Boston Whaler 21 Justice Series Operation & Maintenance Manual
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Boston Whaler 21 Justice Series Operation & Maintenance Manual

Boston Whaler 21 Justice Series Operation & Maintenance Manual

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Operation & Maintenance Manual
Boston Whaler
®
®
21 Justice
Series
©
2013 Brunswick Commercial & Government Products. All Rights Reserved.
420 Megan Avenue Edgewater Florida 32132 USA

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Summary of Contents for Boston Whaler 21 Justice Series

  • Page 1 Operation & Maintenance Manual Boston Whaler ® ® 21 Justice Series © 2013 Brunswick Commercial & Government Products. All Rights Reserved. 420 Megan Avenue Edgewater Florida 32132 USA...
  • Page 2 Safety Notices Brunswick Commercial & Government Prod- ucts reserves the right to make changes at This manual uses three levels of notification any time, without notice, to features, specifi- for safety-related information. cations, and model availability. The right is also reserved to change any specification, The signal words CAUTION, WARNING, and part, or system without incurring any obliga- DANGER identify specific levels of hazard.

  • Page 3: Table Of Contents

    Table of Contents Section 1 - Safety Operator Responsibilities ......1-1 Giving Assistance ........1-1 Personal Flotation Devices ....1-2 Exhaust Emissions .........1-3 Fire Extinguishers ........1-4 Fires ............1-4 Severe Weather ........1-5 EPIRB ............1-5 Boat Load Capacities ......1-6 Capsizing ..........1-6 Swamping ..........1-7 Diving Operations ........1-7 Dive/Rescue Door ........1-8 Proposition 65 Information ....1-9 Deck Occupancy Chart ......1-10...
  • Page 4 Table of Contents Section 2 - Boat Operation Pre-operation Checklist ......2-1 Boat Trim Tabs ........2-19 Ignition Shutoff Switch ......2-2 Operation ........2-20 Main Engine Key Switch ......2-4 Stopping Procedure ......2-21 Battery Parallel Switch ......2-6 Trailering ..........
  • Page 5 Table of Contents Section 3 - Fuel Systems Safety Warnings ........3-1 General Description ........3-2 Fuel System Diagram ......3-4 Racor® Gasoline Filter ......3-6 Fuel Gauge and Sending Unit ....3-7 Bonding System ........3-8 Maintenance ........3-8 Repair ..........3-8 Fueling Procedures ........3-9 Safety Warnings .......3-9 Static Electricity ......3-10 General Guidelines ......3-11 Contaminated Gasoline ......3-12...
  • Page 6 Table of Contents Section 4 - Boat Systems General Description ....... 4-1 Battery Status Indicator ..... 4-15 Control Console Layout ......4-2 Bilge Pump Special ....... 4-15 Steering System ........4-4 Console Interior Light ......4-16 Steering System Diagram ...... 4-5 T-top Combination Light ......
  • Page 7 Table of Contents Section 5 - Battery Systems General Description ........5-1 Batteries ...........5-2 Safety Warnings .......5-2 Capacities .........5-3 Charging ...........5-4 Grounding and Bonding ......5-5 Definitions ........5-5 Grounding ........5-5 Bonding ..........5-6 Battery Switches ........5-8 Battery Parallel Switch ....5-8 Battery OFF-ON Switches ....5-9 Bilge Pump Special ......5-9 DC Power Distribution ......5-10 Outboard Engine ......5-10...
  • Page 8 Table of Contents Section 6 - Boat Maintenance Section 6 - Maintenance Specifications ......... 6-1 Batteries ..........6-12 Hull Identification Number ..... 6-2 Safety Warnings ......6-12 Options ............ 6-3 Capacities ........6-13 Hull Maintenance ........6-3 Maintenance ........6-13 Washing ...........

  • Page 9: Operator Responsibilities

    Safety Section 1 Operator Responsibilities It is expected by Brunswick Commercial & Govern- ment Products (BCGP) that the personnel authorized to operate this boat are experienced boat handlers familiar with high-performance boating. BCGP cannot predict, nor warn against, every possible hazardous situation related to the operation and maintenance of this boat.

  • Page 10: Personal Flotation Devices

    Section 1 Safety Personal Flotation Devices Personal Flotation Devices (PFDs) are designed to save lives. It is your responsibility to ensure that the boat has a sufficient number of PFDs for your crew. It is your responsibility to ensure that non-swimmers wear PFDs at all times and that everyone wears a PFD during emergencies, special operations, and severe weather.

  • Page 11: Exhaust Emissions

    Safety Section 1 Exhaust Emissions Gasoline-powered engines produce carbon monoxide when they are running. Carbon monoxide is a color- less and odorless gas. It is extremely toxic. Always be aware of operating conditions that might allow carbon monoxide to collect in occupied spaces on your boat.

  • Page 12: Fire Extinguishers

    Section 1 Safety Fire Extinguishers Your boat is equipped with at least two 2¾-pound United States Coast Guard approved Type ABC fire extinguishers. Each extinguisher is UL Rated 1-A:10- BC. This rating indicates that each extinguisher can be used to fight Class A, B, and C fires. These classes include fires involving wood, cloth, gasoline, oil, grease, and live electrical equipment.

  • Page 13: Severe Weather

    Safety Section 1 Severe Weather Follow these important safety precautions if you must operate your boat in severe weather conditions: • Review the condition and operation of all safety and communication gear • Have everyone wear personal flotation devices • Verify that your radio’s Digital Selective Calling system (DSC) is functioning •...

  • Page 14: Boat Load Capacities

    Section 1 Safety Boat Load Capacities The United States Coast Guard requires boats less than 20 feet (6 m) to display a capacity plate that indi- cates the maximum number of people and the maxi- mum weight that the boat can support under normal operating conditions.

  • Page 15: Swamping

    Safety Section 1 Swamping Swamping (flooding the interior of the boat) can occur for a number of reasons, including severe weather conditions, improper operation, and improper load- ing. Consider the following: • Know the safe loading limits for this boat under normal conditions.

  • Page 16: Dive/Rescue Door

    Operating a Boston Whaler when the dive/rescue door is out requires experience and a high level of skill. Always operate any boat within the limits of your expe- rience.

  • Page 17: Proposition 65 Information

    Safety Section 1 Proposition 65 Information When you received your boat, NMMA hang tag part number NW501-07 was attached to the steering wheel. The distribution of this tag is required by Cali- fornia’s Safe Drinking Water and Toxic Enforce- ment Act of 1986. This hang tag outlines important information about certain chemicals known by the State of California to cause cancer and birth defects.

  • Page 18: Deck Occupancy Chart

    Section 1 Safety Deck Occupancy Chart 1-10...
  • Page 19 Safety Section 1 Working Decks: Do not allow passengers on these decks while the boat is underway. These decks can only be used when you are at the dock, mooring, or anchoring. Accommodation Decks: You can allow passengers to move around these decks while the boat is under- way.

  • Page 20: Warning Label Chart

    Section 1 Safety Warning Label Chart 1-12...
  • Page 21 Safety Section 1 1 1017078 Do Not Stand 2 1017136 Hi-performance Boat 3 1016518 Steering Effort 4 1950698 Rotating Propellers 5 2090315 Dive/Rescue Door 6 1811368 Carbon Monoxide 7 1744737 Discharge of Oil 8 2025442 NMMA Capacity Plate 9 0995704 Fuel Fill 0 1016898 Do Not Drill, Fuel Lines...
  • Page 22 Operator Notes 1-14...

  • Page 23: Pre-Operation Checklist

    Boat Operation Section 2 Pre-operation Checklist Review all the items on this checklist each time you prepare for a mission. Resolve any issues before you begin your mission. ❑ Drain plug installed in hull ❑ Hull in seaworthy condition ❑ Submit mission plan to officer-in-charge ❑...

  • Page 24: Ignition Shutoff Switch

    Section 2 Boat Operation Ignition Shutoff Switch Your boat is equipped with one ignition shutoff switch. The ignition shutoff switch is located on the control console face. The ignition shutoff switch is designed to shut off the outboard engine if you move away from the helm sta- tion by accident, either by falling down or by being ejected from the helm seat.
  • Page 25 Boat Operation Section 2 Understand this important information about your ignition shutoff switch: • It is your responsibility to decide when to attach the switch lanyard, but we strongly recommend that you use the shutoff switch anytime you are operating the boat. •...

  • Page 26: Main Engine Key Switch

    Section 2 Boat Operation Main Engine Key Switch Your boat is equipped with one main engine key switch. The key switch is located on the control con- sole face. The key switch controls the starting, run- ning, and stopping of the outboard engine. The key switch also controls the operation of certain engine accessory systems.
  • Page 27 Boat Operation Section 2 To START the outboard engine, the control lever must be in the NEUTRAL position. The ignition shutoff switch clip and lanyard must be attached to the shutoff switch. Turn the main engine key switch to the ON position and then to the START position.

  • Page 28: Battery Parallel Switch

    Section 2 Boat Operation Battery Parallel Switch Your boat is equipped with an emergency battery par- allel switch. The switch is located on the control con- sole face. You can use the emergency battery parallel switch to connect the house battery and the engine starting battery in parallel if the outboard engine will not start due to low battery voltage.

  • Page 29: Starting Procedure

    Boat Operation Section 2 Starting Procedure Use the following checklist each time you start the out- board engine. Additional detailed information about these systems is covered in the engine operator’s manual. ! DANGER Never start or operate the engine when people are in the water near your boat.

  • Page 30: Shift And Throttle Control

    Section 2 Boat Operation Shift and Throttle Control Boat direction, boat speed, and close-quarter maneu- vering are controlled by the single-lever control. The single-lever control includes gear selection, engine speed, and engine trim angle functions. Additional detailed information about your single-lever control is covered in the engine operator’s manual.

  • Page 31: Speed Control

    Boat Operation Section 2 Speed Control • Move the shift lever forward from the FORWARD gear detent to increase engine speed in forward gear. • Move shift lever backward from REVERSE gear detent to increase speed in reverse gear. Engine Trim ! WARNING Certain combinations of engine trim angle, boat operating angle, and boat speed can reduce...
  • Page 32 Section 2 Boat Operation You must determine the correct engine trim adjust- ments through experimentation or experience, based on your mission loads and operating conditions. • Your single-lever control has an engine trim switch located on the control lever. • The trim switch moves the outboard engine through its trim range to change general boat operating angle.

  • Page 33: Engine Gauges

    Boat Operation Section 2 Engine Gauges Your boat might be equipped with a number of dash- mounted gauges that display the condition of various engine systems. The gauges power up when the engine ignition switch is turned to the ON position. The engine gauges are illuminated for nighttime oper- ation.

  • Page 34: Hour Meter

    Section 2 Boat Operation Hour Meter The hour meter records cumulative hours of engine operation. The hour meter powers up when the engine ignition switch is turned to the ON position. Always turn the engine ignition switch to the OFF posi- tion when the engine is secured from service.

  • Page 35: Water Pressure Gauge

    Boat Operation Section 2 Water Pressure Gauge The water pressure gauge displays the pressure in the engine’s cooling system. The gauge’s unit of measure is pounds per square inch (PSI). The water pressure gauge is a good indicator of cool- ing system condition.

  • Page 36: Trim Gauge

    Section 2 Boat Operation Trim Gauge The trim gauge measures the engine’s angle position relative to the boat’s transom. The first 15° of move- ment is the engine’s trim range. The additional engine movement is referred to as the tilt range. Engine movement through the tilt range does not reg- ister on the trim gauge.

  • Page 37: Smartcraft Vessel View® System

    Boat Operation Section 2 ® SmartCraft Vessel View System Your boat might be equipped with Mercury Marine’s SmartCraft Vessel View boat and engine information system. The Vessel View color LCD display is located on the control console, directly above the steering wheel.

  • Page 38: Propellers

    Section 2 Boat Operation Propellers Your outboard engine is equipped with a propeller of a tested size and design to provide best engine and boat performance. Refer to the engine operator’s manual for detailed information about propeller designs and the correct propeller selection method.
  • Page 39 Boat Operation Section 2 Reducing propeller pitch and diameter will increase acceleration and load carrying capability, with a slight decrease in top speed. It will also increase the engine’s full-throttle RPM at a rate of about 150 RPM per inch of pitch change. Increasing propeller pitch...

  • Page 40: Load Distribution

    Section 2 Boat Operation Load Distribution Placement and concentration of non-permanent loads in a boat can affect boat performance and crew safety. Refer to Boat Load Capacities in Section 6 of this manual for additional information. ! WARNING Improper operation, excessive loading, improper load distribution, and mismatching...

  • Page 41: Boat Trim Tabs

    Boat Operation Section 2 Boat Trim Tabs ® Your boat is equipped with Lenco electro-mechanical trim tabs. The trim tab control buttons and LED indica- tor lights are located on the control console face, near the engine controls. Using the boat trim tabs properly requires experience and skill.

  • Page 42: Operation

    Section 2 Boat Operation Operation The trim tab switch panel is labeled and wired to make tab operation simple. When operating the trim but- tons, think of how you want the bow of the boat to move to properly trim the boat. To lower the port bow, push the left DOWN button.

  • Page 43: Stopping Procedure

    Boat Operation Section 2 Stopping Procedure Use the following checklist at the end of each mission to verify that the appropriate boat systems are config- ured for a short period of non-use at the dock. If you are not going to use the boat for a long period of time, refer to Off-Season Storage in Section 6.

  • Page 44: Trailering

    Section 2 Boat Operation Trailering If Boston Whaler supplied the trailer for your boat, it is designed specifically for your boat and it is commer- cial-grade. The trailer construction is heavy-duty and it exceeds the capacity requirements for your boat.
  • Page 45 Boat Operation Section 2 If you supplied the trailer for your boat, you must verify that the trailer’s design is adequate for your boat. Review these guidelines when evaluating a customer- supplied trailer: • The trailer’s net carrying capacity must exceed the weight of the boat in its fully-loaded condition •...

  • Page 46: Safety Checklist

    Section 2 Boat Operation Safety Checklist Use the following safety checklist to verify that your boat, trailer, and towing vehicle are in good condition. Use this checklist each time you prepare for a mission. Resolve any issues before beginning your mission. ❑...

  • Page 47: Towing

    Boat Operation Section 2 Towing ! WARNING Tow vehicle GCWR must exceed the combined weights of your tow vehicle, boat, and trailer. Overloading the tow vehicle is unsafe and could cause loss of vehicle control. Towing your boat on a trailer requires experience and skill.

  • Page 48: Backing

    Section 2 Boat Operation Backing Backing a trailer requires experience and skill. Always operate a towing vehicle within the limits of your expe- rience. If you do not have this experience, ask some- one to instruct you or gain experience through experimentation under controlled conditions.

  • Page 49: Lifting And Slinging

    Boat Operation Section 2 Lifting and Slinging Safety Warnings ! DANGER Verify that the lifting equipment, spreader bars, slings, attaching hardware professionally certified to a working load of at least 6000 pounds (2722 kg) with a safety factor of five. Failure of any lifting component could cause extensive damage to the boat, serious injury, or death.

  • Page 50: Gunwale Lifting Eyes

    6000 pounds (2722 kg) with a safety factor of five. Your boat might have been shipped with a Boston Whaler lifting sling set that meets all manufacturer requirements for lifting this boat.

  • Page 51: Forklift

    Boat Operation Section 2 Forklift You can use a large marine forklift to move your boat. The forklift must be professionally rated to a working load of at least 6000 pounds (2722 kg) with a safety factor of five. Adjust the forks to lift the boat evenly. The forks must not contact any thru-hull fittings on the bottom of the boat.
  • Page 52 Operator Notes 2-30...

  • Page 53: Safety Warnings

    Fuel Systems Section 3 Safety Warnings ! WARNING Inspect your fuel system and fuel tank before each mission. Correct the cause of any gasoline leak immediately. Ventilate the area to eliminate gasoline vapor before energizing any electrical circuits or starting the outboard engine. ! DANGER Leaking gasoline is a fire and explosion hazard.

  • Page 54: General Description

    Section 3 Fuel Systems General Description Read and understand all the fuel-related information and warnings in this section and in your outboard engine operator’s manual. Your boat is equipped with a built-in gasoline fuel sys- tem that includes an aluminum fuel tank. The fuel tank is manufactured using marine-grade 5052-H32 alumi- num alloy and is installed in the mid-bilge area.
  • Page 55 Fuel Systems Section 3 The Fuel System Diagram in this section shows loca- tions of the fuel tank, fuel fill, fuel tank vent, fuel level sending unit, fuel withdrawal tubes, fuel shutoff valves, fuel filter, and certain emission system components. The fuel fill cap is located on the starboard ring deck, midship.

  • Page 56: Fuel System Diagram

    Section 3 Fuel Systems Fuel System Diagram...
  • Page 57 Fuel Systems Section 3 1 Valve, fuel level vent 2 Valve, flow-control 3 Cap, fuel fill 4 Tank, gasoline, 90 gallons 5 Sender, fuel level 6 Label, manufacturer compliance 7 Valve, grade level vent 8 Tube, fuel withdrawal (3 per tank) 9 Valve, fuel shutoff (3 per tank) 0 Hose, fuel distribution, USCG A1 A Canister, carbon, vent...

  • Page 58: Racor® Gasoline Filter

    Section 3 Fuel Systems ® Racor Gasoline Filter Your boat might be equipped with one Racor 320R- RAC-01 gasoline filter. This filter features a water- separating 10-micron filter element, a replaceable spin-on canister, and a clear bowl to help detect water in your fuel.

  • Page 59: Fuel Gauge And Sending Unit

    Fuel Systems Section 3 Fuel Gauge and Sending Unit The fuel tank has an electric sending unit that sends fuel level information to a fuel gauge located at the helm station. The fuel level sending unit is manufac- tured by ISSPRO. The sending unit is fully electronic and compatible with Mercury Marine’s SmartCraft gauge system.

  • Page 60: Bonding System

    Section 3 Fuel Systems Bonding System A system of green #8 awg insulated copper wires forms a common bond among most non-current carry- ing metal objects in your boat, including the fuel tank, the fuel fill cap, and the bonding plate on the hull. Bonding is the process of connecting various metal components in the boat to a common electrical con- tact.

  • Page 61: Fueling Procedures

    Fuel Systems Section 3 Fueling Procedures Safety Warnings ! DANGER Gasoline vapor is extremely flammable and highly explosive under certain conditions. Always stop the engines and never smoke or allow open flames or sparks within 50 feet of the fueling area when refueling. ! DANGER A discharge of static electricity can ignite gasoline vapor, causing serious injury, death,...

  • Page 62: Static Electricity

    Section 3 Fuel Systems Static Electricity A discharge of static electricity can ignite gasoline vapor that has accumulated during the fueling pro- cess. Use extreme caution when fueling your boat under unusual circumstances such as when the boat is suspended in a boatlift. Your boat has important safety features and systems that can be defeated by not following standard fueling practices.

  • Page 63: General Guidelines

    Fuel Systems Section 3 General Guidelines Also follow these important guidelines during fuel- ing operations: ! WARNING This fuel system is not designed to support an automatic “hands free” fuel nozzle. Never use an automatic fuel nozzle to fill this tank and never leave a fueling process unattended.

  • Page 64: Contaminated Gasoline

    Section 3 Fuel Systems Contaminated Gasoline Water from condensation and sediment from contami- nated gasoline can collect in your fuel tank. Contami- nated gasoline can damage boat fuel system components, corrode the fuel tank, clog fuel filters, and damage your engine’s fuel system. Your fuel filter inspection and servicing routine is directly related to the quality and quantity of gasoline that you take on-board.

  • Page 65: Blended Fuels

    Fuel Systems Section 3 Blended Fuels ! WARNING The components in your boat fuel system are designed to work with automotive gasoline containing up to 10% ethanol, by volume. Using automotive gasoline with higher concentrations of ethanol will damage boat fuel system components and might cause fuel leaks.
  • Page 66 Section 3 Fuel Systems • If E-10 gasoline absorbs enough moisture, it can suffer phase separation. The ethanol and water mixture will fall out of suspension and collect in the lowest parts of the fuel system. The ethanol and water mixture can damage engines, clog fuel filters, and corrode metal fuel system parts.

  • Page 67: General Description

    Boat Systems Section 4 General Description This section contains general theory and functional information about the boat systems. This information is intended to give you an idea about how each boat system is configured and how it should be used. The content of this section is based on the most cur- rent design and assembly information available at the time of publication.

  • Page 68: Control Console Layout

    Section 4 Boat Systems Control Console Layout...
  • Page 69 Boat Systems Section 4 1 Light, anchor 2 Radio, VHF 3 Control head, Whelen light bar 4 Panel, switch, floodlights 5 Floodlights, LED (4 places) 6 Compass, magnetic 7 Display, navigation 8 Touch pad, ACR spotlight 9 Outlet, accessory, 12 VDC 0 Panel, switch, helm station A Engine instrumentation B Panel, switch, Lenco tabs...

  • Page 70: Steering System

    Section 4 Boat Systems Steering System The steering system installed in your boat is a Teleflex Sea Star II hydraulic system. This is a manually oper- ated, closed-loop hydraulic system requiring no pumps or electric motors. The system consists of the follow- ing components: •...

  • Page 71: Steering System Diagram

    Boat Systems Section 4 Steering System Diagram 1 Outboard engine 5 Helm reservoir 2 Steering cylinder 6 Fill port 3 Steering arm 7 Steering wheel 4 Hydraulic hoses...

  • Page 72: Navigation Lights

    Section 4 Boat Systems Navigation Lights Your boat is equipped with navigation lights for your safety. Regulations state that all boats, regardless of size, must display navigation lights at night. Your navigation lights let people operating other ves- sels know the approximate size of your boat and the direction your boat is traveling.

  • Page 73: Compass

    Boat Systems Section 4 Compass ! WARNING magnetic compasses subject magnetic interference, which can produce errors called deviation. Compass deviation can contribute to inaccurate course plotting and position fixes, placing your crew, your boat, and others at risk. Deviation Your magnetic compass is located in line with the helm station, below the operator’s line of sight so it can be easily read during normal boat operation.

  • Page 74: Bilge Pump

    Section 4 Boat Systems Bilge Pump Your bilge pump system consists of one 1500 gallon per hour (GPH) pump. The bilge pump is connected to a water level sensor that will automatically activate the system when water in the bilge reaches a depth of about two inches.

  • Page 75: Operation

    Boat Systems Section 4 Operation The bilge pump is controlled by a 2-position rocker switch located on the helm station switch panel. The AUTO switch position supplies constant power to the water level sensor so water is pumped anytime it is detected.

  • Page 76: Battery Parallel Switch

    Section 4 Boat Systems Battery Parallel Switch Your boat is equipped with an emergency battery par- allel switch. The switch is located on the control con- sole face. You can use the emergency battery parallel switch to connect the house battery and the engine starting battery in parallel if the outboard engine will not start due to low battery voltage.

  • Page 77: Trim Tabs

    Boat Systems Section 4 Trim Tabs ® Your boat is equipped with Lenco electro-mechanical trim tabs. The trim tab system consists of four major components. The switch panel with LED tab indica- tors is located at the helm station, near the engine controls.

  • Page 78: Trim Tab Control Box

    Section 4 Boat Systems Trim Tab Control Box The trim tab control box operates on power supplied through the accessory fuse block. The trim tab power circuit is protected by a 20-amp blade fuse. The trim tab control box senses 12 VDC when the outboard engine ignition key switch is in the ON position.

  • Page 79: Proper Boat Trim

    Boat Systems Section 4 Proper Boat Trim All boats “break over” or get on plane at a particular speed. This speed is determined by load distribution, water conditions, and other factors. Trim tabs allow your boat to plane at speeds below its natural planing speed.

  • Page 80: Trim Tabs And Engine

    Section 4 Boat Systems Trim Tabs and Engine Adjusting the trim tabs in conjunction with the trim function on your outboard engine will improve your boat performance and maneuverability. When the boat comes on plane, adjust the trim tabs to achieve the desired running attitude of the boat.

  • Page 81: Signal Horn

    Boat Systems Section 4 Signal Horn Your boat is equipped with a 12 VDC signal horn. The signal horn is installed on the control console face. The HORN push button switch is located on the con- sole face, near the steering wheel. This signal horn satisfies United States Coast Guard Navigation Rule 36 for signals to attract attention.

  • Page 82: Console Interior Light

    Section 4 Boat Systems Console Interior Light Your control console is equipped with an interior dome light. The dome light is used to light the interior of the console for inspection or servicing. It is accessed through the console door. The OFF-ON rocker switch for the console interior dome light is located on the light fixture.

  • Page 83: Floodlights

    Boat Systems Section 4 Floodlights Your boat might be equipped with one or more 12 VDC floodlights. The floodlights are usually mounted on the T-top and the tow tower frame. You can use the floodlights to illuminate the deck or surrounding water while you are working or doing boarding opera- tions.

  • Page 84: Siren And Strobe Light

    Section 4 Boat Systems Siren and Strobe Light ® Your boat might be equipped with a Whelen flush- mount siren and strobe light. The normal mounting location is on the forward side of the control console. Use the siren control head to operate the various strobe, radio, siren, and public address features.

  • Page 85: Remote Spotlight

    Boat Systems Section 4 Remote Spotlight Your boat might be equipped with a remotely operated ® spotlight manufactured by ACR . The spotlight is usu- ally mounted on the T-top or a folding mast. The soft- touch remote control is mounted on the console face, near the steering wheel.

  • Page 86: Towing System

    Section 4 Boat Systems Towing System Your boat might be equipped with a towing system. Towing another boat requires experience and skill. Always operate any boat within the limits of your expe- rience. If you do not have this experience, ask some- one to instruct you or gain experience through experimentation under controlled conditions.

  • Page 87: Being Towed

    Boat Systems Section 4 • Keep all crew in both boats clear of the tow rig. • Keep your tow line clear of your engines and pro- pellers. • Always avoid shock loading your tow rig and tow- ing system. Never attempt to jerk an excessive load into motion.

  • Page 88: Elci System

    Section 4 Boat Systems ELCI System If your boat is equipped with a 110 VAC or 220 VAC shore power system, the installation includes an elec- trical leakage circuit interrupter (ELCI). The ELCI system is an important safety feature designed to elim- inate the possibility of stray current in the water around your boat when the shore power system is active.

  • Page 89: Sea Water Washdown Pump

    Boat Systems Section 4 Sea Water Washdown Pump Your boat might be equipped with a 12 VDC sea water washdown system. The sea water pump and sea strainer are located in the transom area. The pump and sea strainer can be inspected and serviced through the transom hatches just forward of the engines.
  • Page 90 Operator Notes 4-24...

  • Page 91: General Description

    Battery Systems Section 5 General Description Your boat is equipped with a 12 volt direct current (12 VDC) electrical system. The 12 VDC electrical system provides power to all DC electrical loads on the boat. The complete 12 VDC electrical system consists of six main power distribution circuits that are electrically connected on the negative side of the system.

  • Page 92: Batteries

    Section 5 Battery Systems Batteries Safety Warnings ! CAUTION Batteries should always be enclosed in the covered battery boxes provided with your boat. The boxes will contain any spilled acid and will protect the battery terminals from damage or shorting due to contact with metal objects. The battery boxes should always be secured using the heavy-duty straps and aluminum trays provided.

  • Page 93: Capacities

    Battery Systems Section 5 Capacities ® Exide marine heavy-duty 12-volt batteries are nor- mally selected for your boat. One Group 24 1000 marine cranking amp (MCA) battery is provided for engine starting and one Group 27 115 amp hour, deep cycle battery is normally provided for the boat’s electri- cal accessories.

  • Page 94: Charging

    Section 5 Battery Systems Charging The outboard engine alternator charges the two bat- teries when the engine is running above idle speed. All outboard engines charge their starting batteries through the starting circuit. Some outboard engines charge the house battery through an integral auxiliary charging circuit and some require an external battery charge isolator.

  • Page 95: Grounding And Bonding

    Battery Systems Section 5 Grounding and Bonding Definitions The terms grounding and bonding are often incorrectly used interchangeably. They are different systems that can work together to provide solutions to common problems and risks on the water. Bonding is the process of connecting various non-cur- rent carrying metal components in the boat to a com- mon electrical contact.

  • Page 96: Bonding

    Section 5 Battery Systems Bonding Your boat’s bonding system starts with a bronze plate located below the water line at the center of the tran- som. A #8 awg green cable connects the bronze plate to the bonding buss system. The fuel tank, fuel fill, engine crash rail, hand rails, engine bracket, and tow post are also connected to the bonding buss system with #8 awg green cables.
  • Page 97 Operator Notes...

  • Page 98: Battery Switches

    Section 5 Battery Systems Battery Switches Battery Parallel Switch Your boat is equipped with an emergency battery par- allel switch. The switch is located on the control con- sole face. You can use the emergency battery parallel switch to connect the house battery and the engine starting battery in parallel if the outboard engine will not start due to low battery voltage.

  • Page 99: Battery Off-On Switches

    Battery Systems Section 5 Battery OFF-ON Switches Your boat is equipped with two battery OFF-ON switches that allow you to turn battery power on and off to the outboard engine and to each main 12 VDC power distribution circuit in the boat. The battery OFF- ON switches are located on or inside the control con- sole.

  • Page 100: Dc Power Distribution

    Section 5 Battery Systems DC Power Distribution All DC electrical devices and systems in your boat are controlled and protected by six main 12 VDC power distribution circuits. Outboard Engine Main 12 VDC power circuit 1 of 6 provides power for starting the outboard engine through a battery OFF- ON switch connected to a Group 24 1000 MCA bat- tery.

  • Page 101: Bilge Pump

    Battery Systems Section 5 Bilge Pump Main 12 VDC power circuit 2 of 6 provides uninter- ruptible power to the bilge pump switch located on the helm station switch panel. The circuit is directly con- nected to the outboard engine battery OFF-ON switch. The connection is made on the battery side of the battery OFF-ON switch and is always powered, regardless of switch position.

  • Page 102: Helm Station Switch Panel

    Section 5 Battery Systems Helm Station Switch Panel Main 12 VDC power circuit 3 of 6 provides power to the helm station switch panel. The helm station switch panel controls most of the basic boat systems, such as navigation lights, floodlights, and courtesy lights. The bilge pump switch is located on the helm sta- tion switch panel, but it is not included in this power circuit.

  • Page 103: Accessory Fuse Block

    Battery Systems Section 5 Accessory Fuse Block Main 12 VDC power circuit 4 of 6 provides power to the accessory fuse block located inside the control console. The accessory fuse block protects most of the basic boat systems, such as spotlights, trim tabs, and 12-volt outlets.

  • Page 104: T-Top Fuse Block

    Section 5 Battery Systems T-top Fuse Block Main 12 VDC power circuit 5 of 6 provides power to the fuse block located inside the T-top radio box. The T-top fuse block supplies power to the floodlight switch panel and protects any radios installed in the T-top radio box.

  • Page 105: Electronics Distribution Panel

    Battery Systems Section 5 Electronics Distribution Panel Main 12 VDC power circuit 6 of 6 provides power to the electronics distribution panel (optional) located inside the control console. The electronics distribution panel protects your sensitive communication and navi- gation systems. This circuit is protected by one 60-amp, push button breaker.

  • Page 106: Battery Systems

    Section 5 Battery Systems Wire Color Chart Black Ground Gray Navigation lights Black/brown Ground, pumps Gray/white Anchor light Black/orange Ground, accessories Gray/black Masthead light Black/green Ground, water level sender Gray/red Remote spotlight Black/blue Ground, lighting Gray/green Strobe light Black/gray Ground, navigation lights Gray/blue Flood lights Black/white...

  • Page 107: Specifications

    Boat Maintenance Section 6 Specifications Length, overall 20 ft. 9 in. 6,3 m Trailered length, engine tilted 29 ft. 8,8 m Trailered height - Note 1 8 ft. 10 in. 269 cm Trailered height - Note 2 11 ft. 7 in. 353 cm Beam 8 ft.

  • Page 108: Hull Identification Number

    Section 6 Boat Maintenance Hull Identification Number The Hull Identification Number (HIN) is located on the starboard outboard side of the transom. This is the most important form of boat identification and it must be included in all correspon- dence related to your boat. Model and serial number information for each piece of equipment installed on your boat was gathered during the construction process.

  • Page 109: Options

    Boat Maintenance Section 6 Options Brunswick Commercial & Government Products (BCGP) designs, engineers, and manufactures each boat for your specific mission. We add extra Phenolic plate, aluminum plate, and fiberglass material during the molding process to reinforce attachment points for the various options.

  • Page 110: Waxing

    Section 6 Boat Maintenance Waxing ! WARNING Gelcoat surfaces are always slippery when wet. Use extreme caution when walking on wet surfaces to avoid slipping or falling. Never wax portions of the boat that have a non-skid pattern. The interior and exterior fiberglass parts of the hull should be waxed a minimum of twice per year to pro- tect the gelcoat from salt, dirt, and ultraviolet degrada- tion.

  • Page 111: Trim Care

    Brunswick Commercial & Government Products Customer Service Department for the correct repair procedures. The repair must be done following Boston Whaler’s recommendations. Improper repairs can lead to hull failure and might void portions of your commercial warranty.

  • Page 112: Cutwater & Chafe Plates

    Section 6 Boat Maintenance Cutwater & Chafe Plates Your boat might be equipped with an optional stainless steel cutwater. This is a plate that protects the keel against debris while underway and possible damage while beaching. Inspect the cutwater several times a year for loose screws, missing screws, and large gaps along the outside edges.

  • Page 113: Storage And Trailers

    Heavy-duty trailers and storage cradles supplied by BCGP meet all these requirements and are approved for use with Boston Whaler and Impact boats. ! CAUTION Storing your boat on a sub-standard trailer or boatlift can cause serious, permanent damage to the hull.

  • Page 114: Trailer Setup

    Section 6 Boat Maintenance Trailer Setup...

  • Page 115: Fuel System

    Boat Maintenance Section 6 Fuel System Your boat is equipped with one below-deck aluminum fuel tank that requires little maintenance. You should visually inspect the fuel tank and all associated hoses and fittings for leaks or deterioration before each mis- sion.

  • Page 116: Steering System

    Section 6 Boat Maintenance Steering System Your boat is equipped with a manual hydraulic steer- ing system. ! WARNING Follow the steering system manufacturer’s maintenance recommendations exactly. Improper maintenance might cause loss of steering, which could cause property damage or serious injury. Be sure to check the operation of the steering system before each mission.

  • Page 117: Approved Steering Fluids

    Boat Maintenance Section 6 Every six months, a qualified marine technician should check the following items: • Check fluid level in the helm reservoir. • Check outboard engine tilt tube for salt deposits or signs of corrosion. Clean and grease as required.

  • Page 118: Batteries

    Section 6 Boat Maintenance Batteries Safety Warnings ! CAUTION Batteries should always be enclosed in the covered battery boxes provided with your boat. The boxes will contain any spilled acid and will protect the battery terminals from damage or shorting due to contact with metal objects. The battery boxes should always be secured using the heavy-duty straps and aluminum trays provided.

  • Page 119: Capacities

    Boat Maintenance Section 6 Capacities ® Exide marine heavy-duty 12-volt batteries are nor- mally selected for your boat. One Group 24 1000 marine cranking amp (MCA) battery is provided for engine starting and one Group 27 115 amp hour, deep cycle battery is normally provided for the boat’s electri- cal accessories.

  • Page 120: Cleaning

    Section 6 Boat Maintenance Remove the batteries from the boat during cold weather or off-season storage. Always protect the batteries from freezing temperatures. You must not allow your batteries to become com- pletely discharged. As a battery discharges, the active material on both positive and negative plates changes to lead sulfate, causing the plates to become similar in chemical composition.

  • Page 121: Bilge Pump

    Boat Maintenance Section 6 Bilge Pump The bilge pump and water level sensor are sealed units and do not require any periodic maintenance. Check the bilge area weekly to make sure there is no debris or sludge that could foul the water level sensor or clog the pump.

  • Page 122: Off-Season Storage

    Section 6 Boat Maintenance Off-Season Storage All boat and engine systems must be carefully pre- pared for long periods of non-use. This preparation is particularly important in regions where you experience extreme changes in temperature or where the winter temperatures are consistently below freezing. Outboard Engine You must protect your outboard engine from freeze damage and from internal corrosion caused by...

  • Page 123: Batteries

    Boat Maintenance Section 6 Batteries Remove the batteries from the boat during cold weather or off-season storage. Always protect the batteries from freezing temperatures. You must not allow your batteries to become com- pletely discharged. As a battery discharges, the active material on both positive and negative plates changes to lead sulfate, causing the plates to become similar in chemical composition.

  • Page 124: Fuel System

    Section 6 Boat Maintenance Fuel System You must take appropriate steps to protect your boat’s fuel system and outboard engine during periods of non-use. Situations where fuel isn’t being consumed and exposure to extreme changes in temperature will cause condensation to accumulate in your fuel sys- tem.

  • Page 125: Sea Water Washdown System

    Boat Maintenance Section 6 Sea Water Washdown System Your boat might be equipped with a sea water wash- down system. You must protect the washdown sys- tem from damage caused by freezing temperatures. Use the following steps to prepare this system for off- season storage: •...

  • Page 126: Hull Drainage

    Section 6 Boat Maintenance Hull Drainage Remove the main hull drain plug. Open all internal seacocks and drains. Verify that there is no debris plugging any drain, seacock, or limber hole. Store the boat with the bow higher than the stern to promote adequate drainage.
  • Page 127 OEM warranty. This accessory warranty is not transferable from the original owner. None of these warranties applies to any Boston Whaler hull, accessory, or part that has been structurally altered or subjected to unreasonable use, improper storage, lack of reasonable and proper maintenance, negligence, or accident.
  • Page 128 World-class support for World-class boats.

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