Boston Whaler 21 Justice Series Operation & Maintenance Manual Download Page 55

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3-3

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. The fuel fill hose is equipped with a flow-con-

trol valve which will not allow liquid gasoline to escape

from the fuel fill cap during normal fueling operations.

The fuel tank vent is located in the engine splashwell,

port side. The fuel tank venting system is equipped

with a carbon canister which reduces vapor hydrocar-

bon (HC) emissions.

WARNING

Do not allow any liquid gasoline to enter the

boat or accumulate in the bilge. Liquid gasoline

is a fire and explosion hazard. Gasoline vapor

is extremely flammable and highly explosive

under certain conditions.

Summary of Contents for 21 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: ...2 8 Speed Control 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 Load Distribution 2 18 Boat Trim Tabs 2 19 Operation 2 20 Stopping Procedure 2 21 Trailering 2 22 Safety Checklist 2 24 Towing 2 25 Backing 2 26 Lifting and Slinging 2 27 Safety Warnings ...

Page 5: ...cription 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 Blended Fuels 3 13 ...

Page 6: ...tion 4 9 Battery Parallel Switch 4 10 Trim Tabs 4 11 Trim Tab Control Box 4 12 Proper Boat Trim 4 13 Rough Water 4 13 Trim Tabs and Engine 4 14 Signal Horn 4 15 Battery Status Indicator 4 15 Bilge Pump Special 4 15 Console Interior Light 4 16 T top Combination Light 4 16 Floodlights 4 17 Cockpit Lighting 4 17 Siren and Strobe Light 4 18 Remote Spotlight 4 19 Towing System 4 20 Towing a Boat 4 20 B...

Page 7: ...nding 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 Bilge Pump 5 11 Helm Station Switch Panel 5 12 Accessory Fuse Block 5 13 T top Fuse Block 5 14 Electronics Distribution Panel 5 15 Wire Color Chart 5 16 ...

Page 8: ...5 Cutwater Chafe Plates 6 6 Drains Scuppers 6 6 Storage and Trailers 6 7 Trailer Setup 6 8 Fuel System 6 9 Steering System 6 10 Approved Steering Fluids 6 11 Batteries 6 12 Safety Warnings 6 12 Capacities 6 13 Maintenance 6 13 Cleaning 6 14 Bilge Pump 6 15 Trim Tabs 6 15 Off Season Storage 6 16 Outboard Engine 6 16 Fire Pump 6 16 Batteries 6 17 Fuel System 6 18 Sea Water Washdown System 6 19 Fresh...

Page 9: ... and 2 Understand the operation of all boat controls and systems Make this manual available to any person who might operate this boat Always operate this boat within the limits of your skill and experience If you do not have the appropriate level of experience ask someone to instruct you Understand and follow all applicable boating regu lations Always use safety equipment and operating pro cedures...

Page 10: ... and foul weather Type II Buoyant vest appropriate for near shore and inland waters Type III Flotation aid appropriate for 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 vest includes harnesses working vests and rafting vests These vests must be worn while underway to count toward m...

Page 11: ...n fined areas such as boat houses Be aware of engine exhaust from other boats when you are moored Be aware of wind direction when operating your boat at slow speeds Adjust hatches doors windows and canvas to increase air movement in confined spaces when your 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 yo...

Page 12: ...fire 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 be...

Page 13: ...PIRB Your boat might be equipped with 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 ...

Page 14: ... of the boat and its 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 engine to avoid injury and additional damage Activate EPIRB and DSC systems if possible Locate all crew and evalua...

Page 15: ... the 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 ho...

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: ...ired 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 The hang tag also includes information about limiting your exposure to these harmful chemicals Read the information on this hang tag and store the tag in your owner s bag ...

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 accommo dation 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 i...

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

Page 21: ...scue 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 A 1817722 Customer Information Tag B 1795087 Proposition 65 Tag C 1016443 Do Not Drill Fuel Tank D 1016922 Battery Terminals E 1903624 Rotating Propellers F 1811367 Carbon Monoxide G 1016880 Do Not Paint ...

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

Page 23: ...fuel load for mission Fuel tank and fuel hoses good condition Fuel filter in good condition No water in water separator Navigation lights operational RIAM lights operational Signal horn operational Bilge pump 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 Igni...

Page 24: ...s or severe operating conditions Do not use the ignition shutoff switch to stop the out board engine during normal boat operation You should connect the ignition shutoff switch clip and lanyard to a sturdy part of your life vest or your cloth ing If you move beyond the scope of the lanyard the ignition shutoff switch will be activated and the out board engine will shut off immediately WARNING Do n...

Page 25: ...ard 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 life vest or your clothing Do not shorten the switch lanyard It must be long enough to avoid inadvertent switch activati...

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: ...ngine automatically If the outboard engine does not start turn the key to the OFF position and repeat the starting process To STOP the 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 CAU...

Page 28: ...itch position is OFF Both the left and right switch positions are momentarily ON when held down When you release the switch it will return to the center OFF position If your 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 posi...

Page 29: ...ol lever to NEUTRAL position Attach ignition shutoff switch clip and lanyard Start 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 t...

Page 30: ...must be running before you shift into FORWARD or REVERSE From 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...

Page 31: ...steer Trimming your engine up or out increases boat per formance 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: ...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 signal fro...

Page 34: ...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 fuel level reading decreases below FUL...

Page 35: ...ges 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 the engine battery charg ing 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 engi...

Page 36: ...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 engine trim range is usually inefficient Generally engine trim IN is good for acceleration and load carrying Engine trim OUT is good for speed and ...

Page 37: ... 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 1 Propulsion includes all engine systems infor mation 2 Vessel includes information about...

Page 38: ...u 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 peller 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 the propeller required CAUTION Never use a propeller that ...

Page 39: ... per inch 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 servicing dealer Refer to the engine operator s manual ...

Page 40: ...ront to 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 Imprope...

Page 41: ...ution Adjust 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...

Page 42: ...ush both UP buttons 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 that the trim tabs are moving up Refer to the Lenco opera...

Page 43: ...the 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 roc...

Page 44: ...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 45: ...at s running surface 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 weight at any single concentrated ...

Page 46: ...h cable 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 coupler securely attached to tow vehicle Trailer safety cables attached to tow vehicle using cris...

Page 47: ...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 48: ...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 49: ...ailure 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 lifti...

Page 50: ...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 Mo...

Page 51: ...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 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 52: ...2 30 Operator Notes ...

Page 53: ...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 boat fuel system components and might cause fuel leaks CAUTION Carefully foll...

Page 54: ...dard H24 18 4 1 and in Code of Federal Regula tions CFR Title 40 sub parts 1045 and 1060 These design elements work to limit liquid and vapor hydro carbon HC emissions from your on board gasoline fuel system The fuel system working capacity is 90 gallons The fuel tank has an electric sending unit that sends fuel level information to a fuel gauge located at the helm station The fuel tank has separa...

Page 55: ...equipped with a flow con trol valve which will not allow liquid gasoline to escape from the fuel fill cap during normal fueling operations The fuel tank vent is located in the engine splashwell port side The fuel tank venting system is equipped with a carbon canister which reduces vapor hydrocar bon HC emissions WARNING Do not allow any liquid gasoline to enter the boat or accumulate in the bilge ...

Page 56: ...3 4 Section 3 Fuel Systems Fuel System Diagram 1 2 3 4 7 0 A C 5 6 8 9 B ...

Page 57: ...l 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 B Filter gasoline Racor optional C Vent fuel tank ...

Page 58: ... 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 these filters to avoid engine damage or fuel leaks Refer to the manufacturer s instruction booklet in your ow...

Page 59: ...hms empty and 33 ohms full The fuel gauge powers up when the outboard engine main 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 fuel load is approximately linear from FULL to FULL The accuracy of the reading decreases below FULL because of the tank s pro file The most accurate fuel ...

Page 60: ...ken or damaged You can verify the integrity of the system by checking for continuity with an ohmmeter or continuity light between the bonding plate and the fuel fill cap 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 bond...

Page 61: ... 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 boat fuel system components and might...

Page 62: ...e 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 increase the pos...

Page 63: ...p gasoline This contact must be continu ously maintained until gasoline flow has stopped Never exceed a fill rate of 9 GPM Slow the fill rate to 6 GPM 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 or lower Close and secure the fuel fill cap ...

Page 64: ... boat angle so that the lowest portion of the fuel tank is below the fuel withdrawal tubes If possi ble let the gasoline rest for 30 minutes before sam pling Use the engine s fuel supply hose and primer bulb to pump the sample gasoline into a clean container and inspect for moisture or particulate contamination If the test sample shows evidence of moisture or par ticulate contamination consult a p...

Page 65: ...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 66: ... 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 67: ...ilable 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 should be main tained by an experienced marine technician ...

Page 68: ...4 2 Section 4 Boat Systems Control Console Layout 1 2 3 4 5 7 6 8 9 0 B A C E G I D F H J K ...

Page 69: ...d ACR spotlight 9 Outlet accessory 12 VDC 0 Panel switch helm station A Engine instrumentation B Panel switch Lenco tabs C Panel switch battery parallel D Control engine single lever E Button horn 12 VDC F Gauge operating hours engines G Helm steering manual hydraulic H Panel LED battery status I Switch key engine ignition J Switch engine emergency shutoff K Storage batteries engine house ...

Page 70: ...des over pressure protection for the mechanical compo nents the hydraulic 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 hose and then into the steering cylinder As the fluid is pumped into one side of the steering cylinder an equal volume of fluid is displaced from the opposite side The steering cylinder body ...

Page 71: ...4 5 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 1 2 4 4 3 5 6 7 ...

Page 72: ... Operation Operate your navigation lights using the three position rocker switch located on the helm station switch panel The down position is ANCHOR the center position is OFF and the up position is NAV While underway move the rocker switch up 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 ring deck The 360 w...

Page 73: ...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 chart Night Lighting The internal red night operation light i...

Page 74: ...essed through the splashwell hatch The pump discharges on the starboard side just for ward of the transom The bilge pump power circuit is wired directly to the battery side of the engine battery OFF ON switch The bilge pump system has an uninterruptible power supply that is not affected by the position of the engine battery OFF ON switch The uninterruptible bilge pump power circuit is pro tected b...

Page 75: ...The rocker switch has a red LED indicator that will be lighted anytime the bilge pump is running CAUTION Keep the bilge pump switch in the AUTO position anytime the bilge drain plug is in place whether the boat is in the water or on a trailer Keeping the switch in the AUTO position allows the system to sense rainwater or melting snow that might accumulate in the bilge CAUTION The bilge pump will b...

Page 76: ...itch position is OFF Both the left and right switch positions are momentarily ON when held down When you release the switch it will return to the center OFF position If your 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 posi...

Page 77: ...he switch panel is labeled to make trim tab operation simple When operating the tab buttons 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 This lowers the trim plane on the starboard side of the transom To lower the starboard bow push the right DOWN button This lowers the trim plane on the port side of the transom To even...

Page 78: ...n 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 Turning the house battery OFF ON switch to the OFF position at the end of your mission will cut power to the trim tab control box CAUTION The trim tabs will automatically retract when the outboard engine is tur...

Page 79: ...lay 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 BOW UP buttons to raise the bow Rough Water When running in chop or heavy seas press both BOW DOWN buttons to lower the bow elevation This will bring the V of the hull in more contact with the waves and reduce the pounding effect WARNING The ...

Page 80: ...tabs to achieve the desired running attitude of the boat Then trim the outboard engine up using the trim function on the single lever control until the engine propeller is parallel with the surface of the water If necessary readjust the boat trim tabs to fine tune the running attitude of the boat Refer to the Lenco operation manual in your owner s bag for detailed information about the operation a...

Page 81: ...ndicator panel The panel is mounted at the helm station The panel has a green LED that is lighted anytime a bat tery switch or a boat accessory circuit is powered and active Turn all battery OFF ON switches to the OFF posi tion before you leave the boat unattended for any period of time Check to make sure that the bat tery status green LED is not lighted Leaving the boat unattended with the batter...

Page 82: ...e OFF position at the end of your mission will cut power to the console interior dome light circuit T top Combination Light If your boat is equipped with a T top you have a com bination red white light fixture above the helm area Operation of the red white light is controlled by its black bezel There is no OFF ON switch on the helm station switch panel Rotate the bezel in either direc tion to sele...

Page 83: ...odlight circuits 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 port and starboard Typically they are located on the interior hull sides under the gunwale boards or ring deck To operate the red cockpit lights move the COCKPIT LIGHT...

Page 84: ...ess features Refer to the Whelen operator s manual for detailed information about the siren and strobe functions The siren amplifier circuit is protected by a 10 amp blade fuse located in the accessory fuse block inside the control console Turn off the siren and strobe features when they are not required to avoid discharging the house battery Turning the house battery OFF ON switch to the OFF posi...

Page 85: ...N position A dim light in the center of the control pad will indi cate the spotlight is in STANDBY mode Push the ON OFF button one time to turn on the spotlight The indicator light will brighten and the spotlight will turn on Push the soft touch control pad to control the spotlight Push the SPEED button one time to slow the spotlight response speed Push the ON OFF button one time to turn off the s...

Page 86: ...t 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 Set engines or rudders on target boat to maintain station behind your boat CAUTION Your towing s...

Page 87: ...wed 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 tow rig Set your engines to mainta...

Page 88: ...wer system Move main ELCI breaker to the OFF position Route and connect shore power cord Listen for audible warning indicating reverse polarity Verify green POWER light on ELCI panel Move main ELCI breaker to the ON position Press TEST button on ELCI panel Red FAULT light should come on and ELCI breaker should trip Press RESET button on ELCI panel Verify green POWER light on ELCI panel Move main E...

Page 89: ...utput can be accessed through the hose fitting located on the interior transom bulk head The pump is controlled by an OFF ON rocker switch located on the helm station switch panel The pump power circuit is protected by a 10 amp push button breaker located above the rocker switch The pump is equipped with a pressure switch that acti vates the pump on demand when the rocker switch is in the ON posit...

Page 90: ...4 24 Operator Notes ...

Page 91: ...rged when the outboard engine is running above idle speed regard less 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 one or more circui...

Page 92: ...ipment 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 electrical systems WARNING Always wear eye protection when servicing batteries Batteries contain sulfuric acid...

Page 93: ...batteries are considered wet cell and require periodic maintenance Your boat might be equipped with Optima Blue Top marine batteries Optima batteries use spiral cell tech nology to improve vibration resistance and service life These batteries are classified as non spillable and do not require periodic checks of electrolyte levels With proper care these marine heavy duty batteries will last several...

Page 94: ...t tery 2 by keeping the batteries electrically isolated The battery charge isolator output circuits are pro tected by two 70 amp push button circuit breakers located inside the control console Your boat is normally equipped with one 110 VAC bat tery charger that charges both batteries when the boat is connected to shore power Both batteries are charged when the 110 VAC battery charger is active re...

Page 95: ... 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 house and starting bat teries and the negative cable from the outboard engine are connected together at the negative buss bars located inside the...

Page 96: ...and tow post are also connected to the bonding buss system with 8 awg green cables Also directly connected to the bonding system are any shielded cables from certain sensitive electronic devices This helps mitigate radio frequency interfer ence RFI generated by various electrical systems The negative buss system and the bonding buss sys tem are also connected to each other to reduce the possibilit...

Page 97: ...5 7 Operator Notes ...

Page 98: ...oltage 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 ...

Page 99: ...e from the OFF position to remove it Disabling the battery OFF ON switches gives you an additional level of security when the boat is left unattended Bilge Pump Special The only exception to the 12 VDC circuit control described above is the bilge pump system The 10 amp in line blade fuse that protects the bilge pump system has an uninterruptible power supply that origi nates at the battery side of...

Page 100: ...FF ON switch is properly labeled and is located on or inside the control console The main power and negative battery cables from the outboard engine route through the splash well boot and connect to this power circuit through a main two position heavy duty terminal strip located near the transom This main terminal strip simplifies engine removal for service or replacement Turning the outboard engi...

Page 101: ...ide of the battery OFF ON switch and is always powered regardless of switch position The circuit is protected by one 10 amp in line blade fuse located within seven inches of the outboard engine battery OFF ON switch This uninterruptible power circuit provides flexibility in controlling your bilge pump With the outboard engine battery OFF ON switch in the OFF position you can still operate your bil...

Page 102: ...o the negative side of the 12 VDC electrical system Any accessories installed on these switches must also connect to the negative side of the 12 VDC electrical system through one of the negative terminal strips pro vided These negative terminal strips are located inside the control console If the 60 amp push button breaker trips electrically troubleshoot the power circuit and its protected devices...

Page 103: ... to the 12 VDC electrical system at the accessory 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 push button breaker trips electrically troubleshoot the power circuit and its protected devices before you reset the breaker Turning the ho...

Page 104: ...al system at the T top electronics fuse 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 push button breaker trips electrically troubleshoot the power circuit and its protected devices before you reset the breaker Turning the house battery OFF ...

Page 105: ...mp switch able breaker This panel provides 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 push button breaker trips electrically troubleshoot the power circuit and its protected dev...

Page 106: ...n 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 Sea water washdown Brown blue Fresh water washdown Brown purple Availab...

Page 107: ... cm Bridge clearance floating Note 2 104 in 264 cm Engine shaft length single 25 in 64 cm Engine shaft length dual N A N A Load capacity people gear engine 3755 lbs 1703 kg Maximum engine power 300 HP 224 kW Maximum engine weight 700 lbs 318 kg Minimum engine power 150 HP 112 kW Fuel tank capacity Note 4 90 gallons 341 liters Fuel minimum octane rating 87 AKI 90 RON Note 1 With standard console no...

Page 108: ...your boat Model and serial number information for each piece of equipment installed on your boat was gathered during the construction process This important information was recorded on a Serial Number Sheet A copy of the Serial Number Sheet is in your owner s bag Keep a copy of this important information somewhere safe on shore USCG Manufacturer s Identification Month Built January A Boat Serial N...

Page 109: ...rotect it 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 cle...

Page 110: ...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 111: ... 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 112: ... 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 113: ...fully loaded condition Construction materials must suit your operating environment The trailer should have torsion axles Trailer bunks must be continuous and as long as the boat s running surface 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 bunks must not be segmented or swivel T...

Page 114: ...6 8 Section 6 Boat Maintenance Trailer Setup ...

Page 115: ...tion 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 ac...

Page 116: ...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 117: ...draulic 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 5430 Texaco H015 Aero She...

Page 118: ...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 119: ...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 120: ...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 121: ...essure 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 natural result...

Page 122: ...ways Internal engine parts can be damaged by corrosion due to lack of proper storage lubrication Your out board engine operator s manual has a detailed proce dure for adding extra internal lubrication just before the engine is stored Refer to the OEM engine manual in your owner s bag for detailed information about storage and winteriza tion Fire Pump You must protect your portable fire pump from f...

Page 123: ...e and negative plates changes to lead sulfate causing the plates to become similar in chemical composition The battery electrolyte becomes weaker and the voltage drops As the bat tery remains discharged this process continues until recharging the battery becomes impossible Leave the batteries in their plastic boxes Store the batteries in a cool dry location Check the battery condition monthly duri...

Page 124: ...suggestions to minimize the possibility of damage to your fuel system and engines during stor age 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 125: ...a fresh water sys tem You must protect the fresh water system from damage caused by freezing temperatures Use the following steps to prepare this system for off season storage Treat the fresh water holding tank with a non toxic antifreeze following the manufacturer s recom mendations Run the treated water through all the outlets and faucets to protect the under deck plumbing Marine Sanitation Devi...

Page 126: ...rnal 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 Secure the main hull drain plug to the steering wheel to alert personnel that the boat is in storage configura tion ...

Page 127: ...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 128: ...World class support for World class boats ...

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Boston Whaler 21 Justice Series, Operation & Maintenance Manual

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