Boston Whaler 20 Justice Series Operation & Maintenance Manual Download Page 56

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3-2

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. The fuel system includes a single, centerline fuel

tank. The fuel tank is manufactured from marine-

grade 5052-H32 aluminum alloy and it is installed in

the mid-bilge area. The fuel tank has a manufacturer’s

compliance label next to the fuel level sending unit.

The compliance label includes information about tank

capacity, construction materials, and date of manufac-

ture.

Your fuel system is designed to meet the diurnal emis-

sions requirements outlined in ABYC Standard

H24.18.4.1 and in Code of Federal Regulations (CFR)

Title 40, sub-parts 1045 and 1060. These design ele-

ments work to limit liquid and hydrocarbon emissions

from your on-board gasoline fuel system.

The fuel tank working capacity is 110 gallons (416

liters).

The fuel tank has an electric sending unit that sends

fuel level readings to the fuel gauge at the helm sta-

tion.

The fuel tank has one fuel withdrawal tube for the out-

board engine and one fuel withdrawal tube for auxiliary

equipment such as a fire pump. Each fuel withdrawal

tube has a manual fuel shutoff valve. You can use

these valves to stop fuel flow during storage, during

fuel system servicing, or in the event of an on-board

fire.

The fuel valve is in the

position when the lever is

parallel with the valve body and the fuel valve is in the

OFF

position when the lever is perpendicular to the

valve body.

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 filters, and certain emission system components.

Summary of Contents for 20 Justice Series

Page 2: ...l models or equipment but are intended as representative views for reference only The continuing accuracy of this manual cannot be guaranteed Certain features parts options systems and accessories discussed in this manual might not be found on your boat Be sure that the operator and at least one other person in the boat are familiar with the contents of this manual A second person should be able t...

Page 3: ... 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 Warning Label Chart 1 12 ...

Page 4: ...ol 2 9 Engine Trim 2 9 Engine Gauges 2 11 Tachometer 2 11 Hour Meter 2 12 Fuel Gauge 2 12 Water Pressure Gauge 2 13 Voltmeter 2 13 Trim Gauge 2 14 SmartCraft Vessel View System 2 15 Propellers 2 16 Maneuvering 2 18 Load Distribution 2 20 Boat Trim Tabs 2 21 Operation 2 22 Stopping Procedure 2 23 Trailering 2 24 Safety Checklist 2 26 Towing 2 27 Backing 2 28 Lifting and Slinging 2 29 Safety Warning...

Page 5: ...g Unit 3 8 Fill and Vent Locations 3 9 Bonding System 3 10 Maintenance 3 10 Repair 3 10 Fueling Procedures 3 11 Safety Warnings 3 11 Static Electricity 3 12 General Guidelines 3 13 Hose Routing 3 14 Fill Hose Replacement 3 14 Removal 3 14 Installation 3 14 Vent Hose Replacement 3 15 Removal 3 15 Installation 3 15 Contaminated Gasoline 3 16 Blended Fuels 3 17 ...

Page 6: ...ntenance 4 12 Trim Tabs 4 13 Trim Tab Control Box 4 14 Proper Boat Trim 4 15 Rough Water 4 15 Trim Tabs and Engine 4 16 Maintenance 4 16 Compass 4 17 Deviation 4 17 Variation 4 17 Night Lighting 4 17 Battery Parallel Switch 4 18 Console Interior Dome Light 4 19 Cockpit Lighting 4 19 Siren Strobe Light 4 20 Floodlights 4 20 Signal Horn 4 21 Battery Status Indicator 4 21 Bilge Pump Special 4 21 Towi...

Page 7: ...ery Switches 5 8 Battery Parallel Switch 5 8 Battery OFF ON Switches 5 9 Bilge Pump Special 5 9 DC Power Distribution 5 11 Outboard Engine 5 11 Bilge Pump 5 12 Helm Station Switch Panel 5 13 Accessory Fuse Block 5 14 T top Fuse Block 5 15 Electronics Distribution Panel 5 16 DC Circuit Distribution 5 17 Helm Station Switch Panel 5 17 Accessory Fuse Block 5 19 T top Fuse Block 5 19 Electronics Distr...

Page 8: ...6 5 Deck Hardware 6 5 Cutwater Chafe Plates 6 6 Drains Scuppers 6 6 Hull Blistering 6 7 Storage 6 8 Inspection 6 8 Waxing 6 8 Bottom Painting 6 8 Fuel System 6 11 Steering System 6 12 Approved Steering Fluids 6 13 Batteries 6 14 Safety Warnings 6 14 Capacities 6 15 Maintenance 6 15 Cleaning 6 16 Bilge Pump 6 17 Trim Tabs 6 17 Off Season Storage 6 18 Outboards 6 18 Batteries 6 18 Fuel System 6 19 H...

Page 9: ...perience If you do not have the appropriate level of experience ask someone to instruct you Understand all of the information contained in this manual particularly Sections 1 and 2 Understand the operation of all boat controls and systems Understand and follow all applicable boating regu lations Always use safety equipment and operating pro cedures that are appropriate for your mission Never work ...

Page 10: ...st appropriate for near shore and inland waters Type III Flotation aid appropriate for continuous use in calm inland waters Type IV Throwable device appropriate to throw to a person already in the water These devices must never be worn as a vest Type V Special purpose device includes harnesses certain jackets and rafting vests These vests must be worn while underway to count toward minimum PFD req...

Page 11: ... generator in confined areas such as boat houses Be aware of other boats when you are moored Be aware of wind direction when operating at slow speeds Adjust hatches doors windows and canvas to increase air movement in confined spaces when engines and generator are running For more information about the dangers of carbon monoxide read the booklet What You Can t See that is in your owner s bag DANGE...

Page 12: ... plan in advance that will help you evaluate your risk and response in case of an on board fire emergency Fires Most marine fires result from spilled gasoline or oil accumulating in the bilge Careful use of on board fire extinguishers should control small fires Direct the fire extinguisher output toward the base of the flames in a sweeping motion Check carefully and verify that the fire has been e...

Page 13: ...ith an emergency posi tion indicating radio beacon EPIRB The EPIRB is capable of sending important location information to the Cospas Sarsat satellite system dur ing an emergency You must register the EPIRB with the National Oceanic Atmospheric Administration NOAA to ensure an effective search and rescue response In case of an emergency the beacon can be deployed manually or it can be released by ...

Page 14: ...ts crew even if the capacity limits have not been exceeded Capsizing Your boat might capsize due to improper loading improper operation or severe weather conditions Formulate a capsizing plan in advance that includes the following actions Try to turn off the outboard engines to avoid injury and additional damage Locate all crew and evaluate their condition Stay with the boat it will always float a...

Page 15: ...he dive door if equipped Adjust boat trim and speed to match weather con ditions Avoid backing into large waves whenever possi ble Check operation of all bilge pumps float switches and water level sensors before each trip Diving Operations Navigational Rules require a vessel which is engaged in diving operations to display a rigid replica of the international Alpha signal flag during daylight hour...

Page 16: ...rescue door is removed You must manage the water the rescue operation and all personnel to avoid swamping or capsizing your boat Refer to Load Distribution in Section 2 for additional information When your dive rescue door is in place it must be secured with the cam locks provided When your dive rescue door is out it must be stored and secured in the storage blocks provided WARNING The dive rescue...

Page 17: ...s known to the State of California to cause cancer birth defects and other reproductive harm Examples include Engine and generator exhaust Gasoline diesel fuel coolants and motor oil Cooking fuels Cleaners solvents and paint Waste materials that result from wear of boat components Lead from battery terminals and other sources To avoid harm Keep away from engine generator and cooking fuel exhaust f...

Page 18: ...1 10 Section 1 Safety Deck Occupancy Chart ...

Page 19: ...ually evaluate the sea state and boat performance Restrict passenger access to these decks if conditions warrant Keep accommodation decks free of loose gear 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 DANGER Never occupy working decks while the boat is...

Page 20: ...1 12 Section 1 Safety Warning Label Chart 1 2 3 4 5 7 9 6 8 0 B 7 G A C D E F ...

Page 21: ...ellers 6 1016518 Steering Effort 7 2090315 Dive Rescue Door 8 1016534 Fuel Tank Readings 9 1811368 Carbon Monoxide 0 1974618 U S EPA Compliant A 1817722 Customer Information Tag B 1977870 NMMA Capacity Plate 20 JC C 1016443 Do Not Drill Fuel Tank D 1016922 Battery Terminals E 1811367 Carbon Monoxide F 1903624 Rotating Propellers G 1016880 Do Not Paint ...

Page 22: ...1 14 Operator Notes ...

Page 23: ...s good condition Fuel filter in good condition No water in water separator Navigation lights operational RIAM lights operational Signal horn operational Bilge pump operational Bilge pump float switch operational Water level sensor operational Engine starting battery in good condition House battery in good condition Battery OFF ON switches correctly set Engine control lever in NEUTRAL Ignition shut...

Page 24: ... techniques or severe operating conditions Do not use the ignition shutoff switch to stop the outboard engine during nor mal boat operation You should connect the ignition shutoff switch clip and lanyard to a sturdy part of your clothing If you move beyond the scope of the lanyard the ignition shutoff switch will be activated and the outboard engine will shut off immediately WARNING Do not activat...

Page 25: ... and lanyard while the outboard engine is at idle speed The outboard engine should stop immediately The outboard engine will not start if the clip and lanyard is not attached to the shutoff switch The switch can only function properly when the lanyard is attached to a sturdy part of your cloth ing Do not shorten the switch lanyard It must be long enough to avoid inadvertent switch activation dur i...

Page 26: ...tch is in the OFF position Record and save the key number following the instructions in Sec tion 6 You must turn the engine battery OFF ON switch to the ON position before you use the main engine key switch You must turn the main engine key switch to the OFF position after you secure the engine from service You should turn the engine battery OFF ON switch to the OFF position after you secure the e...

Page 27: ... automatically If the outboard engine does not start turn the key to the OFF position and repeat the starting process To STOP the outboard engine turn the main engine key switch to the ACC or OFF position If you are securing the engine from service turn the main engine key switch to the OFF position For additional engine control information refer to the engine operator s manual in your owner s bag...

Page 28: ...ltage use the battery parallel switch to provide power from the house battery Push and hold the battery parallel switch ON to either the left or right position Note this position Hold the battery parallel switch in the ON position and try to start the engine If the engine does not start release the battery parallel switch to the OFF position Move the battery parallel switch to ON in the opposite d...

Page 29: ...r to NEUTRAL position Attach ignition shutoff switch clip and lanyard Start outboard engine using the main engine key switch Use emergency battery parallel switch if required Verify engine cooling system operation by observing the overboard indicator Verify all engine systems using the gauges Let outboard engine idle in NEUTRAL for five minutes before leaving the dock DANGER Never start or operate...

Page 30: ...m NEUTRAL move the shift lever forward to select FORWARD gear From NEUTRAL move the shift lever backward to select REVERSE gear Never shift directly from FORWARD to REVERSE without pausing in NEUTRAL Never shift directly from REVERSE to FORWARD without pausing in NEUTRAL Neutral Throttle The single lever control has a neutral throttle fea ture Depress the Throttle Only button and move the shift le...

Page 31: ...steer Trimming the engine up or out increases boat perfor mance and fuel economy Excessive trim angle will reduce boat performance Excessive trim angle might cause propeller ventilation and engine over speed alarms WARNING Certain combinations of engine trim angle boat operating angle and boat speed can reduce your forward facing visibility Reduced operator visibility can contribute to collisions ...

Page 32: ...engine through its trim range to change general boat operating angle Adjusting engine trim angle can affect ride com fort and boat performance 4 bow up is an average setting for boat operating angle Adjusting engine trim angle can improve fuel economy improve ride comfort and compensate for uneven boat loading CAUTION Do not trailer your boat with the engine in its fully tilted position CAUTION Ce...

Page 33: ...perator s manual for detailed information about the gauges and their functions Tachometer The tachometer displays engine speed in revolutions per minute RPM You can take the gauge reading on most tachometers and multiply by 1 000 to calculate engine speed You can use engine RPM to influence fuel consumption adjust boat performance and evalu ate propeller selection Some tachometers are driven by a ...

Page 34: ...ting hours can be used to schedule periodic maintenance for the boat and the engine Fuel Gauge The fuel gauge powers up when the engine ignition switch is turned to the ON position The fuel gauge displays the approximate fuel level in the fuel tank The correlation between the gauge reading and fuel load is approximately linear from FULL to FULL The accuracy of the reading decreases below FULL beca...

Page 35: ... charges its starting battery when the engine is running above idle speed The voltmeter displays engine battery voltage measured in DC volts VDC These readings indicate that engine battery system is in good condition Key OFF 0 volts Key ON engine not running 12 volts Engine running above idle 14 volts Refer to the engine operator s manual for additional detailed information about the engine s char...

Page 36: ...the trim gauge The trim gauge displays this value as relative Bow Up or Bow Down It takes specific experience with each boat engine pro peller combination to identify the best engine trim set tings for certain conditions Remember that either extreme of the trim range is usually inefficient Generally engine trim IN is good for acceleration and load carrying Engine trim OUT is good for speed and fue...

Page 37: ...tion speed over ground and fuel to destination Your Vessel View system has a user friendly interface that is controlled by seven buttons and a track pad These controls allow you to calibrate and control all of the information reports and formats The Vessel View information reports are grouped into four categories Propulsion includes all engine systems informa tion Vessel includes information about...

Page 38: ...You should replace your propeller when it becomes damaged to avoid additional damage to the engine In some situations you might want to change the pro pellers to give your boat slightly different performance characteristics Changes to your boat s configuration such as additional equipment or adding bottom paint can affect the type and size of propeller required CAUTION Never use a propeller that a...

Page 39: ... of pitch change Increasing propeller pitch and diameter will decrease acceleration and might increase top speed It will also decrease the engine s full throttle RPM at a rate of about 150 RPM per inch of pitch change If you are considering a propeller change the type pitch and diameter should be discussed with an authorized outboard engine service dealer Refer to the engine operator s manual for ...

Page 40: ...nt High traffic areas Mission related time limitations Confined or restricted areas Carrying hazardous cargo Compromised boat or engine systems Always follow established boating regulations and directions from boating law authorities when maneu vering or underway Always maneuver around objects docks and other boats at idle speed Always evaluate the wind strength wind direction cur rent strength an...

Page 41: ...vers To turn quickly to port or star board at slow speed turn the steering wheel in the direction you want to go After you have turned the steering wheel increase the engine speed and the boat will turn quickly It is important to turn the steer ing wheel before you increase engine speed because the boat will accelerate in the direction it is steered Backing down you can control boat direction with...

Page 42: ...o back and port to starboard The center of the non permanent load distribution should be in the center of the boat Do not allow your non permanent loads or cargo to shift unexpectedly Always secure non perma nent loads and cargo with netting tie down straps lines and appropriate deck hardware You must be prepared to adjust the load distribu tion as operating conditions change WARNING Improper oper...

Page 43: ... for strong crosswinds Adjust for changing weather conditions Trim the boat fore and aft Trim the boat port and starboard Improve ride smoothness Improve boat performance The electro mechanical cylinders and trim tabs are located on the lower portion of the boat s transom The trim tab control box senses switched 12 VDC at the outboard engine main ignition key switch The trim tab system will only o...

Page 44: ...push both switches forward To evenly raise the bow push both switches back The Lenco switch panel includes two LED segment bars that represent the relative position of both trim tabs When you lower one or both of the trim tabs the LED segment bars will extend to indicate that the trim tabs are moving down When you raise one or both of the trim tabs the LED segment bars will retract to indi cate th...

Page 45: ... outboard engine before tilting to avoid contact with any special towing equipment Raise the engine to full Tilt Up position and engage tilt lock Turn engine battery OFF ON switch to OFF posi tion Turn house battery OFF ON switch to OFF posi tion Remove battery OFF ON switch knobs if appro priate Bilge pump has an uninterruptible power supply to support automatic operation Verify bilge pump rocker...

Page 46: ...t your mission Regulations controlling trailer equipment and manu facture vary from place to place You must verify that your trailer meets the laws and transportation regula tions in the states or countries where you use it Refer to the trailer owner s manual for detailed infor mation about the operation and maintenance of this trailer CAUTION Do not trailer your boat with the engine in its fully ...

Page 47: ...ailer bunks must be continuous and as long as possible Trailer bunk contact angle must match the hull deadrise angle Trailer bunks must be parallel with the boat cen terline and must not touch any lifting strake Trailer should be equipped with a barge stop to support the boat s bow Trailer bunks must not be segmented or swivel Trailer must not be an all roller design Trailer must not support boat ...

Page 48: ... tight and locked Bow safety cable attached Bow tie down link secured Stern tie down straps secured Trailer surge or electric brakes operational Trailer tires and spare in good condition Tire pressures are correct Lug nuts are correctly tightened Wheel bearings lubricated and functional Trailer pintle or coupler securely attached to tow vehicle Trailer safety cables attached to tow vehicle using c...

Page 49: ...ay close attention to road and weather condi tions Always avoid traffic situations where rapid accel eration or deceleration is required Double the standard following distance for your vehicle speed Always be aware of traffic conditions around you Identify any possible blind spots behind or on either side of your trailer Plan ahead and check your mirrors carefully when changing lanes stopping or t...

Page 50: ...s constantly Always know where the boat is in relation to any fixed objects Never accelerate in reverse Back up slowly When the trailer is straight behind the tow vehicle the rear of the trailer will move opposite the direc tion that you turn the steering wheel If you turn the steering wheel clockwise the trailer will move to the left If you move the steering wheel counter clockwise the trailer wi...

Page 51: ... failure could cause serious injury or death DANGER Inspect all lifting equipment for signs of wear or fatigue each time you lift the boat Re certify or replace the lifting equipment annually Failure of any lifting component could cause serious injury or death WARNING Never use the boat s bow eye stern eyes cleats or railings as attachment points to lift this boat Failure of these items during lif...

Page 52: ... Your boat might have been shipped with a Boston Whaler lifting sling set that meets all manufacturer requirements for lifting this boat To provide a 5 bow up angle during lifting the front two straps are slightly longer than the rear two straps The front two straps are marked FORWARD and rear two straps are marked REAR Attach at least two guide lines to control the boat while it is being lifted M...

Page 53: ...ader bar and slings to lift the boat evenly The boat s longitudinal center of gravity LCG is approximately 84 inches 213 cm forward of the transom Position the slings so they do not contact any thru hull fittings on the sides or bottom of the boat Attach at least two guide lines to control the boat while it is being moved Move the boat slowly DANGER Never allow anyone to be in the boat or under th...

Page 54: ... 000 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 Move the boat slowly DANGER Never allow anyone to be in the boat or under the boat while you are lifting it A mistake in the lifting procedure or a component failure could cause serious injury or death ...

Page 55: ...cause of any gasoline leak immediately 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 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 conce...

Page 56: ...e design ele ments work to limit liquid and hydrocarbon emissions from your on board gasoline fuel system The fuel tank working capacity is 110 gallons 416 liters The fuel tank has an electric sending unit that sends fuel level readings to the fuel gauge at the helm sta tion The fuel tank has one fuel withdrawal tube for the out board engine and one fuel withdrawal tube for auxiliary equipment suc...

Page 57: ...which might be subject to electrolytic corrosion caused by stray voltage Prevent the build up of electrical potential on exposed metal parts which might cause personal injury Provide a low resistance electrical connection to ground when components are exposed to voltage spikes such as a lightning strike Reduce radio frequency interference RFI The common bonding conductor a green 8 awg insu lated c...

Page 58: ...3 4 Section 3 Fuel Systems Fuel System Diagram RACOR 1 0 2 3 4 5 6 7 8 9 A ...

Page 59: ...rol 3 Valve fluid level vent 4 Label manufacturer compliance 5 Sender fuel level 6 Tank gasoline 110 gallons 416 liters 7 Valve grade level vent 8 Tube fuel withdrawal 8 Valve fuel shutoff 9 Canister carbon vent 0 Vent fuel tank A Filter gasoline Racor optional ...

Page 60: ...3 6 Operator Notes ...

Page 61: ... to Blended Fuels in this section for more infor mation about water in gasoline Replace the filter element on this schedule whichever happens first Every 100 operating hours Annually Noticeable engine performance loss WARNING Follow the manufacturer s recommendations exactly when servicing this gasoline filter to avoid engine damage or fuel leaks Refer to the manufacturer s instruction booklet in ...

Page 62: ...hms empty and 33 ohms full The fuel gauge powers up when the engine ignition key switch is turned to the ON position The fuel gauge displays the approximate fuel level in the fuel tank The correlation between the gauge reading and the fuel load is approximately linear from FULL to FULL The accuracy of the reading decreases below FULL because of the tank s profile The most accurate fuel level readi...

Page 63: ...cape from the fill cap during normal fueling operations The fuel tank vent is located high on the port side of the engine splashwell bulkhead The fuel tank venting system is equipped grade level valves that keep liquid fuel from entering the vent hose The fuel tank venting system is also equipped with a carbon canister which reduces hydrocarbon emissions HC Refer to Fueling Procedures in this sect...

Page 64: ... If the meter or light indicates a break in continuity replace the bonding system wires After testing coat all screws and terminals with liquid neoprene Repair The following procedure covers the removal and installation of the bonding system wires Bonding wires are accessed through the deck access plates and access hatches Perform a continuity test as described in Bonding System Maintenance Remove...

Page 65: ...ty 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 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 boa...

Page 66: ... discharge while fueling Always keep your boat in continuous contact with the water or a land based grounding system dur ing fueling Always keep the fuel nozzle in contact with the fuel fill assembly or the edge of the fuel tank opening during the fueling process This contact must be continuously maintained until fuel flow has stopped Never fuel your boat under unsafe conditions that could increas...

Page 67: ...before you pump gasoline This contact must be continu ously maintained until gasoline flow has stopped Never exceed a fill rate of 9 GPM 34 lpm Slow the fill rate to 6 GPM 23 lpm for the final of tank DO NOT fill the tank completely Allow a mini mum of 2 of tank volume for temperature related expansion Allow for 6 expansion if the temperature of the gasoline taken on board is 32 F 0 C or lower Clo...

Page 68: ...m under the deck plate slowly until it is completely free Installation If your fuel system is equipped with a flow control valve transfer the valve to the new fill hose Match the original orientation of the valve exactly during installation Route the new static conductive fill hose under the fuel fill plate assembly until it reaches the elbow on the fuel tank Secure the hose to the tank elbow with...

Page 69: ... system is equipped with a carbon canister transfer the canister to the new vent hose Match the original orientation of the canister exactly during instal lation Route the vent hose under the deck until it reaches the elbow on the fuel tank Secure the hose to the tank elbow with two hose clamps Attach the other end of the hose to the vent fitting at the engine splashwell and secure with two hose c...

Page 70: ...for evidence of moisture before and after every mission Refer to Blended Fuels in this section for more infor mation about water in gasoline If your fuel shows evidence of moisture or particulate contamination consult a professional tank cleaning contractor about having your fuel tank pumped out and cleaned Verify that the contractor is fully licensed and that he can dispose of the contaminated ga...

Page 71: ...r boat Read and understand all of the fuel related safety warnings and maintenance procedures outlined in this operator manual Read and understand all of the fuel related safety warnings and maintenance procedures outlined in your outboard engine operator s manual Ethanol is hygroscopic meaning that it attracts and easily mixes with moisture E 10 gasoline will corrode metal fuel system parts faste...

Page 72: ... possible to reduce exposure to moisture from condensation and humidity Concentrations of ethanol greater than 10 can change the physical properties of some rubber and plastic fuel system parts such as gaskets hoses tanks and filters Regularly inspect all non metal fuel system parts for signs of swelling or deterioration In some extreme cases rubber parts such as hoses and gaskets can actually swe...

Page 73: ... the most cur rent design and assembly information available at the time of publication The information and illustrations are general representations of the boat systems the information is not meant to be used as a detailed parts manual or a service manual Certain features parts systems and accessories dis cussed in this section might not be found on your boat This boat and these boat systems shou...

Page 74: ...4 2 Section 4 Boat Systems 4 2 Section 4 Boat Systems 4 2 Section 4 Boat Systems 4 2 Section 4 Boat Systems 4 2 Section 4 Boat Systems Console Layout 1 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J ...

Page 75: ...as 5 Radio box 6 Magnetic compass 7 Engine instrumentation 8 Navigation display 9 Panel switch helm station 0 Panel switch Lenco tabs A Helm steering hydraulic B Panel switch battery parallel C Cup holders D Control engine single lever E Button horn 12 VDC F Panel LED battery status G Switch engine emergency shutoff H Switch engine ignition I Switches battery engine and house J Fire extinguisher T...

Page 76: ...4 4 Section 4 Boat Systems 4 4 Section 4 Boat Systems 4 4 Section 4 Boat Systems 4 4 Section 4 Boat Systems 4 4 Section 4 Boat Systems Deck Layout 1 2 3 4 5 6 7 8 9 0 A B D F C E G H J L I K M ...

Page 77: ...ne and house 7 Console control 8 Cup holders 9 Helm steering hydraulic 0 Control single lever engine A Plate access fuel level sender B Leaning post with storage C Fire extinguisher Type ABC 2 pound D Plate access fuel shutoff valves E Locker deck storage 2 places F Tow post G Filter gasoline Racor H Main disconnect engine battery cables I Locker aft storage 2 places J Plate access aft bilge K Cra...

Page 78: ...nless the steering wheel is turned The lock valve also contains a pressure relief valve which provides over pressure protection for the mechanical components the hydrau lic hoses and the fittings When the steering wheel is turned clockwise hydrau lic fluid is pumped out of the helm unit into the star board hydraulic line and then into the steering cylinder As the fluid is pumped into one side of t...

Page 79: ...ractice and become familiar with the following procedures Going Ahead The bow turns to starboard when the steering wheel is turned clockwise The bow turns to port when the steering wheel is turned counter clockwise The number of revolutions of the steering wheel and the speed of the boat determine the rate of directional change You can use the engine throttle to greatly increase boat response whil...

Page 80: ...p the boat The stern moves to starboard when the steering wheel is turned clockwise The stern moves to port when the steering wheel is turned counter clockwise The stern can be made to run straight in reverse by determining the proper rudder angle Experiment with engine speed and rudder angle to determine this posi tion Return the steering wheel to the CENTERED position when you turn the engine OF...

Page 81: ...s Section 4 4 9 Boat Systems Section 4 4 9 Boat Systems Section 4 4 9 Boat Systems Section 4 1 2 4 5 6 7 8 3 Steering System Diagram 1 Engine 2 Tiller Arm 3 Hydraulic Cylinder 4 Steering Wheel 5 Fill Port 6 Helm Pump 7 Console 8 Hydraulic Hoses ...

Page 82: ...ation lights are in working condition and that proper lighting is displayed Operation Operate your navigation lights using the switch located on the helm station switch panel It is a three position rocker switch marked NAV ANCHOR While underway move the switch to the NAV position This turns on the port red starboard green and 360 white lights The red and green lights are located on the forward dec...

Page 83: ...at has an 1100 gallon per hour GPH bilge pump located in the aft bilge Pump operation is con trolled by a rocker switch located on the helm station switch panel and a mechanical float switch located next to the bilge pump The mechanical float switch senses water in the bilge and will turn on the bilge pump when the rocker switch is in the AUTO position The bilge pump and mechanical float switch ca...

Page 84: ...e is no water in the bilge The rocker switch has a red LED indicator that will be lighted anytime the bilge pump is running Maintenance The bilge pump is a sealed unit and maintenance is very simple Check the bilge area weekly to make sure there is no debris or sludge that could foul the float switch or clog the pump Regularly check the condition of the float switch to ver ify that it is not stuck...

Page 85: ...r conditions The switch panel is labeled to make tab operation sim ple When operating the trim switches think of how you want the bow of the boat to move to properly trim the boat To lower the port side of the bow push the left switch forward This lowers the trim plane on the starboard side of the transom To lower the starboard side of the bow push the right switch forward This lowers the trim pla...

Page 86: ...d engine ignition key switch is in the ON position Because the trim tab control box senses switched 12 VDC at the outboard engine ignition switch The trim tab system will only operate when the outboard engine ignition switch is ON The trim tabs will automatically retract when the outboard engine ignition switch is turned OFF CAUTION The trim tabs will automatically retract when the outboard engine...

Page 87: ...time you move the control switches to the time the boat reacts This is normal and varies with boat speed Be careful not to over trim the boat An over trimmed boat will plow or bow steer If you over trim the boat push both trim switches back to raise the bow Rough Water When running in chop or heavy seas press both switches forward to lower the bow elevation This will bring the V of the hull in mor...

Page 88: ...de of the boat Maintenance Periodically check the condition of the trim tab actua tors The actuators are completely sealed and require no maintenance However marine growth should be removed from the actuator shafts by pressure wash ing Cold temperatures do not affect the trim tab system No winterization procedure is necessary In saltwater to control galvanic corrosion a zinc anode should be attach...

Page 89: ...er to the compass manufacturer s literature for detailed information about the compensation proce dure Variation It is important to understand that magnetic compasses point toward magnetic north There is a difference between magnetic north and true north That differ ence is called variation Variation differs depending on your geographical location and can be determined by referring to a local char...

Page 90: ...ur outboard engine will not start due to low battery voltage use the battery parallel switch to provide power from the house battery Push and hold the battery parallel switch ON to either the left or right position Note this position Hold the battery parallel switch in the ON position and try to start the engine If the engine does not start release the battery parallel switch to the OFF position M...

Page 91: ... the control console interior dome light circuit Cockpit Lighting Your boat might be equipped with red cockpit night lighting The lights are used to illuminate the deck sur faces without creating glare at night The red cockpit lights are usually installed in pairs where one light would be located on the port side and one would be on the starboard side Typically they are located on the interior hul...

Page 92: ...e OFF position at the end of your mission will cut power to the siren amplifier and strobe power circuits Refer to the Whelen operator s manual for detailed information about the siren and strobe functions Floodlights Your boat might be equipped with one or more 12 VDC floodlights The floodlights are usually mounted on the T top frame You can use the floodlights to illu minate the deck or surround...

Page 93: ...ttery Status Indicator Your boat is equipped with a battery status indicator panel The panel is mounted on the control console face The panel has a green LED that is lighted any time a battery switch or a boat accessory circuit is powered and active Turn all battery OFF ON switches to the OFF position before you leave the boat unattended for any period of time Check to make sure that the battery s...

Page 94: ...fore beginning a tow operation Remove all non essential crew from the target boat Make sure that all tow rig components on both boats are of sufficient capacity for the tow Set the tow rig as low and as close to the boat centerlines as possible Take at least one half turn around the tow bar before you secure the tow line using a series of figure eights DO NOT use any knots to secure the tow line S...

Page 95: ...d this information before being towed by another boat Evaluate the condition of your boat before begin ning the tow operation Remove all non essential cargo and crew from your boat Make sure that all tow rig components on both boats are of sufficient capacity for the tow Set the tow rig as low and as close to the boat centerlines as possible Use your boat s bow eye as the attachment point for the ...

Page 96: ... s ladder and boarding platform The platform is permanently attached to the starboard transom Never move the boat when the swimmer s ladder is deployed Always retract and secure the swimmer s ladder when you are not using it DANGER Never start or operate the engine when people are in the water near your boat Contact with the boat engine or rotating propeller can cause serious injury or death ...

Page 97: ...outboard engine is running above idle speed regardless of battery OFF ON switch position Each electrical circuit is configured as a two wire neg ative return system which includes a 12 VDC power lead and a negative return lead Each electrical circuit is powered by one of two 12 volt batteries is con trolled by one of two battery OFF ON switches and is protected by two or more circuit breakers All ...

Page 98: ...s in place while the boat is underway reducing the possibility of damage to the batteries and other equipment in the storage area DANGER Never use an open flame in the battery storage area Avoid striking sparks near the batteries A battery can explode if a flame or spark ignites the free hydrogen gas vented during charging Always disconnect the batteries before doing any work on the 12 VDC electri...

Page 99: ...equire periodic checks of electrolyte levels With proper care these marine heavy duty batteries will last several years Maintenance Only use elastic lock nuts with flat washers or stan dard hex nuts with split lock washers and flat washers to secure cables to the battery terminals DO NOT use wing nuts to secure cables to the battery termi nals Periodic battery maintenance is important to assure th...

Page 100: ... have dirt or corrosion on the terminals the batteries should be cleaned To clean the batteries turn the battery OFF ON switches to the OFF position Disconnect the bat tery cables from the terminals Remove the negative black cable first Remove the battery from the plas tic battery box Clean the terminals and casing with a solution of baking soda and water Use a soft wire brush on the terminals Do ...

Page 101: ...m discharging into a lower charged bat tery 2 by keeping the batteries electrically isolated If a battery fails to accept a charge from the engine alternator check the following items before replacing the battery Check the two 70 amp push button circuit break ers Check for unexpected current draw from boat electrical devices Check the engine alternator following the engine manufacturer s instructi...

Page 102: ...he surrounding water for the purpose of energy dissipation Properly designed grounding and bonding systems incorporating zinc or aluminum anodes and bronze plates will also help control corrosion of aluminum and stainless steel parts Grounding The negative terminals of both batteries and the nega tive cable from the outboard engine are connected together at a negative buss bar located inside the c...

Page 103: ... negative buss system The fuel tank fuel fill control console engine crash rail leaning post and transom cap are also connected to the negative buss system with 8 awg green cables Also directly connected to the bonding system are any shielded cables from electronic devices This helps dissipate radio frequency interference generated by various electronic devices Note All bonding wires and cables ar...

Page 104: ...battery voltage use the battery parallel switch to provide power from the house battery Push and hold the battery parallel switch ON to either the left or right position Note this position Hold the battery parallel switch in the ON position and try to start the engine If the engine does not start release the battery parallel switch to the OFF position Move the battery parallel switch to ON in the ...

Page 105: ...se from the OFF position to remove it Disabling the battery OFF ON switches gives you an additional level of security if the boat is left unattended Bilge Pump Special The only exception to the 12 VDC circuit control described on this page is the bilge pump system The 15 amp in line blade fuse that protects the bilge pump system has an uninterruptible power supply that originates at the battery si...

Page 106: ...5 10 Operator Notes ...

Page 107: ...ttery OFF ON switch is located in the control console just inside the console door The main power and negative cables from the out board engine route through the splash well boot and connect to this power circuit through a main two posi tion heavy duty terminal strip located near the tran som The main terminal strip simplifies engine removal for service or replacement Turning the outboard engine b...

Page 108: ...rdless of switch position The circuit is protected by one 15 amp in line blade fuse located within seven inches of the outboard engine battery OFF ON switch If the 15 amp blade fuse fails electrically troubleshoot the power circuit and the bilge pump before you replace the fuse This uninterruptible power circuit provides flexibility in controlling your bilge pump With the outboard engine battery O...

Page 109: ...tem Any accessories installed on these switches must also connect to the negative side of the 12 VDC electrical system through the negative terminal strip provided One negative terminal strip is located in the control console If the 60 amp breaker trips electrically troubleshoot the power circuit and its protected devices before you reset the breaker Turning the house battery OFF ON switch to the ...

Page 110: ...fuse block The accessory fuse block also has ten connection points for the negative side of the 12 VDC electrical system Some of the electrical accessories might have been installed at the factory If the 60 amp breaker trips electrically troubleshoot the power circuit and its protected devices before you reset the breaker Turning the house battery OFF ON switch to the OFF position at the end of yo...

Page 111: ... block The T top electronics fuse block also has ten connec tion points for the negative side of the 12 VDC electri cal system Some of the electronics might have been installed at the factory If the 60 amp breaker trips electrically troubleshoot the power circuit and its protected devices before you reset the breaker Turning the house battery OFF ON switch to the OFF position at the end of your mi...

Page 112: ...s a convenient point to connect all existing and future electronics The electronics distribution panel also has nine connection points for the negative side of the 12 VDC electrical system Some of the electronics might have been installed at the factory If the 60 amp breaker trips electrically troubleshoot the power circuit and its protected devices before you reset the breaker Turning the house b...

Page 113: ...he navigation lights switch controls the red green and 360 white lights for night operations You can select all navigation lights while underway or the 360 white light by itself for anchoring The cockpit lights switch provides power to the aft cockpit red lights optional mounted under the port and starboard gunwales Each cockpit light also has its own OFF ON switch Several spare switches are provi...

Page 114: ...cker switch has a red LED indicator that will be lighted anytime the bilge pump is running Turning the house battery OFF ON switch to the OFF position at the end of your mission will cut power to all of the helm station switch panel circuits except the bilge pump system See Wire Color Chart in this section for wire colors CAUTION Keep the bilge pump switch in the AUTO position anytime the bilge dr...

Page 115: ...rs T top Fuse Block The T top electronics fuse block is a ten position blade fuse design It is located inside the T top radio box The T top electronics fuse block is convenient when installing or servicing radios and electronics mounted in or on the T top See Wire Color Chart in this section for wire colors Electronics Distribution Panel The electronics distribution panel optional has eight switch...

Page 116: ...een yellow AC grounding Blue black Dome light T top Blue black Dome light console Brown Bilge pumps manual Blue red Boarding lights Brown red Bilge pumps automatic Blue red Courtesy lights Brown orange Fuel transfer pumps Blue purple Deck lights Brown white Macerator pumps Brown yellow Baitwell pumps White CO monitor Brown green Raw water pumps Brown blue Fresh water pumps Brown purple Washdown pu...

Page 117: ...ed 15 in 38 cm Engine Shaft Length Single 25 in 64 cm Engine Shaft Length Dual N A N A Weight Base Boat No Engines 2700 lbs 1225 kg Load Capacity Crew Engine Gear 3300 lbs 1497 kg Maximum Engine Weight 700 lbs 318 kg Maximum Engine Power 250 HP 186 kW Minimum Engine Power 135 HP 101 kW Fuel Capacity Note 3 110 gallons 416 liters Note 1 With T top no options Note 2 From the waterline with T top Not...

Page 118: ...ted to your boat The engine and electronics model and serial numbers are also important when obtaining parts or service for these items Record all significant numbers for HIN keys engines capital equip ment and electronics on the pages provided at the end of this section Keep a copy of that record somewhere safe on shore USCG Manufacturer s Identification Month Built January A Boat Serial Number U...

Page 119: ...from deteriora tion caused by its working environment Your experi ence with your particular working environment will help determine the appropriate time intervals between sig nificant system inspections Washing Exterior and interior laminated fiberglass parts and all metal parts should be washed frequently using fresh water a mild soap and clean cloths or a sponge DO NOT use abrasive cleaners abra...

Page 120: ...hly cleaned to remove all dirt and oil Use a fine grade compound formulated for gelcoat and fiberglass parts Follow the manufacturer s instructions carefully After compounding re wax all surfaces following the above steps Gelcoat Fiberglass Repair The interior and exterior of your hull might sustain damage that cannot be compounded or waxed out Typical damage would be cracks gouges holes and chips...

Page 121: ... items can be cleaned with a mild soap and a soft cloth or sponge Aluminum Wash aluminum parts with clear water and mild deter gent Protect surface with liquid cleaner or wax DO NOT use harsh chemicals or abrasives To minimize corrosion from contact between dissimilar metals use a high quality marine grade caulking compound when mounting non aluminum hardware Also ensure all electrical equipment i...

Page 122: ... but sometimes the powder coat might be worn or chipped away If the powder coat gets chipped away touch up the part with a high quality acrylic enamel Drains Scuppers Check all compartment drains scuppers and bilge discharge fittings at least once a month Inspect for gaps in sealant tightness cracks and UV damage Inspect scupper flaps for deterioration If any drains or thru hull fittings are damag...

Page 123: ... gelcoat and substrate forming a blister Blistering is caused by the deterioration of certain water soluble materials in the hull laminate Blisters can form in near surface layers of gelcoat or very deep in the fiberglass substrate The damage can range from cosmetic to structural although structural damage is a rare occurrence Studies point to long term immersion of a boat in warm water as a prima...

Page 124: ...out trailer design and proper boat support Inspection Inspect the entire surface of the boat bottom on a fre quent basis Address any structural or cosmetic issues immediately Even a minor scratch or scrape might allow water to enter the hull laminate Waxing Applying a high quality wax formulated for marine use can slow the hydrolysis process Be sure the boat bot tom is clean and follow all of the ...

Page 125: ...ider using one of the newer formulations of paint that does not contain cop per compounds To determine the waterline place the boat in the water with a full load of fuel and gear and mark the waterline Measure above the marked line about two inches 5 cm for placement of the tapeline Use a vinyl rubber masking tape such as 3M 471 CAUTION Some compound of copper is the active ingredient in most conv...

Page 126: ...the manufacturer s rec ommendations for applying the paint Always use the etching primer called for by the paint manufacturer Humidity and weather will play a role in how and when the paint is applied Several thin layers are better than one thick layer Make sure there is enough paint left to cover areas that were not accessible during painting because of slings or jack stands Follow the manufactur...

Page 127: ...ction and servicing routine is directly related to the quality and quantity of gasoline that you take on board You should check the sight bowl for evidence of moisture before and after every mission Replace the filter element on this schedule whichever happens first Every 100 operating hours Annually Noticeable engine performance loss WARNING Do not allow any liquid gasoline to enter the boat or a...

Page 128: ...sual noise If any unusual movement or noise is detected have the steering system serviced before operating the boat Weekly check the steering fluid level in the helm res ervoir It should be maintained at no less than inch and no more than inch below the bottom of the filler cap threads Be careful not to overfill the reservoir WARNING Follow the steering system manufacturer s maintenance recommenda...

Page 129: ...ydraulic fluid leaks Refill and purge system as necessary Check steering hoses for signs of chafing cuts and leaks Replace any steering hose that shows signs of damage Inspect the bilge console interior and splashwell for signs of leaking hydraulic fluid Approved Steering Fluids The following fluids are approved for use in this man ual hydraulic steering system Sea Star HA 5490 Texaco H015 Aero Sh...

Page 130: ...s in place while the boat is underway reducing the possibility of damage to the batteries and other equipment in the storage area DANGER Never use an open flame in the battery storage area Avoid striking sparks near the batteries A battery can explode if a flame or spark ignites the free hydrogen gas vented during charging Always disconnect the batteries before doing any work on the 12 VDC electri...

Page 131: ...equire periodic checks of electrolyte levels With proper care these marine heavy duty batteries will last several years Maintenance Only use elastic lock nuts with flat washers or stan dard hex nuts with split lock washers and flat washers to secure cables to the battery terminals DO NOT use wing nuts to secure cables to the battery termi nals Periodic battery maintenance is important to assure th...

Page 132: ...o have dirt or corrosion on the terminals the batteries should be cleaned To clean the batteries turn the battery OFF ON switches to the OFF position Disconnect the bat tery cables from the terminals Remove the negative black cable first Remove the battery from the plas tic battery box Clean the terminals and casing with a solution of baking soda and water Use a soft wire brush on the terminals Do...

Page 133: ...afts by pressure wash ing Cold temperatures do not affect the trim tab system No winterization procedure is necessary In saltwater to control galvanic corrosion a zinc anode should be attached to the top of each trim tab The anode must be in clean direct contact with the stainless steel trim plane Do not ground the trim tabs to other underwater metal objects Erosion of the anode material is a natu...

Page 134: ...proce dure for adding extra internal lubrication just before the engines are stored Follow all the storage and winterization recommenda tions in your outboard operator s manual 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 ...

Page 135: ...gestions to minimize the possibility of damage to your fuel system and your engine during storage If possible use fuel that does not contain ethanol on a regular basis or just before storing your boat Store your boat with the fuel tank full to avoid exposing the fuel to moisture in the atmosphere Refer to Fueling Procedures in Section 3 of this manual for fueling information Add a high quality fue...

Page 136: ... in storage configura tion Raw Water Washdown System Your boat might be equipped with a raw water wash down system You must protect the washdown sys tem from the effects of freezing temperatures Use the following steps to prepare this system for off season storage Remove the cap from the hose outlet fitting Verify that the inlet seacock is in the OPEN posi tion Run the washdown pump for approximat...

Page 137: ...6 21 Operator Notes ...

Page 138: ...6 22 Operator Notes ...

Page 139: ...able and proper maintenance negligence or accident The obligation of BCGP under this warranty is limited to the pro rata cost to repair or replace a hull or part that has within the warranty period been determined by BCGP to be defective in material or workmanship The decision to repair or replace a hull or part shall be solely at the election of BCGP If a warranted defect is determined to exist B...

Page 140: ...World class support for World class boats ...

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Boston Whaler 20 Justice Series, Operation & Maintenance Manual

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