Boston Whaler 37 Justice Series Manual

© 2012 Brunswick Commercial & Government Products. All rights reserved.
420 Megan Avenue, Edgewater, FL 32132 USA
Operation & Maintenance Manual
Part Number 2081409
Boston Whaler®
37 Justice®Series
Fast Patrol Boat

Safety Notices
This manual uses three levels of notication for
safety-related information.
The signal words CAUTION, WARNING, and
DANGER identify specic levels of hazard.
They are dened 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 dam-
age, serious injury, or death. If you do not un-
derstand a safety warning, call the Customer
Service Department at Brunswick 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 contents
without prior written permission from Bruns-
wick Commercial & Government Products. All
rights related to this manual are reserved and
protected by Brunswick Commercial & Gov-
ernment Products.
Brunswick Commercial & Government Prod-
ucts reserves the right to make changes at
any time, without notice, to features, specica-
tions, and model availability. The right is also
reserved to change any specication, part, or
system without incurring any obligation to up-
date older boats.
The information in this manual is based on the
latest specications 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 oth-
er person in the boat are familiar with the con-
tents 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 responsibilities
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 Identication 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
WARNING
A hazard that might result in injury or
damage to property or equipment.
A hazard that could result in death or
serious injury.
DANGER
A hazard that will result in death or
serious injury.

T-1
Section 1: Safety
O p erator Resp onsib ilities....................1- 1
Giving Assistance ................................1- 1
Personal F lotation Devices..................1- 2
Ex haust Emissions...............................1- 3
Carb on Monox ide Detector..................1- 3
F ire Ex tinguishers................................1- 4
F ire Sup ression System.......................1- 4
F ires.......................................................1- 5
Severe Weather.....................................1- 5
Cap sizing...............................................1- 6
Boat L oad Cap acities...........................1- 6
Swamp ing..............................................1- 7
Ignition Shutoff Switch ........................1- 8
Prop osition 6 5 Information..................1- 9
Deck O ccup ancy Chart......................1- 10
Warning L ab els...................................1- 11
T ABL E O F CO NT ENT S

T-2
Section 2: Boat O p eration
Pre- O p eration Checklist.......................2- 1
Ignition Shutoff Switch ........................2- 2
Starting the Engines.............................2- 4
Battery Selector Switches ...................2- 4
Main Ignition K ey Switches.................2- 5
Push- to- Start Panel..............................2- 5
Automatic Charging Relays ( ACR) ....2- 6
Starting Procedure...............................2- 7
Shift and T hrottle Control....................2- 8
Shadow Mode T echnology ..................2- 8
Shifting..................................................2- 8
Sp eed Control.......................................2- 9
Auto Sync® ..........................................2- 9
T hrottle O nly.........................................2- 9
Docking ...............................................2- 10
1 L ever.................................................2- 10
Engine T rim.........................................2- 11
SmartCraft V essel V iew® System.....2- 13
Prop ellers............................................2- 14
Maneuvering ......................................2- 16
L oad Distrib ution................................2- 18
Boat T rim T ab s....................................2- 19
Bow T hruster ......................................2- 21
Stop p ing Procedure...........................2- 23
T railering .............................................2- 24
Safety Checklist..................................2- 25
Securing Boat to T railer.....................2- 26
T owing.................................................2- 26
Backing................................................2- 28
L ifting and Slinging............................2- 29
Slings...................................................2- 3 0
F orklift .................................................2- 3 1
T ABL E O F CO NT ENT S

T-3
Section 3 : F uel System
General Descrip tion .............................3 - 2
Generator F uel System........................3 - 2
Generator F uel F ilter............................3 - 2
Gasoline F uel System..........................3 - 3
Diesel F uel System Diagram ...............3 - 4
Gasoline F uel System Diagram...........3 - 5
F uel T ank Bonding System..................3 - 6
Static Electricity....................................3 - 8
General Guidelines...............................3 - 9
H ose Routing......................................3 - 10
F ill H ose Rep lacement.......................3 - 10
Removal...............................................3 - 10
V ent H ose Rep lacement.....................3 - 11
Removal...............................................3 - 11
Installation...........................................3 - 11
Contaminated Gasoline .....................3 - 12
Ethanol- Blended F uels.......................3 - 13
Storage................................................3 - 16
T ABL E O F CO NT ENT S

T-4
Section 4 : Boat Systems
General Descrip tion ............................4 - 1
F eature O verview..................................4 - 2
H elm L ayout .........................................4 - 4
Switch Panel .........................................4 - 5
T hru- H ull F ittings..................................4 - 6
Bow T hruster ........................................4 - 7
Navigation L ights .................................4 - 8
O p eration...............................................4 - 8
Magnetic Comp ass...............................4 - 9
Deviation ...............................................4 - 9
V ariation ................................................4 - 9
Signal H orn .........................................4 - 10
Sp otlight..............................................4 - 10
Programming the T ransmitter...........4 - 10
Map L ights...........................................4 - 11
Blue Aesthetic lighting.......................4 - 11
Cockp it L ighting.................................4 - 11
Cab in L ighting ....................................4 - 11
Sp reader L ights..................................4 - 12
H ardtop Access ..................................4 - 12
Electric Windshield V ent....................4 - 13
Windshield Wip er/ Washer..................4 - 13
Bilge Pump s........................................4 - 14
Access to the Pump s.........................4 - 15
Maintenance........................................4 - 15
F loat Switch ........................................4 - 15
F uel & O il Sp illage..............................4 - 16
F resh Water System ..........................4 - 16
F illing the T ank ...................................4 - 16
F resh Water System Maintenance ....4 - 18
F reshwater Pump ...............................4 - 18
Deck Showers.....................................4 - 19
Anchor L ocker Washdown ................4 - 19
Water H eater .......................................4 - 20
Maintenance........................................4 - 21
Cab in Shower......................................4 - 22
T ABL E O F CO NT ENT S

T-5
T ABL E O F CO NT ENT S
Section 4 : Boat Systems ( continued)
V anity...................................................4 - 23
Coffee Maker.......................................4 - 23
Microwave...........................................4 - 23
Cab in Refrigerator..............................4 - 23
Sky L ights ...........................................4 - 24
H anging L ocker & Storage ................4 - 24
Raw Water System .............................4 - 24
Raw Water Washdown .....................4 - 24
Maintenance........................................4 - 25
H ead System.......................................4 - 25
V acu- F lush® H ead..............................4 - 27
O p eration.............................................4 - 27
Macerator & Dockside Discharge .....4 - 28
O verb oard Discharge.........................4 - 28
Environmental Considerations .........4 - 28
Maintenance........................................4 - 29
Waste System V ent.............................4 - 3 0
Dockside Pump - O ut...........................4 - 3 0
Gray Water Sump ...............................4 - 3 1
Maintenance........................................4 - 3 1
T hru H ull Discharge H oses................4 - 3 1
Access.................................................4 - 3 1
Air Conditioning .................................4 - 3 2
O p eration.............................................4 - 3 2
Windshield Defogging V ents.............4 - 3 3
Maintenance........................................4 - 3 3
Generator ............................................4 - 3 4
F uel......................................................4 - 3 4
Starting T he Generator ......................4 - 3 7
Stop p ing T he Generator ....................4 - 3 9
O p erating the generator in EU ..........4 - 4 0
Generator F uel F ilter..........................4 - 4 0
F uel F ilter Maintenance......................4 - 4 1
Rep lacing the F ilter............................4 - 4 1
Raw Water Strainer Maintenance......4 - 4 1
Power Steering ...................................4 - 4 2

T-6
T ABL E O F CO NT ENT S
Section 4 : Boat Systems ( continued)
Shore Power........................................4 - 4 4
EL CI .....................................................4 - 4 4
T esting & T roub leshooting................4 - 4 5
Dual Shore Power ..............................4 - 4 6
Single Cord w/ Generator ...................4 - 4 7
Single Cord, No Generator ................4 - 4 7
Battery Charging ...........................4 - 4 8
Shore Power L oad Management.......4 - 4 8
Isolation T ransformers.......................4 - 4 9
F ire Sup p ression System ..................4 - 5 0
Manual O verride System....................4 - 5 2
Dive Door.............................................4 - 5 3
Dive L adder.........................................4 - 5 3
T ransom Door.....................................4 - 5 4
Swim L adder.......................................4 - 5 4
In- Deck Storage with Pump O ut .......4 - 5 5
Storage Garage...................................4 - 5 6
Storage Garage L ock .........................4 - 5 6
Adjustab le H elm Seat.........................4 - 5 6
F old Down V isib ility Platform............4 - 5 6
Anchoring ..........................................4 - 5 7
L owering the Anchor..........................4 - 5 7
Anchor Windlass................................4 - 5 8
O p eration.............................................4 - 5 9
O p erating from the H elm ...................4 - 5 9
O p erating from the Bow.....................4 - 5 9
Windlass Remote................................4 - 6 0
O p erating T he Windlass Manually....4 - 6 1

T-7
T ABL E O F CO NT ENT S
Section 5 : Electrical Systems
DC O verview .........................................5 - 1
Batteries................................................5 - 2
Battery Charger ....................................5 - 3
Battery Switches...................................5 - 4
Automatic Charging Relays ( ACR) .....5 - 5
Manual Control O verride......................5 - 5
Grounding and Bonding......................5 - 6
enitions.............................................5 - 6
Grounding.............................................5 - 7
Bonding.................................................5 - 7
Bow T hruster Batteries........................5 - 8
Bow T hruster Battery Maintenance....5 - 8
T hruster Battery Charging...................5 - 9
12V Recep tacles...................................5 - 9
120 V olt Recep tacles..........................5 - 10
Main DC Breaker Panel......................5 - 11
Main AC Breaker Panel ......................5 - 12
Comp onent Breakers.........................5 - 13
H elm Breaker Panel............................5 - 14
L eaning Post Breaker Panel..............5 - 15
Battery Switch Breaker Panel............5 - 16
F use Blocks ........................................5 - 17
Ground F ault Interrup ter ( GF I) ..........5 - 18
T esting.................................................5 - 18
Rigging................................................5 - 19
T ransducer Mounting Area................5 - 19
iring Identication Chart.................5 - 20
Battery System Diagram....................5 - 21
Battery Switch Panel Diagram...........5 - 22
H elm Breaker Panel Diagram ............5 - 23
H elm Switch Panel Diagram..............5 - 24
L eaning Post Switch Panel................5 - 25
L ighting Schematic Deck...................5 - 26
Windlass Schematic...........................5 - 27
Discharge and H olding T ank.............5 - 28

T-8
T ABL E O F CO NT ENT S
Section 5 : Electrical Systems ( continued)
DC Distrib ution Panel.........................5 - 29
DC Wiring Schematic Cab in..............5 - 3 0
H ardtop Schematic.............................5 - 3 1
120V / 6 0H z Shore Power.....................5 - 3 2
AC Distrib ution Panel ........................5 - 3 3
220V / 5 0H z Shore Power.....................5 - 3 4
AC Distrib ution Panel ( 220V / 5 0H z) .5 - 3 5
Bow T hruster Schematic ...................5 - 3 6
Bilge Wiring Schematic......................5 - 3 7
Stereo Schematic ...............................5 - 3 8
DC Wiring H arness.............................5 - 3 9
DC Wiring H arness ( continued) ........5 - 4 0
DC Wiring H arness ( continued) ........5 - 4 1
DC Wiring H arness ( continued) ........5 - 4 2
H ardtop Wiring H arness ....................5 - 4 2
AC Wiring H arness.............................5 - 4 3

T-9
Section 6 : Boat Maintenance
Specications .......................................6 - 1
ull Identication Number IN .........6 - 2
H ull Maintenance..................................6 - 3
Washing ................................................6 - 3
Wax ing ..................................................6 - 4
Comp ounding.......................................6 - 4
Gelcoat & F ib erglass Rep air ...............6 - 4
T rim Care ..............................................6 - 5
Aluminum..............................................6 - 5
Deck H ardware......................................6 - 5
Cutwater & Chafe Plates .....................6 - 6
Drains & Scup p ers ...............................6 - 7
H ull Blistering ......................................6 - 7
Storage ................................................6 - 8
Insp ection..............................................6 - 8
Wax ing...................................................6 - 8
Bottom Painting....................................6 - 8
F uel System ........................................6 - 10
Steering System .................................6 - 12
F illing & Maintenance.........................6 - 12
Bilge Pump ..........................................6 - 14
Access to the Pump s.........................6 - 14
Maintenance........................................6 - 15
F loat Switches ....................................6 - 15
Batteries..............................................6 - 16
Cap acities............................................6 - 17
Battery Maintenance ..........................6 - 17
Storage................................................6 - 17
Cleaning ..............................................6 - 18
Battery Charging .........................6 - 19
T rim T ab s.............................................6 - 19
O ff- Season Storage............................6 - 20
O utb oards ...........................................6 - 20
H ull Drainage ......................................6 - 20
F uel System .......................................6 - 21
Raw Water System .............................6 - 22
T ABL E O F CO NT ENT S

T-10
T ABL E O F CO NT ENT S
Section 6 : Boat Maintenance ( continued)
Maintenance........................................6 - 22
Raw Water Washdown Pump ............6 - 22
F resh Water System ..........................6 - 23
F illing the T ank ...................................6 - 23
Water H eater .......................................6 - 24
Maintenance........................................6 - 25
V acu- F lush® H ead..............................6 - 26
Macerator Maintenance......................6 - 26
Gray Water Sump Maintenance.........6 - 26
T hru H ull Discharge H ose Access....6 - 27
Air Conditioning Maintenance...........6 - 27
Generator ............................................6 - 28
Generator F uel F ilter..........................6 - 3 0
Rep lacing the F ilter............................6 - 3 0
Generator Strainer..............................6 - 3 0
Shore Power........................................6 - 3 1
Before Each U se.................................6 - 3 1
F ire Sup p ression System ..................6 - 3 2

Safety Section 1
1-1
O p erator Resp onsib ilities
It is expect ed by B runswick Commerci al & Government
P roduct s ( B CGP ) that the personnel authorize d to
operatethisboatareexperience dboathandlersfamiliar
with high-performance boating. B CGP ca n neither
predict , nor warn against, every possible haza rdous
situation related to the operation and maintenance of
this boat.
If you use a method or proce dure different from one
outlined in this manual, you must satisfy yourself that
your method or proce dure will not put your boat or your
cr ew at risk.
Thesafetyofthisboatanditscr ewisyourresponsibility.
Always follow these general guidelines when operating
this boat:
• Always operate this boat within the limits of your
ski ll and experience . If you do not have the
appropriate level of experience , ask someone
to instruct you.
• Understand all of the information co ntained in
this manual, particu larly S ect ions 1 and 2
• Understand the operation of all boat co ntrols
and systems
• Understand and follow all applica ble boating
regulations
• Always use safety eq uipment and operating
proce dures that are appropriate for your mission
• Never work alone around mach inery such as
outboard engines, generators, and  re pumps
Giving Assistance
The 19 7 1 F ederal Boat Safety Act grants “ good
samaritan” protect ion to any boater who offers good
faith assistance to someone in distress. The Act
also protect s that boater from liability related to any
assistance given.
Y ou should attempt to give assistanc e when you see a
distress signal while boating, if you ca n do so without
endangering your boat or cr ew.

Section 1 Safety
1-2
Personal F lotation Devices
P ersonal F lotation D evice s ( P F D ’s) are designed to save lives. It is your responsibility to ensure
that the boat has a sufcient number of PD’s for your crew. It is your responsibility to ensure
that non-swimmers wear P F D ’ s at all times and that everyone wears a P F D during emergenci es
and severe weather.
The United S tates Coast Guard reco gnize s four types of wearable device s and one type of
throwable device .
• T yp e I- L ife preserver, appropriate for off-shore and foul weather.
• T yp e II- B uoyant vest, appropriate for near-shore and inland waters.
• T yp e III- F lotation aid, appropriate for co ntinuous use in ca lm inland waters.
• T yp e IV - Throwable device , appropriate to throw to a person already in the water. These
device s must never be worn as a vest.
• T yp e V - S peci al-purpose device ; incl udes harnesses, ce rtain jacke ts, and rafting vests.
These vests must be worn while underway to co unt toward minimum P F D req uirements.
All P F D ’ s must be easily acce ssible. They must be removed from their shipping bags and they
should be unbuck led. M ake sure that everyone kn ows where the P F D ’ s are loca ted. M ake sure
that everyone kn ows how to put one on and co rrect ly adjust it.
Check the availability and co ndition of all P F D ’ s before each mission.

Safety Section 1
1-3
Ex haust Emissions
Gasoline and diesel-powered engines produce ca rbon
monoxide when they are running. Carbon monoxide is
a co lorless and odorless gas. It is extremely toxic. B e
aware of the threat and respond acco rdingly.
Always be aware of operating co nditions that might allow
ca rbon monoxide to co llect in occu pied space s on your
boat. Remember these general preca utions:
• Avoid running engines or generators in conned
areas such as boat houses
• B e aware of other boats when you are moored
• B e aware of wind direct ion when operating at
slow speeds
• Adjust hatch es, doors, windows, and ca nvas to
increase air movement in conned spaces when
engines and generator are running
• S leeping aboard a boat req uires a worki ng ca rbon
monoxide detect ion system, preferably in each
sleeping q uarter. Always ensure these monitors
are funct ioning before heading out.
Carb on Monox ide Detector
There is a ca rbon monoxide detect or for your boat that
should be loca ted on the starboard side of the ca bin
under the ca binet above the sink. The detect or is very
sensitive and will notify you before dangerous amounts
of ca rbon monoxide ca n accu mulate which will allow you
to take measures to dissipate the gas from the areas.
F ollow all reco mmendations regarding this sect ion to
reduce the risk of ca rbon monoxide poisoning. F or more
information about the dangers of ca rbon monoxide, read
thebookl etWhat Y ou Can’ t See that isin youroperator’s
bag.
Prolonged ex p osure to carb on monox ide can
cause serious injury or death. Always ensure that
conned spaces in your boat have an adequate
sup p ly of fresh air.
DANGER

Section 1 Safety
1-4
F ire Ex tinguishers
Y our boat is eq uipped with three United S tates Coast
Guard approved Type ABC re etinguishers. Each
extinguisherisUL Rated1 -A: 1 0 -B C. Thisratingindica tes
that each etinguisher can be used to ght Class A, B,
and C res. These classes include res involving wood,
cl oth, gasoline, oil, grease, and live elect rica l eq uipment.
ne re etinguisher is located to port at midship, ust
forward of the dive door. The other two are port and
starboard, just forward of the bow storage co mpartment
area. B e familiar with these loca tions. Read and
understand the instruct ions on the extinguisher label and
in the manufact urer’ s instruct ion bookl et loca ted in your
operator’ s bag.
ormulate a re plan in advance that will help you
evaluate your risk and response in ca se of an on-board
re.
F ire Sup ression System
This vessel has a SCG approved automatic re
supression system which is loca ted on the forward port
bilge bulkh ead by the battery trays and ca n be acce ssed
by lifting the hatch in the aft co ckp it deck. The system
will act ivate when the temperature in the encl osed area
reach es 1 6 5 ° F ( 7 4 ° C) .
O NOT handle the etinquisher actuator. The
re supression system is under pressure 1
p si) . Accidental discharge may result in death or
serious injury.
DANGER

Safety Section 1
1-5
F ires
Most marine res result from spilled fuel or oil
accumulating in the bilge. Careful use of onboard re
etinguishers should control small res.
Direct the re etinguisher output toward the base of
the ames in a sweeping motion. Check carefully and
verify that the re has been etinguished. Evaluate the
damage and get assistance immediately.
Larger res involving the boat’s fuel tank might result
in explosion and co mplete destruct ion of the boat.
ormulate a re plan in advance that will help you decide
if you can ght the re or if you should abandon the boat.
asoline and other ammable liquids oat on
water. If you ab andon the b oat, swim up wind or
up current from the b oat to avoid b urning fuels
that might sp read on the surface of the water.
Severe Weather
Take these general safety preca utions if you must
operate your boat in severe weather co nditions:
• Review the co ndition and operation of all safety
and co mmunica tion gear
• Have everyone wear personal oatation devices
• Use your ignition shutoff cl ip and lanyard
• S tow loose gear and lash down eq uipment
• Close all hatch es, doors, and windows
• Install the dive door, if eq uipped
• Reduce boat speed
• P eriodica lly report your loca tion and situation by
radio
• M onitor marine weather advisories
WARNING

Section 1 Safety
1-6
Cap sizing
Y our boat might ca psize due to improper loading,
improper operation, or severe weather co nditions.
F ormulate a ca psizi ng plan in advance that incl udes the
following act ions:
• Try to turn off the engines to avoid injury and
additional damage
• L oca te all cr ew and evaluate their co ndition
• Stay with the boat, it should oat and it is easier
to loca te
• D istribute P F D ’s if possible
• Try to cl imb onto the hull
• Initiate emergency loca ting signal or radio
co mmunica tion if possible
Boat L oad Cap acities
Specic capacity information for this boat is listed in the
Maintenance Section.
• D o not exce ed the ca paci ty limits of this boat
under any ci rcu mstance s
• Consider reduci ng these ca paci ty limits during
speci al operations and severe weather co nditions
• Y ou are always responsible for the safety of the
boat and its cr ew even if the ca paci ty limits have
not been exce eded.
Ex cessive loading, imp rop er load distrib ution,
and mismatching loads to ex isting conditions
can contrib ute to b oat swamp ing or cap sizing.
T hese situations can result in serious injury or
death.
WARNING

Safety Section 1
1-7
Swamp ing
Swamping or ooding the interior of the boat can occur
for a number of reasons, incl uding severe weather
co nditions, improper operation, and improper loading.
Consider the following:
• K now the safe loading limits for this boat under
normal conditions. Refer to the boat specications
in the Maintenance Section of this manual.
• Consider reduci ng loading limits during speci al
operations or severe weather co nditions.
• D istribute any load or ca rgo evenly front to back
and port to starboard so that the approximate
ce nter of the load is near the middle of the boat.
• Close all hatch es, doors, and windows during
severe weather.
• Install the dive door, if eq uipped.
• Adjust boat trim and speed to match weather
co nditions.
• Avoidbacki nginto largewaves wheneverpossible.
• Check operation of all bilge pumps, oat switches,
and water level sensors before each trip.

Section 1 Safety
1-8
Ignition Shutoff Switch
This vessel is eq uipped with an emergency engine stop
switch . The switch is loca ted on the co nsole, below the
shift/ throttle co ntrol.
The ignition shutoff safety switch inco rporates a shut-
off switch , switch cl ip, lanyard and lanyard cl ip, which is
cl ipped to the operator when running. If an emergency
arises and the engines must be shut down, a pull on the
co rd to release the cl ip from the shut-off will shut off the
engines.
This switch is designed to shut the engines off when the
operator of the boat leaves the co ntrol station, either
acci dentally by falling into the boat, or by being eject ed
overboard.
S ee more details in Section 2 of this manual.
Do not activate the ignition shutoff switch during
normal op erations when the b oat is on p lane.
Activating the ignition shutoff switch at p laning
sp eedswillcausetheb oattosuddenlydecelerate,
p ossib ly injuring or ejecting p assengers.
Y ou should co nnect the ignition shutoff switch cl ip and
lanyard to a sturdy part of your cl othing. If you move
beyond the sco pe of the lanyard, the ignition shutoff
switch will be act ivated and both engines will shut off
immediately.
WARNING