SeaSTAR i6800 User manual

i6800 Shift & Throttle System
INSTALLATION MANUAL
ELECTRONIC SHIFT & THROTTLE (EST)
Before you do it your way,
please try it our way
www.seastarsolutions.com
68
SIXTY EIGHT
ISO 9001

All information, illustrations and specifications in this manual are
based on the latest information available at the time of publishing.
The illustrations used in this manual are intended as representative
reference views only. Moreover, because of our continuous product
improvement policy, we may modify information, illustrations and/or
specifications to explain and/or exemplify a product, service or
maintenance improvement. We reserve the right to make any
change at any time without notice.
©2014 SeaStar Solutions.
All Rights Reserved. This document, subject matter and all information
herein is the sole, exclusive and confidential property of SeaStar
Solutions and shall not be disclosed, copied, reproduced or used in
whole or in part for any purpose other than as specifically authorized
in writing by Marine Canada Acquisition (DBA SEASTAR SOLUTIONS).
is a registered trademark of the American Boat &
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.
California
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the
state of California to cause cancer
and reproductive harm.
Wash hands after handling.

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© 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C
IMMEDIATE HAZARDS WHICH, IF NOT ACTED UPON, WILL RESULT
IN SEVERE PERSONAL INJURY OR DEATH.
DANGER
HAZARDS OR UNSAFE PRACTICES WHICH, IF NOT ACTED UPON,
COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
WARNING
Hazards or unsafe practices which COULD result in minor injury or
product or property damage.
CAUTION
Throughout this publication, Dangers, Warnings and Cautions
(accompanied by the International Hazard Symbol )are used to
alert the user to special instructions concerning a particular service
or operation that may be hazardous if ignored or performed
incorrectly or carelessly. Observe Them Carefully!
These safety alerts alone cannot eliminate the hazards that they
signal. Strict compliance with these special instructions during
installation, operation, and maintenance, plus common sense
operation, are important measures to prevent accidents.
This book contains the information required to install and setup the
i6800 EST System.
It is to be delivered to the customer when installation is complete.
Thank you for choosing an i6800 Electronic Shift and Throttle (EST)
System. You have chosen a state of the art shift and throttle system
that will provide years of effortless and trouble free performance.
Information which is important to proper use or maintenance, but is
not hazard-related.
NOTICE
About this Book
Notice to the Installer

ii © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C
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INDEX
1.0 Safety .................................................................................... 1-1
1.1 Safety Labels ................................................................... 1-3
2.0 System Overview..................................................................... 2-1
2.1 System Description........................................................... 2-1
2.2 System Overview Diagram ................................................. 2-2
3.0 Installation ............................................................................. 3-1
3.1 Important Information/Technical Support Contact ............... 3-1
3.2 Installing the Control Head ................................................ 3-1
3.2.1 Control Head Trim Switch Connection ........................ 3-1
3.3 Installing the Actuators .................................................... 3-3
3.3.1 Location, Identification & Mounting .......................... 3-3
3.3.2 Start-In-Gear Protection .......................................... 3-3
3.3.3 Actuator Power Connections .................................... 3-4
3.3.4 Actuator Ignition Connections .................................. 3-4
3.3.5 Shift Actuator Electrical Connections........................ 3-5
3.3.6 Throttle Actuator Electrical Connections.................... 3-6
3.4 CAN2 Harness Connections............................................... 3-7
3.5 Engine RPM Source ........................................................ 3-10
3.5.1 NMEA Gateway Connection..................................... 3-10
4.0 System Setup ......................................................................... 4-1
4.1 Initial Setup...................................................................... 4-1
4.2 Actuator Setup ................................................................ 4-4
4.2.1 Step 1 – Actuator Configuration Using the
CANtrak Display...................................................... 4-4
4.2.2 Step 2 – Cable Installation and Adjustment ............... 4-7
4.2.2.1 Shift Cable Installation................................ 4-8
4.2.2.2 Throttle Cable Installation............................ 4-9
4.2.3 Final Setup and Actuator Adjustment....................... 4-10
4.3 Control Head Setup ........................................................ 4-13
5.0 Sea Trial .............................................................................. 5-1
5.1 Shift Performance............................................................. 5-1
5.2 Throttle Performance ........................................................ 5-1
5.3 Control Head Adjustments................................................. 5-1
5.4 Conclusion of Sea Trial...................................................... 5-2
6.0 System Faults & Hazards......................................................... 6-1
6.1 Hazard Definitions ............................................................ 6-1
6.1.1 Danger ................................................................... 6-1
6.1.2 Warning .................................................................. 6-1
7.0 Warranty .............................................................................. 7-1
7.1 Statement of Limited Warranty ........................................... 7-1
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© 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C

7.2 Return Goods Procedure .................................................... 7-1
7.3 Technical Support.............................................................. 7-1
Appendix A – Mounting Templates .................................................... A-1
A.1 Control Head – Dual Lever. ................................................ A-1
A.2 Control Head – Single Lever............................................... A-2
Appendix B – Using the Color CANtrak Display ................................... B-1
B.1 Display Navigation ............................................................ B-1
B.2 Documentation Conventions ...............................................B-2
B.3 Initial Startup .................................................................. B-3
B.4 Unlocking the Dealer Menu............................................... B-3
B.5 Menu Structure ............................................................... B-4
Appendix C – Setup with Datalink ..................................................... C-1
C.1 Dealer Tools ......................................................................C-1
C.2 Connection........................................................................C-1
C.3 Navigating Datalink ........................................................... C-3
C.4 Actuator Setup ................................................................ C-5
C.4.1 Step 1 – Actuator Configuration Using Datalink ....... C-5
C.4.2 Step 2 – Cable Installation and Adjustment ............. C-7
C.4.3 Step 3 – Final Setup and Actuator Adjustment ......... C-7
C.5 Control Head Setup ......................................................... C-9
Appendix D – Updating Firmware ..................................................... D-1
D.1 Checking Component Firmware Revision Levels.................. D-2
D.1.1 Using DATALINK ...................................................... D-2
D.2 Updating Actuators and Control Head................................ D-3
D.3 Updating the CANtrak Software......................................... D-4
iv © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C

1.0 SAFETY INFORMATION
THE SAFETY INFORMATION PROVIDED HERE IS INTENDED TO
INFORM YOU OF THE DANGERS THAT MAY BE PRESENT BEFORE,
DURING, AND AFTER INSTALLATION. IT IS CRITICAL THAT YOU
READ AND UNDERSTAND THIS INFORMATION.
WARNING
Safe operation of the shift and throttle system depends upon proper
installation and maintenance of the system, and the common sense,
safe judgment, knowledge, and expertise of the operator. Every
installer and operator of the i6800 system should know the following
requirements before installing or operating the system. If you have
any questions regarding any of these warnings, contact SeaStar
Solutions.
1. Read and understand all installation and user's manuals provided
with the i6800 components.
2. Ensure that all components required to complete the installation
are on hand (including cables, harnesses, and the proper tools).
3. SeaStar and i6800 components are highly engineered and safety
tested to ensure system integrity. DO NOT substitute any component.
Substitution with non-SeaStar or non-i6800 components may
compromise system safety, performance, and reliability.
Before installation
1. Check that there is no interference between the control head levers
and the steering wheel or any other dash-mounted components.
2. Operate the trim/tilt switch on the control head lever and verify that
the engines tilt in the expected direction.
3. Check that the mechanical cable bends are smooth and have an
appropriate minimum radius.
After Installation
1. Install system components as directed in this manual. Some
component parts and kits may be supplied with additional
installation instructions—refer also to these instructions.
2. SeaStar and i6800 components are highly engineered and safety
tested to ensure system integrity. DO NOT substitute any component.
Substitution with non-SeaStar or non-i6800 components may
compromise system safety, performance, and reliability.
3. If an instruction is unclear, contradictory, or you are otherwise
uncertain how to proceed, do not guess. Call SeaStar Solutions
technical support.
During Installation
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© 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C

Perform a system inspection as outlined below.
1. Check steering fluid level.
2. Verify immediate steering response when turning steering wheel(s).
3. Inspect all steering hoses, fittings, mechanical cables, and
electrical harnesses for wear, kinks, or leaks.
4. Check for binding, loose, worn or leaking steering or shift/throttle
control components.
5. Verify proper shift and throttle response for all control handles.
Prior to every use
1. WEAR A COAST GUARD-APPROVED PERSONAL FLOTATION
DEVICE (PFD).
2. ATTACH ENGINE SHUT-OFF CORD (LANYARD) TO YOUR PFD.
3. Never allow anyone who is not familiar with the operation of the
shift and throttle system to operate the boat at any time.
4. If boat is equipped with multiple helms, ensure that only one is
used at a time.
5. Know and adhere to all applicable federal, state, and municipal laws
and regulations that govern boating in your area.
During use
The i6800 system requires no special attention after use. Periodically
clean the control head with a damp cloth or mild soap. DO NOT use
acetone, or cleaners containing ammonia, acids, or any other
corrosive ingredients.
After use
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER
WORKING CONDITION.
WARNING
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER
WORKING CONDITION.
WARNING
FAILURE TO COMPLY WITH ANY WARNING, NOTICE OR CAUTION
MAY LEAD TO LOSS OF STEERING OR SHIFT/THROTTLE CONTROL
RESULTING IN A COLLISION AND/OR EJECTION FROM THE BOAT
LEADING TO PROPERTY DAMAGE, PERSONAL INJURY AND/OR
DEATH.
WARNING
1-2 © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C

1.1 Safety Labels
THE LABELS BELOW SHOULD CALL ATTENTION TO THE POSSIBLE
HAZARDS ASSOCIATED WITH THE EQUIPMENT SHOWN LATER IN
THIS MANUAL.
WARNING
Component labels
WARNING
PID# 682050
PID# 682049
A B
Insert appropriate
F, R, IDLE or INCREASE
decal here. Consult
installation manual.
Insert appropriate
F, R, IDLE or INCREASE
decal here. Consult
installation manual.
USING THE ACTUATOR OVERRIDE SYSTEM MAY SEVERELY LIMIT
YOUR BOATS CONTROL. IT SHOULD ONLY BE USED IN AN EMERGENCY
IF YOU ARE UNABLE TO CALL FOR ASSISTANCE. ALWAYS TRY
ALTERNATIVE CONTROLLING DEVICES. PROCEED WITH EXTREME
CAUTION, READ USER’S MANUAL, ALWAYS WEAR A PFD & LANYARD.
MANUAL OVERRIDE OPERATION
ACTUATOR
1. MOVE ALL LEVERS AIN THE DIRECTION OF ARROW TO
DISENGAGE DRIVE MECHANISM.
2. ROTATE "SHIFT" LEVER BCLOCKWISE, OR COUNTER-
CLOCKWISE TO MOVE CONTROL CABLE INTO DESIRED GEAR.
3. CONFIRM YOUR DESIRED GEAR IS ENGAGED
BEFORE APPLYING THROTTLE.
4. VERY SLOWLY ROTATE LEVER BON THROTTLE ACTUATOR
TO “INCREASE” RPM. NO MORE THAN 1/2 TURN SHOULD
BE REQUIRED.
5. KEY OFF IGNITION TO SLOW AND STOP VESSEL.
U.S. COAST GUARD REQUIRES START-IN-GEAR PROTECTION.
IF YOUR ENGINE DOES NOT HAVE THIS FEATURE, THIS CONTROL
SYSTEM WILL PROVIDE START-IN-GEAR PROTECTION MEETING
U.S.C.G. REQUIREMENTS OF 33 CFR PART 183, SUB PART L.
CONSULT INSTALLATION MANUAL.
PID# 682048
Affix PORT/STARBOARD decal here,
consult installation manual.
Affix SHIFT/THROTTLE decal here,
consult installation manual.
WARNING
WARNING
Figure 1-1. Start-In-Gear Advisory Decal, PID# 682050.
Figure 1-2. A and B Locator Decal, PID# 682049.
Figure 1-3. Actuator decal, PID# 682048.
The labels shown below are found on the i6800 actuators .
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