Key West Boats 239DFS User manual

QuickGuideand
Schematics

WelcometotheKeyWestFamily!
DearNewBoatOwner,
OnbehalfofeveryemployeeatKeyWestBoats,wearepleasedtowelcomeyoutotheKeyWestFamily!Forover25
years,KeyWestBoatshascontinuouslysetnewstandardsinsafety,construction,anddesign.Ourskilledteam,fromourlaminators
andriggerstooursalesandengineeringdepartment,arededicatedtoeveryboatwebuildandweareconstantlyworkingtoimprove
ourproduct.Ourdedicationtoeachboatandinspirationfornewideascomesfromthemosttheimportantpeople,ourcustomers. We
valueyourinputandencourageyoutoshareyourthoughtswithusaswellasthememoriesyoumakeaboardyour239DFS!Owninga
boatisanamazingexperienceandwededicateourselvestomakingsureyour239DFSwillbethebestexperienceyouhaveonthe
water…
LikeallKeyWestBoats,the239DFSwasdesignedandbuilttoprovideownerswithunmatchedsafetythatincludesbut
notlimitedto,itsuprightandlevelfloatationthatmakesthe239DFSbothunsinkableandguaranteedtoremainuprightifswamped.
Althoughextremelysafebydesign,your239DFSisonlyassafeasthemannerinwhichitisoperated.Regardlessofyourexperience,
weencourageyoutoreadthegenericmanualwehaveprovidedwithyourboatandotherresourcesforinformationonrulesofthe
roadandsafeboatingpracticestoensureyouareoperatingyourboatsafelyandwithintherulesatalltimes.
LikeallKeyWestBoats,the239DFSwasdesignedtobelowmaintenance,ergonomicandanefficientboattomaintain
andoperate.Familiarizingyourselfwiththeboatssystemsandworkingcloselywithyourdealerwillgoalongwayinproviding that.
Wearepleasedtoprovideyouwiththisguideandschematicsofthesystemsinthe239DFStoensureyouareconfidentbeforeyou
stepaboardforyourfirstmemorabletrip!Followingtheinformationinthisguideandyourdealer’sserviceplanwillhelptoprovide
youwithmanyyearsofreliableservicesothatyoucanconsistentlyenjoyyourtimeonthewater,experiencethingsonlypossiblewith
anddiscoverthejoythatowninga239DFSbrings!
Finallyandmostimportantly,likeallKeyWestBoats,your239DFSwasbuiltbyadedicatedandexperiencedteamwho
gaveitauniqueandpersonalizedstorythatstartedwhenyouandyourdealergaveitauniqueandoneofakindcharacter.25+ years
andover20,000boatslater,westilllookateachboatwebuildashavingitsownuniquecharacter,storyandasanimportantpartof
ourfamily.Your239DFSisnotjustanother“Unit”andbecomingtheownerofthis239DFSdoesnotmakeyoujustanother“customer”.
Itmakesyouapartofourfamily,afamilywehavebeendedicatedtoforover25yearsandisover20,000uniqueandpersonalized
storiesstrong.Wearehonoredtohaveyoupartofourfamilyandwriteanotheruniqueandpersonalizedstory…Safepassagesand
TightLines!
Sincerely,
TheKeyWestTeam

FuelSystem
The239DFSisequippedwithasingle,100Gallon,pressurizedfueltank.Thetankisofaluminumconstructionandissecured/insulatedwithfoam
duringtheconstructionoftheboat.Thetankislocatedoncenterlinebetweenthelivewell andaftendoftheFishbox/SkiLocker.Thereisa
sendingunitinstalledinthetank.Inspectionportsinthedeckandheadcompartmentprovideaccesstotankfittings.
Thereisafuelpickupinstalledinthetank.Thepickupincorporatesashutoffvalvealongwithananti‐siphonvalvethancan beaccessedthrough
theindeckinspectionplate,adjacenttotheconveniencecenter.
Thereisanondeckfuelfilllocatedontheportsideoftheboat,outboardofthewindshieldandadjacenttothepassengerconsoledoor.Thetank
ventsthroughanEPACarbonCanister,locatedintheanchorlocker,whichthanventsoverboardthroughaventfittingonthestarboardsideofthe
hull.Accesstotheventisprovidedthroughaninspectionport.Itisrecommendedthattheseconnectionsbeinspectedannually.
The239DFSwillcomepre‐riggedfromthefactorywithanenginematchedFuelWaterSeparator.Thefuelwaterseparatorisinstalledinthebilge
andaccessedthroughthebilgeaccesshatchlocatedintheenginepod.TheFuelWaterseparatorshouldbecheckedperiodicallytoensurethefuel
isfreeofwater.Fuelshouldbedisposedofinanapprovedwastecollectiondevicewhenservicing/replacing.Thefiltermustbefilledwithfuel
afterservicing/replacingtheminordertoprimetheengine.
Aprimerbulbfortheengineislocatedintheenginepod.Itisusedtoprimetheengineandsystembeforestartingtheengine.Thisshouldbedone
afterserviceorafterperiodsofdowntimefortheboat.
Whenrefuelingthe239DFS,whetherontraileroratamarina,thepressurizedsystemwillpreventoverfilling.Anyblockageofthevent,ventline
and/ororificelinewillprematurelytriggertheshutoffonthefuelnozzleandwillpreventyoufromfillingthetankcompletely.Itisrecommended
toinspectyourfuelsystemannuallytoensurethatallhosefittingsaresecuredandthelinesarefreeofanykinks.Allcomponentsofthe239DFS
FuelSystemareapprovedforusewithethanolblendedfuelsupto10%.E85fuelshouldneverbeused.KeyWestrecommendsusingnonethanol
fuelswheneverpossibletoreducetheriskofmoistureretentioninthefuelsystem,especiallyinareasofhighheat/humidity.
DuetotheemissionrequirementsoftheEPA,certifiedfueltanksandsystemswillnotfilltothetopofthetank.Instead, therewillbeaullage in
thetop10%ofthetank.Thespecifiedcapacityofthetank(100Gallons)accountsforthisullage whenthetankisstaticandlevel.Therefore,itis
importanttomakesuretheboatisaslevelaspossiblewhenfillingthetank.Anyforwardorafttiltwillcausefueltocollectinoneendofthetank
andprematurelyreacheithertheforwardorafttankvent.Whenfuelreachesthesevents,ittriggerstheshutoff.Whentheboatislevel,fuelwill
reachtheseventsatthesametimeandallowthemaximumquantityoffuelintothetank.Thetanksullage willalsoaffectyourfuelgaugeasthe
tankssendingunitwillnotreachthetopofthetank,evenwhenthetankisfilled.Thiswillcausethefuelguage tonotreadfull,eventhoughitis.
Donotrelyonthefuelgaugeexclusivelyasvariationswilloccur.
Thestatedcapacityofthe239DFStankDOESNOT reflectthequantityofusablefuelinthetank.Thetankanditspickuparedesignedtoallowas
muchfueltobeusedaspossiblewhenonplaneorintheboat’slevelfloatingposition,butitwillnotallowallfueltobe used.Whenusingyour
boat,itisagoodpracticetokeepalogandarunningcountofhowmuchfuelyou’veused.

RawWaterSystem
The239DFSfeaturesarawwatersystemforthetransomlivewell andrawwaterwashdown system.
RawWaterSupply
The239DFSfeaturesasinglehighspeedventuri pickupforrawwaterintake.Thepickupincorporatesaseacock.Beforeusingtheboat,itisimportant
tonotethelocationoftheseacocksandthemeanstoachieveaccesstothem.Intheeventofaruptureinarawwaterlineorpumpthatallows
unrestrictedflowofwaterintothebilge,shuttingtheseacockwillbecritical.Seacocksshouldbecheckedperiodicallyandthevalvesmovedtoverify
operationandunrestrictedmovement.Ifproblemsarefound,theyshouldbeaddressedimmediatelybyyourdealer.
Livewell System
Thereisone800GPHlivewell pump.Itismounteddirectlytotheseacock.Thepumpprovidesrawwatertothetransomlivewell.Thepumphasan
independentswitchandcircuitbreaker(SeeElectricalSchematics).Tousethelivewell,itisimportanttocheckandverifythattheseacockisopen.
Failuretoopentheseacockmayresultinpumpfailureifthepumpisrundryforanextendedperiodoftime.Thelivewell pumpisacentrifugalpump
thatisnotpressureregulated.Therefore,itisrecommendedthatthepumponlybeusedwhenusingthelivewell.Thepumpisself‐priming.Before
activatingthepump,makesurethelivewell fillvalveisopenandthanswitchonthepump.Itisimportanttocheckthelivewell pumpannuallyand
periodicallysprayit/themwithacorrosioninhibitor.
RawWaterWashdown System
The239DFSfeaturesastandardrawwaterwashdown system.Thesystemisfedbyapumpthatislocatedundertheconveniencecentersink.The
pumpiscontrolledbyaswitchandcircuitbreaker(SeeElectricalSchematics).Waterissuppliedtothepumpoffoftheaccessoryportonthelivewell
pump(lowerhoseconnectiononthelivewell pump).Usingtherawwaterwashdown doesnotrequirethelivewell pumptobeon,howevertheseacock
mustbeopen.Failuretoopentheseacockmayresultinpumpfailure/damageifthepumpisrundryforanextendedperiodof time.Therawwater
pumpfeaturesanin‐linestrainerforcollectinganydebristhatcoulddamagethepump.Thestrainershouldbecheckedperiodically.Ifyouareusing
theboatin“dirty”wateronaregularbasis,itisrecommendedthestrainerbecheckedroutinely.Thestrainerfeaturesaclearcapforeasyinspection.If
anydebrisisfound,removethestrainerscreenbyuntwistingtheclearcapandcleanthescreen.Thepumpfeaturesabuiltinpressureregulatorthat
willshutthepumpoffwhenpressureisachievedinthesystem.Therawwaterwashdown faucetislocatedontheportside,adjacenttothetransom
benchseat.Iftraileringtheboatorusingtheboatafteranextendedperiodofdowntime,itwillbenecessarytoprimethe washdown pump.Before
activatingthepump,openthewashdown faucetandthanswitchonthepump.Whenthesystemisfreeofair,youcaneitherclosethefaucetorshutoff
thepump.Itisimportanttocheckthewashdown pumpannuallyandperiodicallysprayitwithacorrosioninhibitor.
SystemOperationandMaintainence
Whenusinganyofthetworawwaterpumps,itisimportanttopayattentiontothewateryouareoperatingtheboatin.Operatingthepumpin
shallow/muddywaterorwaterwithhighamountsoffloatingdebrissuchasgrassortrashmayresultiningestionanddamagethepump.Lossof
pressureinpumpmaybetheresultofcontaminantsblockingthethruhulls,bindingofthepumpimpellor,cloggedstrainerbasketand/orblockagein
lines.Whenoperatinginthecontaminatedwater,checkthesupplyofandqualityofwatertothelivewells and/orwashdown frequently.Anylossof
pressureorflowshouldbeaddressedimmediatelytopreventdamage.

Fresh WaterSystem
FreshWaterSupply
Freshwaterisstoredina12gallontanklocatedundertheporttransombenchseat.Accesstothetankandtankfittingsis achievedthroughthebilge
accesshatchlocatedintheenginepod.Thetankfeaturesafillline,ventlineandsupplyline.Thesefittingsshouldbecheckedannually.Itiscriticalthat
onlypotablewaterbeusedinthetank.Failuretodosomayrequireoverhauloftheentirefreshwatersystem.
FreshWaterFillandVent
Thefreshwatertankisfilledfromafilldeckplatemarked“WATER”.Itislocatedontheportswimplatform,directlyforward oftheenginewell.Before
fillingthetank,verifythequalityofthewaterandmakesureareaaroundthefillisfreeofcontainmentsthatcouldenter thetank.Whilefilling,verify
thetankisventingthroughthetankventwhichislocatedinthesplashwell.Anabsenceofairescapingfromtheventmayindicateablockageorkinkin
theventline.Thiswillresultinthetankfailingtofillallthewaywhichwillshowinwaterflowingoutofthefillwellbeforecomingoutofthevent.It
willalsodiminishtheperformanceofthefreshwatersystemasablockedventwillcreateavacuuminthetankaswaterisused,therebyresultinginless
watertothepump,continuouscyclingofthepumpandlossofwaterpressure.Thiscouldultimatelyresultindamagetothepump.Checktheventline
periodicallytoensuretherearenokinksorblocks.
Washdown Pump
Thefreshwatersystemisfedbyapumpthatislocatedundertheconveniencecentersink.Thepumpiscontrolledbyaswitchandcircuitbreaker(See
ElectricalSchematics).Waterissuppliedtothepumpfromthetankoutletlocatedonthebottomofthetank.Thefreshwaterpumpfeaturesanin‐line
strainerforcollectinganydebristhatcoulddamagethepump.Thestrainershouldbecheckedperiodicallyandfeaturesaclear capforeasyinspection.
Ifanydebrisisfound,removethestrainerscreenbyuntwistingtheclearcapandcleanthescreen.Thepumpfeaturesabuiltinpressureregulatorthat
willshutthepumpoffwhenpressureisachievedinthesystem.The239DFScomesequippedwithafreshwaterfaucetintheconveniencecentersink
andafreshwatershowerlocatedontheportswimplatform.Anoptionalfreshwatershowerheadcanbeinstalledinthepassengerconsole.Ifthe
systemhasnotbeenusedforaperiodoftime,itmaybenecessarytoprime/bleedthesystemofanyair.Beforeactivatingthepump,openthefresh
waterwashdown faucetandthenswitchonthepump.Whenthesystemisfreeofair,youcaneitherclosethefaucetorshutoffthepump.Itis
importanttocheckthewashdown pumpannuallyandperiodicallysprayitwithacorrosioninhibitor.
SystemOperationandMaintainence
Onlyusepotablefreshwaterinthesystem.Alwaysverifythereissufficientquantityofwaterinthetankbeforeactivatingeitherthewashdown or
mistersystem.Insufficientwaterquantitywillcausethepumptorundryandmayleadtofailure/damage.Beforeusingthefreshwatersystemforthe
firsttimeonthewater,fillthetankandcycleallthewaterouttoensurethetankiscleanandfreeofcontainmainents.Afterwardscheckstrainer(s)for
debrisandcleanifnecessary.

DrainageSystem
GeneralOverview
Allwaterinthe239DFSisdrainedeitherviagravityorpump.Itiseitherdraineddirectlyoverboardortotheaftbilgewhereitcanbedrainedouteither
viathegarboarddrainplugorthebilgepump.Itisimportanttocheckthedrainagesystemfrequentlytoverifywaterflows freely,hosesaresecureand
therearenoleaks.Thedrainsanddischargepumpareasfollowsstartingatthebow:
AnchorLocker– Gravitydrainalongcenterlineofhulltoaftbilge
CenterBowLocker,PortBowLockerandPassengerConsoleSinkDrain– Gravitydrains,allconnectedviaT‐Connectorstosingledraintoaftbilge
StarboardBowLocker– Gravitydrainrunsthroughstarboardstringertoaftbilge
Fishbox LipDrain– Gravitydrainthroughportstringertoaftbilge
Fishbox Drain– FeedsdirectlytoFishbox MaceratorPump
Fishbox MaceratorPump– Locatedunderconveniencecentersink,discharges1‐1/8”ThruHullontransom(SeeNoteA)
DriverandPassengerConsoleRecessDrains– Gravitydrains,draindirectlytothebilge
Convience CenterSinkDrain– Gravitydraintoaftbilge
SkiLockerDrain– Gravitydrain,connectsviaT‐ConnectortoConvience CenterSinkDrain
PortCockpitDrain– Gravitydraintoporttransom1‐1/2”ThruHull
StarboardCockpitDrain– Gravitydraintostarboardinboard1‐1/2”ThruHull
PortTransomStoragelockers– Gravitydraindirectlytoaftbilge
TransomLivewell OverflowDrain– GravitydrainconnectsviaT‐ConnectortoTransomLivewell Drain
TransomLivewell Drain– Gravitydraintostarboardtransom1‐1/8”ThruHull
CoolerBoxDrain– Gravitydraintoaftbilge
AftBilgePump– Locatedinaftbilge,dischargestoaftportthruhullneartransom
NoteA:Thefishbox maceratorpumpiscontrolledbyaswitchandcircuitbreaker(SeeElectricalSchematics).Neverrunthepumpdryasitwilldamage
thepump.Thefishbox shouldbecleanedaftereveryuseandpumpedoutbeforestoringtheboat.

FloorDrainOverview
Twoofthemostimportantpiecesofequipmentonyour239DFSarethecockpitfloordrainsastheiroperationisintegralto
yoursafetyonthewater.At1‐1/2”indiameter,theyaredesignedtoallowmassivequantitiesofwatertoleavethecockpitof yourboatina
veryshortperiodoftimeintheeventofaswampingorextremedownfloodingevent.Allthedrainsinyour239DFSoperatethis way,
however,thefloordrainsaredesignedsothatwatercanonlyflowinonedirection;outofyourboat.Thedrainfeaturesauniquedesign
thatactslikeacheckvalvetherebypreventingbackflowofwaterintothecockpitofyourboat.
Thedesignofthedrainanditsoperationissolelydependentonthefoamballandsealring.Anydegradationinthefoamwill
compromisetheballsabilitytosealagainstthesealring.Therefore,donotapplypowerwashersoranycleaningchemicalsdirectlytothe
drainareaasthiswillcompromisethefoamintheball.Whenusingchemicalcleanersinyourboatsinterior,useasufficientquantityof
watertodilutethechemical(s)whensprayingoffsothattheydonotaffectthefoamballwhendrainingout.
Thesealringneedstobekeptfreeofdebrissothatfoamballwillsealflush.Thedrainfeaturesagratesothatdebriscannot
flowintothedrain.Intheeventthatasufficientamountofdebriscollectsaroundtheseal,thegrateandtopofthedrainassemblycanbe
removed.Useaspannerwrenchtounscrewthetopofthedrainandcleanthedrainassembly.Thiswillalsoprovideaccesstothefoam
ballwhichcanthanberemovedandreplacedifnecessary.Onlydothisifitbecomesevidentthatballisnotsealingproperly. Thiswillbe
manifestedbysmallamountsofwatercomingthroughthedrainwhentheboatissittingatrestinthewater.DONOT removethedrain
whiletheboatisinthewater.
Wheneverthethruhullsare
submergedbelowwater,back
pressuresealsballagainstsealring,
creatingawatertightsealand
preventsbackflowofwaterfromthe
thruhulls.
Undernormalconditionswhen
thethruhullsareabovewater,
theballisbelowthesealring
therebyallowingwatertoflow
outofthecockpitand
overboard

ElectricalSystem
GeneralOverview
The239DFSisequippedwithastandard12VDCElectricalsystem.
The239DFScanonlyberiggedforasinglemotor.Iftheboatisriggedwithoutanoptionalbatteryselectorswitch,theboatwillberiggedforx1Group
27battery.Ifthebatteryselectorswitchisinstalled,theboatwillberiggedforx2Group27batteries.KeyWestrecommendsthisoptionforthosewho
wishtoinstallanoptionalwindlasstotheirboatduetothehighpowerdemand.Thebattery(s)willprovidepowertotheengine,houseandoptional
windlasssystem.
Allbatteriesandfinalelectricalriggingwillbeperformedbyyourdealerpriortodelivery.Pleaseconsultwithyourdealerregardingthebatteryinstallation
ofyourboatpriortotakingdeliveryofyourboat
12Vpowerisdistributedtothe12Vfactoryinstalledsystemsthroughindividualcircuitbreakerslocatedbeneaththeirrespectiveswitchesonthemain
switchpanel.All12Vsystemsaregroundedindividuallytoagroundingblocklocatedinsidetheconsole.Thegroundingblockisthangroundeddirectly
toabattery.A30ampmaincircuitbreakerisinstalledadjacenttothebatteriestoprotectthehousesystemsfromoverload andisconnectedeither
directlytothebatteriesortheoptionalbatteryselectorswitch.Additionalcircuitbreakersfortheautobilgepumpandstereomemoryarewired
directlytoeitherthebatteryorbatteryselectorswitch.Ifawindlassisinstalled,anadditional50ampcircuitbreakerwill beinstalled.Thesystemis
designedsothatturningthebatteryswitch/switchesoffwillstillallowthebilgepumptofunctioninanautomaticmode.KeyWestrecommendsthat
boatsthataregoingtobeleftinthewaterorinaboatlift,whereaccesstothedrainplugisnotfeasible,beinstalledwithabatterychargertoprevent
dischargebythebilgepump.TrimTabsandoptionalpowersteeringareconnecteddirectlytothebatteryandfeatureovercurrentprotection.Theydo
notenergizeuntiltheengineignitionswitchisturnedtothe“On”position.
ElectricalSystemMaintenance
Allconnectionsintheelectricalharnessfeaturedeutscheconnectorsandheatshrinkbuttconnectorstominimizecorrosion. KeyWestrecommends
thatallconnectionsandterminalsbecheckedatleasttwiceayearandsprayedwithacorrosioninhibitingsprayatleastonceayeartoprotectand
maintaintheintegrityofelectricalconnections.Fortroubleshootingpurposesandfurtherinformation,aschematicoftheelectricalharnessisavailable
fordownloadinPDFonthe239DFSmainpage.