Boston Whaler 19 GuardianSeries User manual

Operation & Maintenance Manual
Boston Whaler®
19 Guardian® Series
©2007 Brunswick Commercial & Government Products. All Rights Reserved.
420 Megan Avenue Edgewater Florida 32132 USA
www.brunswickcgboats.com

Safety Notices
This manual uses three levels of notification
for safety-related information.
The signal words CAUTION, WARNING, and
DANGER identify specific levels of hazard.
They are defined as:
When you see a safety information box in this
manual, carefully read the message before
you proceed. Take these safety warnings
seriously and be alert to the possibility of
property damage, serious injury, or death.
If you do not understand a safety warning, call
the Customer Service Department at Brun-
swick Commercial & Government Products.
About This Manual
The information and illustrations in this man-
ual are protected by copyright. You may not
merge, adapt, translate, modify, assign, store,
reproduce, or distribute this manual’s con-
tents without prior written permission from
Brunswick Commercial & Government Prod-
ucts. All rights related to this manual are
reserved and protected by Brunswick Com-
mercial & Government Products.
Brunswick Commercial & Government Prod-
ucts reserves the right to make changes at
any time, without notice, to features, specifi-
cations, and model availability. The right is
also reserved to change any specification,
part, or system without incurring any obliga-
tion to update older boats.
The information in this manual is based on the
latest specifications available at the time of
publication. The photographs and illustrations
might not depict actual 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 to safely operate the boat if
the primary operator is not available.
Make this manual available to anyone who
will operate this boat.
Warranty Information
Read the Brunswick Commercial & Govern-
ment Products Limited Commercial Warranty
that was shipped with this boat. It explains
what is covered and what is not covered
under warranty. It also explains your respon-
sibilities and obligations as the owner.
A product registration card was shipped with
this boat. Complete this card and mail it to
Brunswick Commercial & Government Prod-
ucts. We use the information to initiate your
warranty coverage and to contact you in case
of a safety-related issue with your boat.
Include your boat’s Hull Identification Number
(HIN) when completing the registration card
and anytime you contact the factory. See the
Maintenance Section for information about
your boat’s HIN.
!CAUTION
A hazard that might result in injury or
damage to property or equipment.
!WARNING
A hazard that could result in death or
serious injury.
!DANGER
A hazard that will result in death or seri-
ous injury.

Table of Contents
Section 1 - !Safety
Operator Responsibilities .....................1-1
Personal Flotation Devices ...................1-1
Exhaust Emissions ................................1-2
Fire Extinguishers ..................................1-3
Fires ........................................................1-3
Giving Assistance ..................................1-4
Severe Weather ......................................1-4
Boat Load Capacities ............................1-5
Capsizing ................................................1-5
Swamping ...............................................1-6
Diving Operations ..................................1-7
Proposition 65 Information ...................1-7
Deck Occupancy Chart ..........................1-8
Warning Label Chart ..............................1-9
Section 2 - Boat Operation
Pre-operation Checklist .........................2-1
Ignition Shutoff Switch ..........................2-2
Ignition Switch .......................................2-3
Starting Procedure .................................2-4
Shift and Throttle Control .....................2-5
Shifting ................................................2-5
Speed Control .....................................2-5
Engine Trim .........................................2-6
Engine Gauges .......................................2-8
Tachometer .........................................2-8
Hour Meter ..........................................2-9
Fuel Gauge ..........................................2-9
Water Pressure Gauge .....................2-10
Voltmeter ...........................................2-10
Trim Gauge .......................................2-11
Propellers .............................................2-12
Maneuvering ........................................2-14
Load Distribution .................................2-16
Boat Trim Tabs .....................................2-17
Stopping Procedure .............................2-19
Trailering ...............................................2-20
Safety Checklist ................................2-21
Towing ..............................................2-22
Backing .............................................2-23
Lifting and Slinging .............................2-24
Gunwale Lifting Eyes .......................2-25
Slings ................................................2-26
Forklift ...............................................2-26
Section 3 - Fuel System
Descriptions ...........................................3-2
Fuel System Diagram ............................3-4
Access Plate Diagram ...........................3-5
Bonding System ....................................3-6
Maintenance .......................................3-6
Repair ..................................................3-6
Fill and Vent Locations .........................3-7
Primer Bulb ............................................3-7
Fueling Procedures ...............................3-8
Static Electricity .................................3-9
Guidelines .........................................3-10
Fuel Gauge and Sending Unit ............3-11
Hose Routing .......................................3-12
Fill Hose Replacement ........................3-12
Removal ............................................3-12
Installation ........................................3-12
Vent Hose Replacement ......................3-13
Removal ............................................3-13
Installation ........................................3-13
Contaminated Fuel ..............................3-14
Fuel Filter/Water Separator ................3-14
Blended Fuels ......................................3-15
Section 4 - Boat Systems
Console Layout ......................................4-1
Steering System ....................................4-2
Operation ............................................4-3
Going Ahead .......................................4-3
Going Astern ......................................4-4

Table of Contents
Steering System Diagram .....................4-5
Navigation Lights ..................................4-6
Operation ............................................4-6
Docking Lights .......................................4-7
Bilge Pump .............................................4-7
Operation ............................................4-8
Maintenance .......................................4-8
Trim Tabs ................................................4-9
Proper Boat Trim .............................4-10
Rough Water .....................................4-11
Trim Tabs and the Engine ...............4-11
Trim Tab Control Box ......................4-11
Maintenance .....................................4-12
Compass ..............................................4-13
Deviation ...........................................4-13
Variation ............................................4-13
Night Lighting ...................................4-13
Battery Parallel Switch ........................4-14
Console Interior Dome Light ..............4-15
Cockpit Lighting ..................................4-15
Siren & Strobe Light ............................4-16
Floodlights ...........................................4-16
Section 5 - Electrical Systems
Descriptions ...........................................5-1
Batteries .................................................5-1
Capacities ...........................................5-2
Maintenance .......................................5-2
Cleaning ..............................................5-3
Charging .............................................5-4
Battery Switches ....................................5-5
Battery Parallel Switch ......................5-5
OFF-ON Switch, Engine .....................5-6
OFF-ON Switch, Electronics .............5-6
Grounding and Bonding .......................5-7
Definition .............................................5-7
Grounding ...........................................5-7
Bonding ...............................................5-8
DC Power Distribution ..........................5-9
Outboard Engine ................................5-9
Bilge Pump .......................................5-10
Helm Station Switch Panel ..............5-11
Accessory Fuse Block .................... 5-12
T-top Fuse Block .............................. 5-13
Electronics Distribution Panel ........ 5-14
DC Circuit Distribution ........................ 5-15
Helm Station Switch Panel .............. 5-15
Accessory Fuse Block .................... 5-17
T-top Fuse Block .............................. 5-17
Electronics Distribution Panel ........ 5-17
Section 6 - MaintenanceSection 6 - 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
Drains & Scuppers ............................. 6-5
Cutwater & Chafe Plates .................. 6-6
Hull Blistering ....................................... 6-6
Storage ............................................... 6-7
Inspection ........................................... 6-7
Waxing ................................................ 6-7
Bottom Painting ................................. 6-7
Fuel System ........................................... 6-9
Steering System .................................. 6-10
Approved Steering Fluids ............... 6-11
Batteries ............................................... 6-12
Capacities ......................................... 6-13
Maintenance ..................................... 6-13
Cleaning ............................................ 6-14
Off-Season Storage ............................. 6-15
Outboard Engine .............................. 6-15
Batteries ........................................... 6-16
Fuel System ..................................... 6-16
Hull Drainage .................................... 6-16
Freshwater System .......................... 6-16

1-1
Safety Section 1
Operator Responsibilities
Always follow these general guidelines when operat-
ing this boat:
• 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 that is appropriate
for your mission
• Never work alone around machinery such as out-
board engines, generators, and fire pumps
Personal Flotation Devices
Personal Flotation Devices (PFD’s) are designed to
save lives. It is your responsibility to ensure that the
boat has a sufficient number of PFD’s for your passen-
gers. It is your responsibility to ensure that non-swim-
mers wear PFD’s at all times and that everyone wears
a PFD during emergencies and severe weather.
The United States Coast Guard recognizes four types
of wearable devices and one type of throwable device.
•Type I- Life preserver, appropriate for off-shore
and foul weather.
•Type II- Buoyant vest, 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. Type IV devices
must never be worn as a vest.
•Type V- Special-purpose device; includes har-
nesses, certain jackets, and rafting vests. Type V
vests must be worn while underway to count
toward minimum PFD requirements.
TYPE I
KC-0041.1
TYPE II
KC-0051.1
TYPE III
KC-0061.1

1-2
Section 1 Safety
All PFD’s must be easily accessible. They must be
removed from their shipping bags and they should be
unbuckled. Make sure that everyone knows where the
PFD’s are located. Make sure that everyone knows
how to put one on and correctly adjust it.
Check the availability and condition of all PFD’s before
each trip.
Exhaust Emissions
Gasoline-powered engines produce carbon monoxide
when they are running. Carbon monoxide is a
colorless and odorless gas. It is extremely toxic.
Always be aware of operating conditions that might
allow carbon monoxide to collect in occupied spaces
on your boat. Remember these general precautions:
• Avoid running engines or 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 “Know More About It” that
is in your owner’s bag.
!DANGER
Prolonged exposure to carbon monoxide can
cause serious injury or death. Always insure
that confined spaces in your boat have an ade-
quate supply of fresh air.
TYPE V
KC-0043
TYPE IV
KC-0071.1

1-3
Safety Section 1
Fire Extinguishers
Your boat is equipped with two or more United States
Coast Guard approved Type ABC fire extinguishers.
Each is UL Rated 1-A:10-BC. This rating indicates
that each extinguisher can be used to fight Class A, B,
and C fires. These classes include fires involving
wood, cloth, gasoline, oil, grease, and live electrical
equipment.
Each fire extinguisher is mounted in a location which
allows quick access. Be familiar with these locations.
Read and understand the instructions on the
extinguisher label and in the manufacturer’s instruction
booklet located in your owner’s bag.
Formulate a fire plan in advance that will help you
evaluate your risk and response in case of an on-
board fire.
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 extinguished. Evaluate the damage and
get assistance immediately.
Larger fires involving the boat’s fuel system might
result in explosion and complete destruction of the
boat. Formulate a fire plan in advance that will help
you decide if you can fight the fire or if you should
abandon the boat.
!DANGER
Gasoline floats on water. If you abandon the
boat, swim up wind or up current from the boat
to avoid the gasoline that might spread on the
surface of the water.
KC-0160

1-4
Section 1 Safety
Giving Assistance
The 1971 Federal Boat Safety Act grants “Good
Samaritan” protection to any boater who offers good
faith assistance to someone in distress. The Act also
protects that boater from liability related to any
assistance given.
You should attempt to give assistance when you see a
distress signal while boating, if you can do so without
endangering your boat or passengers.
Severe Weather
Severe weather can be a very dangerous component
of boating. High winds, rough seas, and storms can
put your passengers and your boat at risk. Listen to
weather advisories before you start your trip and while
you are underway.
Marine weather advisories are unique because of the
special relationship between wind and waves. The
longer the wind blows in a steady direction over water,
the higher and more powerful the waves will be. Wind
of 35 knots can create six-foot waves in two hours.
These are considered severe conditions for most
boating activities.
Take some general precautions if you must boat in
severe conditions.
• Have everyone wear PFD’s
• Use your ignition shutoff clip and lanyard
• Stow loose gear and lash down equipment
• Close all hatches, doors, and windows
• Install the dive door, if equipped
• Reduce boat speed
• Report your location and situation by radio
• Monitor marine weather advisories
KC-0215
OK !

1-5
Safety Section 1
Boat Load Capacities
The United States Coast Guard requires boats less
than 20 feet to display a capacity plate that indicates
the maximum number of people and the maximum
weight that the boat can support under normal
operating conditions. Additional capacity information
for this boat is listed in the Maintenance Section.
• Do not exceed the capacity limits of this boat
under any circumstances.
• Consider reducing these capacity limits during
special operations and severe weather condi-
tions.
• You are always responsible for the safety of the
boat and its passengers 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 engine(s) to avoid injury and
additional damage
• Locate all passengers and evaluate their condi-
tion
• Stay with the boat, it will always float
• Distribute PFD’s if possible
• Try to climb onto the hull
• Initiate emergency locating signal or radio com-
munication if possible
!WARNING
Excessive loading, improper load distribution,
and mismatching loads to existing conditions
can contribute to boat swamping or capsizing.
These situations can result in serious injury or
death.
KC-0170

1-6
Section 1 Safety
Swamping
Swamping or flooding the interior of the boat can occur
for a number of reasons, including severe weather
conditions, improper operation, and improper loading.
Consider the following:
• Know the safe loading limits for this boat under
normal conditions. Refer to the boat specifica-
tions in the Maintenance Section of this manual
and the Certification Plate in the boat.
• Consider reducing those loading limits during spe-
cial operations or adverse weather conditions.
• Distribute the load evenly (fore/aft and port/star-
board) so that the approximate center of the load
is near the middle of the boat.
• Close all hatches, doors, and windows during
severe weather. Install 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.

1-7
Safety Section 1
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 hours.
This display indicates that your boat is operating with
restricted maneuverability.
Some local or state regulations might require the red
and white diver’s flag to indicate that a person is in the
water.
Proposition 65 Information
The following information is included in this manual as
recommended by California’s Safe Drinking Water
and Toxic Enforcement Act of 1986, amended
through Proposition 65.
!WARNING
A wide variety of components used on this boat
contain or emit chemicals 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 fumes
• Wash areas thoroughly with soap and
water after handling the substances listed
in this warning
KC-0250

1-8
Section 1 Safety
Deck Occupancy Chart
Working Decks: Do not allow passengers on
these decks while the boat is underway. These decks
can only be used when you are at the dock, mooring,
or anchoring.
Accommodation Decks: You can allow
passengers to move around these decks while the
boat is underway. You must continually 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 sur-
faces to avoid slipping or falling. Never wax
portions of the boat that have a non-skid pat-
tern.
!DANGER
Never occupy working decks while the boat is
underway. Do not sit on the gunwales or any
part of a working deck while the boat is under-
way.

1-9
Safety Section 1
1
23
4
6
9
B
F
5
8
D
7
0
A
C
E
Warning Label Chart
11017078 Do Not Stand
21017136 Hi-performance Boat
31016518 Steering Effort
41016534 Fuel Tank Readings
51790729 Docking Lights
61811368 Carbon Monoxide
71016963 Do Not Drill
81817722 Customer Information Tag
91109180 Capacity Plate
0995704 Fuel Leaks
A1016898 Do Not Drill
B1016963 Do Not Drill
C1016443 Do Not Drill
D1811367 Carbon Monoxide
E1016922 Battery Terminal
F1016880 Do Not Paint

1-10
Operator Notes

2-1
Boat Operation Section 2
Pre-operation Checklist
Review all the items on this checklist each time you
prepare for a trip. Resolve any issues before depart-
ing.
TDrain plug installed
TCheck regional weather forecast
TVerify trip routing and navigational information
THull in seaworthy condition
TOperator’s Manual on-board
TVHF and HF radios operational
TGPS units operational
TRadar operational
TSafety equipment on board
TAdequate fuel load for trip
TFuel tank selector valve correctly set
TAdequate oil level in reservoir
TNavigation lights operational
TSignal horn and bell operational
TBilge pump operational
TFloat switch operational
TWater level sensors operational
TEngine battery in good condition
TElectronics batteries in good condition
TBattery selector switches correctly set
TOutboard engine operational
TControl shift lever in NEUTRAL
TIgnition Shutoff clip and lanyard in place
TEngine in full Tilt Down position
TSteering system in good condition
TFuel tank, valve, and hoses in good condition
TFuel filter in good condition
TNo water in water separator

2-2
Section 2 Boat Operation
Ignition Shutoff Switch
Your boat is equipped with an ignition shutoff switch.
The ignition shutoff switch is designed to shut off the
engine if you move away from the helm station by
accident, either by falling down or by being ejected
from the helm seat. Both of these situations can be
caused by unsafe operating techniques or severe
operating conditions. Do not use the ignition shutoff
switch to stop the engine during normal operation.
The ignition shutoff switch is connected to your cloth-
ing by a lanyard and clip. If you move beyond the
scope of the lanyard, the ignition shutoff switch will be
activated and the engine will shut off immediately.
!WARNING
Do not activate the ignition shutoff switch dur-
ing normal operations when the boat is on
plane. Activating the ignition shutoff switch at
planing speeds will cause the boat to suddenly
decelerate, possibly injuring or ejecting pas-
sengers.

2-3
Boat Operation Section 2
Understand this information about your ignition shutoff
switch:
• It is your responsibility to decide when to attach
the switch lanyard, but we strongly recommend
that you use the shutoff switch anytime you are
operating the boat.
• Test the ignition shutoff switch periodically by pull-
ing the clip and lanyard while the engine is at idle
speed. The engine should stop immediately.
• The engine will not start if the clip and lanyard is
not attached to the shutoff switch.
• The switch can only work when the lanyard is
attached to a sturdy part of your clothing.
• Do not shorten the switch lanyard. It must be long
enough to avoid inadvertent switch activation dur-
ing normal operator movement.
• Refer to the engine operator’s manual for specific
information about the ignition shutoff switch.
Ignition Switch
Your boat is equipped with an engine ignition switch.
The switch controls the starting, running, and stopping
of the outboard engine. The switch also controls the
operation of certain engine accessory systems.
Refer to the engine operator’s manual for specific
information about the ignition switch.
!DANGER
Never start or operate the outboard engine
when people are in the water near your boat.
Contact with the boat, engine, or rotating pro-
peller can cause serious injury or death.

2-4
Section 2 Boat Operation
Starting Procedure
Use the following checklist each time you start the out-
board engine. Additional detailed information about
these systems is covered in the engine operator’s
manual.
TOperator’s Manual on-board
TReview Pre-operation Checklist
TEngine battery selector switch to ON position
TElectronics battery selector switch(s) to ON posi-
tion
TRelease engine tilt lock and lower engine to full
Tilt Down position
TTurn on fuel tank selector valve
TVerify fuel and oil supply
TPrime engine fuel supply system
TPrime engine oil supply system if the engine has
not been operated in the last 30 days
TMove control shift lever to NEUTRAL position
TAttach ignition shutoff switch clip and lanyard
TStart engine
TLet engine idle in NEUTRAL for five minutes
before leaving the dock
TVerify engine systems using gauges and over-
board cooling system indicator
!DANGER
Never start or operate the outboard engine
when people are in the water near your boat.
Contact with the boat, engine, or rotating pro-
peller can cause serious injury or death.
!CAUTION
Never start or run the engine without an ade-
quate supply of cooling water. The engine will
be damaged immediately.

2-5
Boat Operation Section 2
Shift and Throttle Control
Boat direction, boat speed, and close-quarter maneu-
vering are controlled by the single-lever control. The
single-lever control includes gear selection, engine
speed, and engine trim angle functions.
Additional detailed information about this single-lever
control is covered in the engine operator’s manual.
Shifting
• The shift lever controls gear selection for the
engine. The shift lever must be in NEUTRAL
before starting engine. The engine will not start if
the shift lever is in FORWARD or REVERSE.
• The engine must be running before you shift into
FORWARD or REVERSE.
• Move the shift lever forward to select FORWARD.
• Move the shift lever backward to select
REVERSE.
• Never shift directly from FORWARD to REVERSE
without pausing in NEUTRAL.
• Never shift directly from REVERSE to FORWARD
without pausing in NEUTRAL.
Speed Control
• The shift lever has a NEUTRAL throttle button.
Depress the button and move the shift lever for-
ward to increase engine speed in NEUTRAL.
• Move the shift lever back to the NEUTRAL detent
to disengage the NEUTRAL throttle button.
• Moving the shift lever forward from the FOR-
WARD detent position will increase engine speed
in forward gear.
• Moving the shift lever backward from the
REVERSE detent position will increase speed in
reverse gear.

2-6
Section 2 Boat Operation
Engine Trim
Trimming the engine down or in is good for accelera-
tion and carrying heavy loads. The boat ride tends to
be slower and wetter, and the boat might bow 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 opera-
tor visibility can contribute to collisions, caus-
ing serious injury or death.
!WARNING
Excessive engine trim angle can cause the boat
to “porpoise” or bounce. Porpoising can
reduce operator control and visibility, resulting
in unsafe boat operation.