Boston Whaler 20 Justice Series Manual

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

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 Bruns-
wick 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 written permission from Bruns-
wick Commercial & Government Products.
All rights related to this manual are reserved
and protected by Brunswick Commercial &
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 & Gov-
ernment Products limited commercial war-
ranty statement located on the inside rear
cover of this manual. The statement explains
what is covered and what is not covered
under the warranty. The statement also
explains your responsibilities and obligations
as the boat owner.
A product registration card was shipped with
your boat. Complete this card and mail it to
Brunswick Commercial & Government Prod-
ucts using the postage-paid envelope sup-
plied. We use this 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 Num-
ber (HIN) on the product registration card and
anytime you contact the factory. See informa-
tion about your boat’s HIN in Section 6 of this
manual.
!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
T-1
Section 1 - !Safety
Operator Responsibilities ......................1-1
Giving Assistance ...................................1-1
Personal Flotation Devices ....................1-2
Exhaust Emissions .................................1-3
Fire Extinguishers ...................................1-4
Fires .........................................................1-4
Severe Weather .......................................1-5
EPIRB .......................................................1-5
Boat Load Capacities .............................1-6
Capsizing .................................................1-6
Swamping ................................................1-7
Diving Operations ...................................1-7
Dive/Rescue Door ...................................1-8
Proposition 65 Information ....................1-9
Deck Occupancy Chart .........................1-10
Warning Label Chart .............................1-12

Table of Contents
T-2
Section 2 - Boat Operation
Pre-operation Checklist .........................2-1
Ignition Shutoff Switch ...........................2-2
Main Engine Key Switch ........................2-4
Battery Parallel Switch ...........................2-6
Starting Procedure .................................2-7
Shift and Throttle Control ......................2-8
Shifting .............................................2-8
Neutral Throttle ................................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
Maneuvering .........................................2-18
Load Distribution ..................................2-20
Boat Trim Tabs ..................................... 2-21
Operation ....................................... 2-22
Stopping Procedure ............................. 2-23
Trailering ............................................... 2-24
Safety Checklist ............................ 2-26
Towing ............................................ 2-27
Backing .......................................... 2-28
Lifting and Slinging .............................. 2-29
Safety Warnings ............................ 2-29
Gunwale Lifting Eyes .................... 2-30
Slings ............................................. 2-31
Forklift ............................................ 2-32

Table of Contents
T-3
Section 3 - Fuel System
Safety Warnings .....................................3-1
General Description ................................3-2
Fuel System Diagram .............................3-4
Racor® Gasoline Filter .........................3-7
Fuel Gauge and Sending Unit ................3-8
Fill and Vent Locations ...........................3-9
Bonding System ....................................3-10
Maintenance ...................................3-10
Repair ..............................................3-10
Fueling Procedures ..............................3-11
Safety Warnings .............................3-11
Static Electricity .............................3-12
General Guidelines ........................3-13
Hose Routing .........................................3-14
Fill Hose Replacement ..........................3-14
Removal ..........................................3-14
Installation ......................................3-14
Vent Hose Replacement .......................3-15
Removal ..........................................3-15
Installation ......................................3-15
Contaminated Gasoline ........................3-16
Blended Fuels .......................................3-17

Table of Contents
T-4
Section 4 - Boat Systems
General Description ...............................4-1
Console Layout .......................................4-2
Deck Layout ............................................4-4
Steering System ......................................4-6
Operation ..........................................4-7
Going Ahead ....................................4-7
Going Astern ....................................4-8
Steering System Diagram ......................4-9
Navigation Lights ..................................4-10
Operation ........................................4-10
Bilge Pump ............................................4-11
Operation .......................................4-12
Maintenance ...................................4-12
Trim Tabs ...............................................4-13
Trim Tab Control Box ....................4-14
Proper Boat Trim ..........................4-15
Rough Water ..................................4-15
Trim Tabs and Engine ...................4-16
Maintenance ...................................4-16
Compass ............................................... 4-17
Deviation ........................................ 4-17
Variation ......................................... 4-17
Night Lighting ................................ 4-17
Battery Parallel Switch ......................... 4-18
Console Interior Dome Light ............... 4-19
Cockpit Lighting ................................... 4-19
Siren & Strobe Light ............................. 4-20
Floodlights ............................................ 4-20
Signal Horn .......................................... 4-21
Battery Status Indicator ..................... 4-21
Bilge Pump Special ....................... 4-21
Towing System .................................... 4-22
Towing a Boat ................................ 4-22
Being Towed .................................. 4-23
Swimmer’s Ladder .............................. 4-24

Table of Contents
T-5
Section 5 - Electrical Systems
General Description ................................5-1
Batteries ...................................................5-2
Safety Warnings ...............................5-2
Capacities .........................................5-3
Maintenance .....................................5-3
Cleaning ............................................5-4
Charging ...........................................5-5
Grounding and Bonding .........................5-6
Definitions ........................................5-6
Grounding ........................................5-6
Bonding ............................................5-7
Battery Switches .....................................5-8
Battery Parallel Switch ....................5-8
Battery OFF-ON Switches ...............5-9
Bilge Pump Special .........................5-9
DC Power Distribution .........................5-11
Outboard Engine ............................5-11
Bilge Pump .....................................5-12
Helm Station Switch Panel ............5-13
Accessory Fuse Block ..................5-14
T-top Fuse Block ............................5-15
Electronics Distribution Panel ......5-16
DC Circuit Distribution .........................5-17
Helm Station Switch Panel ...........5-17
Accessory Fuse Block ..................5-19
T-top Fuse Block ...........................5-19
Electronics Distribution Panel .....5-19
Wire Color Chart ...................................5-20

Table of Contents
T-6
Section 6 - MaintenanceSection 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
Hull Blistering ........................................6-7
Storage ...........................................6-8
Inspection .........................................6-8
Waxing ..............................................6-8
Bottom Painting ...............................6-8
Fuel System ...........................................6-11
Steering System ....................................6-12
Approved Steering Fluids .............6-13
Batteries ................................................ 6-14
Safety Warnings ............................ 6-14
Capacities ...................................... 6-15
Maintenance .................................. 6-15
Cleaning ......................................... 6-16
Bilge Pump ............................................ 6-17
Trim Tabs .............................................. 6-17
Off-Season Storage .............................. 6-18
Outboards ...................................... 6-18
Batteries ......................................... 6-18
Fuel System ................................... 6-19
Hull Drainage ................................. 6-20
Raw Water Washdown System .... 6-20

1-1
Safety Section 1
Operator Responsibilities
It is expected by Brunswick Commercial & Govern-
ment Products (BCGP) that the personnel authorized
to operate this boat are experienced boat handlers
familiar with high-performance boating. BCGP cannot
predict, nor warn against, every possible hazardous
situation related to the operation and maintenance of
this boat.
If you use a method or procedure different from one
outlined in this manual, you must satisfy yourself that
your method or procedure will not put your boat, your
crew, or other boaters at risk.
The safety of this boat and its crew is your responsibil-
ity. Always follow these general guidelines when oper-
ating 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 all of the information contained in this
manual, particularly Sections 1 and 2
• Understand the operation of all boat controls and
systems
• Understand and follow all applicable boating regu-
lations
• Always use safety equipment and operating pro-
cedures that are appropriate for your mission
• Never work alone around machinery such as out-
board engines, generators, and fire pumps
Giving Assistance
The 1971 Federal Boat Safety Act grants protection
to any person who offers good faith assistance to
another boater who is in distress. The “Good Samari-
tan” rule will protect you from liability if you act in a rea-
sonable and prudent manner while attempting to
render assistance during a boating emergency.
You should attempt to give assistance when you see a
distress signal while boating if you can do so without
endangering your boat or your crew.

1-2
Section 1 Safety
Personal Flotation Devices
Personal Flotation Devices (PFDs) are designed to save lives. It is your responsibility to ensure
that the boat has a sufficient number of PFDs for your crew. It is your responsibility to ensure
that non-swimmers wear PFDs at all times and that everyone wears a PFD during emergencies,
special operations, and severe weather.
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. These
devices must never be worn as a vest.
•Type V –Special-purpose device; includes harnesses, certain jackets, and rafting vests.
These vests must be worn while underway to count toward minimum PFD requirements.
All PFDs must be easily accessible. They must be removed from their shipping bags and they
should be unbuckled. Make sure that everyone knows where the PFDs are located. Make sure
that everyone knows how to put one on and correctly adjust it.
Check the availability and condition of all PFDs before each mission.
TYPE I
TYPE II
TYPE III
TYPE V
TYPE IV

1-3
Safety Section 1
Exhaust Emissions
Gasoline-powered engines produce carbon monoxide
when they are running. Carbon monoxide is a color-
less and odorless gas. It is extremely toxic.
Always be aware of operating conditions that might
allow carbon monoxide to collect in occupied spaces
on your boat. 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 What You Can’t See 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
adequate supply of fresh air.

1-4
Section 1 Safety
Fire Extinguishers
Your boat is equipped with at least two 2¾-pound
United States Coast Guard approved Type ABC fire
extinguishers. Each extinguisher is UL Rated 1-A:10-
BC. This rating indicates that each extinguisher can
be used to fight Class A, B, and C fires. These
classes include fires involving wood, cloth, gasoline,
oil, grease, and live electrical equipment.
The fire extinguishers are mounted in locations that
allow quick access in case of a fire emergency. 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 emergency.
Fires
Most marine fires result from spilled gasoline or oil
accumulating in the bilge. Careful use of on-board fire
extinguishers should control small fires.
Direct the fire extinguisher output toward the base of
the flames in a sweeping motion. Check carefully and
verify that the fire has been extinguished. Evaluate
the damage and get assistance immediately.
Larger fires involving the boat’s fuel tank 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.
!WARNING
Gasoline floats on water. If you abandon the
boat, swim up wind or up current from the boat
to avoid burning gasoline that might spread on
the surface of the water.
KC-0160

1-5
Safety Section 1
Severe Weather
Take these general safety precautions if you must
operate your boat in severe weather conditions:
• Review the condition and operation of all safety
and communication gear
• Have everyone wear personal floatation devices
• 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
• Periodically report your location and situation by
radio
• Monitor marine weather advisories
EPIRB
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
manually or it can be released by a hydrostatic feature
if the boat sinks.
The EPIRB requires regular attention to stay in mis-
sion-ready condition:
• Every 30 days – perform self-test procedure
• Every 90 days – inspect category 1 bracket
• Every 2 years – replace HRU unit
• Every 5 years – replace EPIRB battery
Refer to the EPIRB operator’s manual for detailed
operation and maintenance information.

1-6
Section 1 Safety
Boat Load Capacities
The United States Coast Guard requires boats less
than 20 feet (6 m) to display a capacity plate that indi-
cates the maximum number of people and the maxi-
mum weight that the boat can support under normal
operating conditions. Additional capacity information
for your boat is listed in Section 6 of this manual.
• Do not exceed the capacity limits of this boat
under any circumstances
• Consider reducing these capacity limits during
emergencies, special operations, and severe
weather
• You are always responsible for the safety 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 engines to avoid injury
and additional damage
• Locate all crew and evaluate their condition
• Stay with the boat, it will always float and it is eas-
ier to locate
• Distribute PFDs if possible
• Try to climb onto the hull
• Initiate emergency locating signal or radio com-
munication if possible
!WARNING
The dive/rescue door is a specialized piece of
rescue equipment. All posted USCG and NMMA
load capacities are suspended when the dive/
rescue door is out. Operate your boat carefully
to avoid swamping or capsizing.
KC-0170

1-7
Safety Section 1
Swamping
Swamping (flooding the interior of the boat) can occur
for a number of reasons, including severe weather
conditions, improper operation, and improper load-
ing. Consider the following:
• Know the safe loading limits for this boat under
normal conditions. Refer to the boat specifica-
tions in Section 6 of this manual and the Certifica-
tion Plate in the boat.
• Consider reducing those loading limits during
emergencies, special operations, and severe
weather.
• Distribute any load or cargo evenly front to back
and port to starboard so that the approximate cen-
ter 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.
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.
During night operations, you would display RIAM
lights on a special display mast. Both these displays
indicate that your boat is operating with restricted
maneuverability.
Some local or state regulations might require the red
and white diver’s flag during daylight hours to indicate
that a person is in the water.
!DANGER
Never start or operate the engine when people
are in the water near your boat. Contact with
the boat, engine, or rotating propeller can cause
serious injury or death.
KC-0250

1-8
Section 1 Safety
Dive/Rescue Door
Your boat might be equipped with a dive/rescue door.
The dive/rescue door can expand your operational
capabilities by providing easy access to the water and
to the boat.
Operating a Boston Whaler when the dive/rescue door
is out requires experience and a high level of skill.
Always operate any boat within the limits of your expe-
rience. If you do not have this experience, ask some-
one to instruct you or gain experience through
experimentation under controlled conditions.
Water can come into the boat when the dive/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 door is a specialized piece of
rescue equipment. All posted USCG and NMMA
load capacities are suspended when the dive/
rescue door is out. Operate your boat carefully
to avoid swamping or capsizing.
!DANGER
Always monitor the amount of water on the
deck while the dive/rescue door is out. An
unexpected shift in water weight might cause
your boat to capsize.

1-9
Safety Section 1
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
contains or emits 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

1-10
Section 1 Safety
Deck Occupancy Chart

1-11
Safety Section 1
Working Decks: Do not allow passengers on these
decks while the boat is underway. These decks can
only be used when you are at the dock, mooring, or
anchoring.
Accommodation Decks: You can allow passengers
to move around these decks while the boat is
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 surfaces to avoid slipping or falling. Never
wax portions of the boat that have a non-skid
pattern.
!DANGER
Never occupy working decks while the boat is
underway. Do not sit on the gunwales or any
part of a working deck while the boat is
underway.

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