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