Brunswick Boston Whaler 22 Guardian Series Operation & Maintenance Manual Download

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Table of Contents

T-6

Section 6 - Maintenance

Section 6 - Boat Maintenance

Specifications ......................................... 6-1

Hull Identification Number ..................... 6-2

Options .................................................... 6-3

Hull Maintenance .................................... 6-3

Washing ........................................... 6-3

Waxing ............................................. 6-4

Compounding .................................. 6-4

Gelcoat & Fiberglass Repair .......... 6-4

Trim Care ................................................ 6-5

Aluminum ......................................... 6-5

Deck Hardware ................................. 6-5

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 System .............................. 6-15

Trim Tabs .............................................. 6-15

Off-Season Storage .............................. 6-16

Outboards ...................................... 6-16

Fire Pump ....................................... 6-16

Batteries ......................................... 6-17

Fuel System ................................... 6-18

Sea Water Washdown System ..... 6-19

Fresh Water System ...................... 6-19

Hull Drainage ................................. 6-19

Summary of Contents for Boston Whaler 22 Guardian Series

Page 2: ...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 disc...

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...

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 Pro...

Page 5: ...ion 3 2 Fuel System Diagram 3 4 Racor Gasoline Filters 3 6 Fuel Gauge and Sending Unit 3 7 Bonding System 3 8 Routine Maintenance 3 8 Repair 3 8 Fueling Procedures 3 9 Safety Warnings 3 9 Static Elect...

Page 6: ...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 Engines 4 14 Signal Horn 4 15 Battery Status Indicator 4 15 Bilge Pump Specia...

Page 7: ...nitions 5 5 Bonding 5 5 Grounding 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 Starboard Engine 5 10 Port Engine 5...

Page 8: ...ck Hardware 6 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 Warnin...

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 experi...

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 a...

Page 11: ...t Remember these important precautions Avoid running your outboard engines or portable fire pump in confined areas such as boat houses Be aware of engine exhaust from adjacent boats when you are moore...

Page 12: ...ire 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 Caref...

Page 13: ...IRB 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 a...

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 capsiz...

Page 15: ...e 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 sens...

Page 16: ...escue 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...

Page 17: ...red 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 bi...

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

Page 19: ...ally 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 slipper...

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

Page 21: ...6518 Steering Effort 5 1950698 Rotating Propellers 6 2090315 Dive Rescue Door 7 1811368 Carbon Monoxide 8 1972938 Battery Chargers 9 2025463 NMMA Capacity Plate 0 1795087 Proposition 65 Tag A 1817722...

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

Page 23: ...ad for mission Fuel tank and fuel hoses good condition Fuel filters in good condition No water in water separators Navigation lights operational RIAM lights operational Signal horn operational Bilge p...

Page 24: ...s or severe operating conditions Do not use the ignition shutoff switch to stop the engines during normal boat operation You should connect the ignition shutoff switch clip and lanyard to a sturdy par...

Page 25: ...p and lanyard while the engines are at idle speed Both engines should stop immedi ately The engines will not start if the clip and lanyard is not attached to the shutoff switch The switch can only fun...

Page 26: ...in the OFF position Record and save the key number following the instruc tions in Section 6 You must turn the engine battery OFF ON switches to the ON position before you use the main engine key switc...

Page 27: ...OFF position and repeat the starting process To STOP the port engine turn the port main engine key switch to the ACC or OFF position If you are securing the port engine from service turn the port mai...

Page 28: ...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 one of your outboard engines will not start due to low ba...

Page 29: ...evers to NEUTRAL posi tion Attach ignition shutoff switch clip and lanyard Start engines using the main engine key switches Use emergency battery parallel switch if required Verify engine cooling syst...

Page 30: ...e 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 direct...

Page 31: ...teer Trimming your engines 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 ov...

Page 32: ...lever control will have three engine trim switches located on the port control lever The center trim switch moves both engines at the same rate to change general boat operating angle The left and rig...

Page 33: ...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...

Page 34: ...an be used to schedule periodic maintenance for the boat and the engines Fuel Gauge The fuel gauge powers up when the starboard engine ignition switch is turned to the ON position The fuel gauge displ...

Page 35: ...hat charges its starting battery when the engine is running above idle speed The voltmeter displays engine battery volt age measured in DC volts VDC These readings indicate that engine battery systems...

Page 36: ...e 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...

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 a...

Page 38: ...ould 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 performanc...

Page 39: ...rotating which means that the port propeller rotates in a counter clockwise direction while in for ward gear when viewed from behind the boat Coun ter rotating propellers have significant advantages...

Page 40: ...rgo evenly front 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 unexpectedl...

Page 41: ...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...

Page 42: ...h 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 exte...

Page 43: ...tboard engines before tilting to avoid contact with any special towing equipment Raise the engines to full Tilt Up position and engage tilt locks Turn engine battery OFF ON switches to OFF position Tu...

Page 44: ...our 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 countr...

Page 45: ...t 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 equip...

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 p...

Page 47: ...y 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 Al...

Page 48: ...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 m...

Page 49: ...ilure 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...

Page 50: ...our 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 a...

Page 51: ...500 pounds 2948 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 a...

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

Page 53: ...ree 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 g...

Page 54: ...ard 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...

Page 55: ...equipped with a flow control valve which will not allow liquid gasoline to escape from the fuel fill cap during normal fueling operations The fuel tank vent is located on the port hull side mid ship...

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

Page 57: ...fuel tank 4 Cap fuel fill 5 Label manufacturer compliance 6 Valve flow control 7 Sender fuel level 8 Tank gasoline 75 gallons 9 Tube fuel withdrawal 3 places 0 Valve fuel shutoff 3 places A Hose fuel...

Page 58: ...er to Blended Fuels in this section for more infor mation about water in gasoline Replace the filter elements on this schedule which ever happens first Every 100 operating hours Annually Noticeable en...

Page 59: ...ms empty and 33 ohms full The fuel gauge powers up when the starboard engine main ignition key switch is turned to the ON position The fuel gauge displays the approximate fuel level in the fuel tank T...

Page 60: ...systems Routine Maintenance Check the bonding system and its optional external anode regularly Check the green cables and their connections at each component Replace the external anode if it is less...

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 syste...

Page 62: ...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 edg...

Page 63: ...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 complete...

Page 64: ...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 one of the engine fuel supply hoses and pri...

Page 65: ...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 maintenanc...

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...

Page 67: ...lable 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 manua...

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

Page 69: ...Display navigation 0 Outlet accessory 12 VDC A Engine instrumentation B Panel switch helm station C Helm steering manual hydraulic D Panel switch Lenco tabs E Panel switch battery parallel F Control...

Page 70: ...over pres sure protection for the mechanical components 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...

Page 71: ...4 5 Boat Systems Section 4 Steering System Diagram 1 Outboard engine 5 Hydraulic hoses 2 Steering cylinder 6 Helm reservoir 3 Tie bar 7 Fill port 4 Steering arm 8 Steering wheel 1 2 2 3 4 4 5 5 6 7 8...

Page 72: ...d Operation Operate your navigation lights using the 3 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...

Page 73: ...nformation 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 Tha...

Page 74: ...e pump is located midship on the starboard side One 1100 GPH pump is located in the aft bilge area and can be accessed through a deck hatch This pump discharges on the starboard side just forward of t...

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 switches in the AUTO position anytime the bilge drain plug is in place whet...

Page 76: ...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 one of your outboard engines will not start due to low ba...

Page 77: ...e 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 le...

Page 78: ...switch The trim tab system will only operate when the starboard engine ignition switch is ON The trim tabs will automatically retract when the starboard engine ignition switch is turned OFF Turning t...

Page 79: ...ay 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...

Page 80: ...abs to achieve the desired running attitude of the boat Then trim the outboard engines up using the trim function on the dual lever control until the engine propellers are parallel with the surface of...

Page 81: ...icator 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 swit...

Page 82: ...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...

Page 83: ...dlight 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...

Page 84: ...ss 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...

Page 85: ...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 th...

Page 86: ...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 befo...

Page 87: ...ed 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 ar...

Page 88: ...er 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 bre...

Page 89: ...p output 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 ci...

Page 90: ...er manently attached to the port 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 operat...

Page 91: ...ged when the outboard engines are 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...

Page 92: ...pment 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 ve...

Page 93: ...batteries are con sidered 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...

Page 94: ...d bat tery 2 by keeping the batteries electrically isolated The battery charge isolator output circuits are pro tected by three 70 amp push button circuit breakers located inside the control console Y...

Page 95: ...he galvanic corrosion of all metal com ponents connected to it The grounding system is a series of redundant con ductors used to connect metallic parts of direct current DC devices to the engine negat...

Page 96: ...cs distribution panel also connect to the negative side of the 12 VDC electrical system at the buss bar The connections are made with 8 AWG black marine cables from each device Also directly connected...

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

Page 98: ...emergency battery parallel switch to provide power from the other starting battery Push and hold the battery parallel switch ON to either the left or right position Note this position Hold the batter...

Page 99: ...switch handle an addi tional 20 counter clockwise 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 Bi...

Page 100: ...ervice or replacement Turning the starboard engine battery OFF ON switch to the OFF position at the end of your mission will cut power to the starboard engine and its accessories Port Engine Main 12 V...

Page 101: ...ry side of the battery OFF ON switch and is always powered regardless of switch position The circuit is protected by one 20 amp in line blade fuse located within seven inches of the port engine batter...

Page 102: ...ction to 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 negativ...

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 accesso...

Page 104: ...l 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...

Page 105: ...p 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...

Page 106: ...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 F...

Page 107: ...78 cm Bridge clearance floating Note 2 7 ft 6 in 229 cm Engine shaft length single 25 in 64 cm Engine shaft length dual 20 in 51 cm Load capacity people gear engines 2655 lbs 1204 kg Maximum engine po...

Page 108: ...our 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...

Page 109: ...otect 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...

Page 110: ...ly 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 follo...

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...

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 scupp...

Page 113: ...ully 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 Trail...

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

Page 115: ...on and servicing routine is directly related to the quality and quantity of gasoline that you take on board You should check the sight bowls for evidence of moisture before and after every mission Rep...

Page 116: ...ual 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...

Page 117: ...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 interi...

Page 118: ...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 striki...

Page 119: ...require 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...

Page 120: ...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 R...

Page 121: ...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 o...

Page 122: ...ternal 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 b...

Page 123: ...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 discharge...

Page 124: ...tions 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...

Page 125: ...Your boat might be equipped with 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...

Page 126: ...6 20 Operator Notes...

Page 127: ...ble 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 bee...

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

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