions, no steering on one engine. 10-5 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 64 If the lever cannot be rotated it is likely the fault is in the engine not the control system. a. enGaGement Lever b. controL Lever Figure 10-4. Actuator manual override. 10-6 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 65: Warning Fault Handling

    In rare cases there may be multiple Warning faults at the same time. You can view a list of all active warning faults from the Faults menu on the display. 10-7 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 66 Some system warning faults may result in a reduced steering response and/or reduced throttle position (system will continue to steer normally but may respond slower or limit boat speed). 10-8 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 67: System Fault Handling - Example

    2. If there are no secondary displays on board, carefully verify (at low speed) that the steering system and shift and throttle operates normally then immediately and cautiously proceed to port for service. 10-9 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 68 2. Set all lever A(s) into manual override position. 3. Slowly turn (shift) lever B to engage gear. Then slowly turn (throttle) lever B to raise RPM. 4. Key off ignition to slow & stop. 10-10 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 69: Buzzer

    SeaStar EPS steering fluid when the boat is returned to port. In the event of an extreme emergency, any non-toxic, non-flammable fluid may provide temporary steering. warnInG never uSe brake fLuId In the SteerInG SyStem. 10-11 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 70 This page left intentionally blank. 10-12 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 71: Maintenance

    4. Check for signs of corrosion. If corrosion is present contact your dealer or Teleflex Marine. 5. Check all electrical harnesses and mechanical cables for chafing and wear. 11-1 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...
  • Page 72 SyStem. GREASE SUPPORT ROD, TILT TUBE & SUPPORT BRACKET HOLE GREASE SUPPORT ROD, TILT TUBE & SUPPORT BRACKET HOLE Figure 11-1. Grease points on cylinder mounts. 11-2 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 73: Troubleshooting

    12.0 troublEsHootINg guIDE warnInG Optimus 360 will provide years of safe reliable performance with a minimum of service if properly installed. whenever, in the following text, a solution calls for removal from Optimus 360 steering systems have been designed with protection...

  • Page 74: Replacement Parts

    The Optimus Steering System is designed for use with genuine SeaStar Electronic Power Steering Fluid. Quart HA5482 For a comprehensive listing of part numbers, please refer to: • Book 50, Optimus EPS Installation Manual, part no. 682100 • Book 60, Optimus 360 Installation Manual, part no. 682102 12-2 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 75: Warranty

    In such a case SeaStar Solutions products found to be defective and covered by this warranty, will be replaced at SeaStar Solutions’ option, and returned to the customer.

  • Page 76: Appendix A Specifications

    Maximum System Pressure: 1200 PSI # of wheel turns: Variable from 3.5 to 8 Typical Average Current Draw: ~6 to 8 Amps Oil Type: SeaStar Electronic Power Steering Fluid 14-2 © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 77: Appendix B - Station Select Protection

    StatIon boatS, aLL SteerInG heLmS are actIve when the optImuS epS IS turned on. thIS IS the Same you wouLd fInd on a conventIonaL hydrauLIc SteerInG SyStem. StatIon SeLect onLy appLIeS to the controL head. © 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C...

  • Page 78: Appendix C Trailering And Storage

    AppENDIX c Trailering and Storage When trailering or storing a boat equipped with an Optimus 360 system, install the steering lock clips to all steering cylinders as shown below. These clips keep the engines from drifting, preventing contact with other components which may result in scuffing or cowling damage.
  • Page 80 SEASTAR SOLUTIONS 3831 NO.6 ROAD RICHMOND, B.C. CANADA V6V 1P6 FAX 604-270-7172 www.seastarsolutions.com ISo 10592 © 2012 MARINE CANADA ACQUISITION INC. DBA SEASTAR SOLUTIONS PRINTED IN CANADA FORM NO. 682103 05/14 REV. C...

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