Boston Whaler 37 Justice Series Operation & Maintenance Manual

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[Page 1] Boston Whaler 37 Justice Series

© 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 ...

[Page 2] Boston Whaler 37 Justice Series

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 t...

[Page 3] Boston Whaler 37 Justice Series

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...............

[Page 4] Boston Whaler 37 Justice Series

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 S...

[Page 5] Boston Whaler 37 Justice Series

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 S...

[Page 6] Boston Whaler 37 Justice Series

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 ...

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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 ...

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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...

[Page 9] Boston Whaler 37 Justice Series

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 Batte...

[Page 10] Boston Whaler 37 Justice Series

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 ................

[Page 11] Boston Whaler 37 Justice Series

T-9 Section 6 : Boat Maintenance Specications .......................................6 - 1 ull Identication Number IN .........6 - 2 H ull Maintenance ..................................6 - 3 Washing ...

[Page 12] Boston Whaler 37 Justice Series

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...

[Page 13] Boston Whaler 37 Justice Series

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 operate this boat are experience ...

[Page 14] Boston Whaler 37 Justice Series

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...

[Page 15] Boston Whaler 37 Justice Series

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 aw...

[Page 16] Boston Whaler 37 Justice Series

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 extinguisher is UL Rated 1 -A: 1 0 -B C. This rating i...

[Page 17] Boston Whaler 37 Justice Series

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 r...

[Page 18] Boston Whaler 37 Justice Series

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 ion...

[Page 19] Boston Whaler 37 Justice Series

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 th...

[Page 20] Boston Whaler 37 Justice Series

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...

[Page 21] Boston Whaler 37 Justice Series

Safety Section 1 1-9 roposition  Inormation The following information is incl uded in this manual as reco mmended by California’ s Safe Drinking Water and T ox ic Enforcement Act of 19 8 6 , amen...

[Page 22] Boston Whaler 37 Justice Series

Section 1 Safety 1-10 Deck O ccup ancy Chart Working Decks: D o not allow passengers on these decks while the boat is underway. These decks c an only be used when you are at the dock, mooring, or anch oring. Ac...

[Page 23] Boston Whaler 37 Justice Series

Warning L ab els Safety Section 1 1-11 q WARNING, SECRE DR  w ESSEL CERTIICATINCAPACITY e EL RECMMENDATIN  CTANE  r S EPA ...

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Section 1 Safety 1-12 O p erator’ s Notes ...

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Boat O p eration Section 2 2-1 Pre- O p eration Checklist Review all the items on this ch eckl ist each time you prepare for a departure. Resolve any issues before you leave the dock. D rain plug( s) inst...

[Page 26] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-2 Ignition Shutoff Switch Y our boat is eq uipped an ignition shutoff switch . The ignition shutoff switch is loca ted on the lower co nsole face , below the throttles. The ignition shutoff switch is desi...

[Page 27] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-3 Understand this important information about your ignition shutoff switch : • It is your responsibility to deci de when to attach the switch lanyard, but we strongly reco mmend...

[Page 28] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-4 Starting the Engines B efore you attempt to start the engines, ensure the lower units are in water of sufcient depth for operation and that there are no people or object s in the vici nity subj...

[Page 29] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-5 Main Ignition K ey Switches The main ignition ke y switch es are loca ted on the bottom of the main breake r panel behind an acce ss door on the port aft wall of the ca bin. T he key...

[Page 30] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-6 Automatic Charging Relays ( ACR) The engine/ house batteries are automatica lly co nnect ed in parallel through the use of ACRs ( Automatic Charging Relay) when a sufcient charging source is present....

[Page 31] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-7 Starting Procedure Use the following ch eckl ist each time you start the engines. Additional detailed information about these systems is co vered in the engine operator’ s manual...

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Section 2 Boat O p eration 2-8 Shift and T hrottle Control B oat direct ion, boat speed, and cl ose-q uarter maneuvering are co ntrolled by the co ntrols. The optional dual-lever D TS co ntrol incl udes gear select ion, engine speed,...

[Page 33] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-9 Sp eed Control • M ove the shift lever forward from the F ORWARD gear detent to incr ease engine speed in forward gear. • M ove the shift lever backw ard from the RE V E R...

[Page 34] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-10 Docking P ressing the “ D OCK ” button initiates docki ng mode. D ocki ng mode reduce s throttle ca pac ity to approximately 5 0 % of normal throttle. To turn off docki ng mode, shift the engine in...

[Page 35] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-11 WARNING WARNING Engine T rim The power trim & tilt system allows you to raise and lower the engines for optimum performance in the water and for trailering, launch ing and b...

[Page 36] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-12 Y ou must determine the co rrect engine trim adjustments through experimentation or experience , based on your mission loads and operating co nditions. The trim switch es are loca ted on a co ntrol pad a...

[Page 37] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-13 SmartCraft V essel V iew ® System Y our boat is eq uipped with the S martCraft V essel V iew boat and engine information system. The V essel V iew co lor L CD display is mounted...

[Page 38] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-14 Prop ellers Y our outboard engines are eq uipped with propellers of a tested size and design to provide best engine and boat performance . Refer to the engine operator’ s manual for detailed informat...

[Page 39] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-15 Reducing p rop eller p itch and diameter will incr ease acce leration and load ca rrying ca pability, with a slight decr ease in top speed. It will also increase the engine’ s f...

[Page 40] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-16 Maneuvering M aneuvering this boat req uires experience and a high level of ski ll. Always operate any boat within the limits of your experience . If you do not have this experience , ask someone to i...

[Page 41] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-17 At idle speed, you ca n co ntrol boat direct ion and position by engine gear select ion alone. With both outboard engines faci ng straight ahead: • Y ou ca n rotate the boat to...

[Page 42] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-18 L oad Distrib ution P lace ment and co nce ntration of non-permanent loads in a boat ca n affect boat performance and cr ew safety. Refer to Boat L oad Cap acities in Section 1 of this manual for addi...

[Page 43] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-19 Boat T rim T ab s Y our boat is eq uipped with L enco ® elect romech anica l trim tabs. The trim tab co ntrol switch es and L E D indica tor lights are loca ted on the co ntrol ...

[Page 44] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-20 The trim tab switch panel is labeled and wired to make tab operation simple. When operating the trim switc hes, think of how you want the b ow of the b oat to move to properly trim the boat. • T...

[Page 45] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-21 Bow T hruster B e sure you thoroughly understand the operation and safety req uirements of the thruster before using. The thruster should not be operated in cl ose proximity to swi...

[Page 46] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-22 CAU T IO N When the desired boat movement has been ach ieved, return the joystick to the ce nter position ( spring return) . The bow thruster motor is eq uipped with an internal thermally-act ivated brea...

[Page 47] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-23 Stop p ing Procedure Use the following ch eckl ist at the end of each mission to verify that the appropriate boat systems are congured for a short period of non-use at the dock....

[Page 48] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-24 T railering If B CGP supplied the trailer for your boat, it is designed specically for your boat and it is commercialgrade. The trailer co nstruct ion is heavy-duty and it exce eds the ca ...

[Page 49] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-25 CAU T IO N T ransp orting your b oat on a sub - standard trailer can cause serious, p ermanent damage to the hull. T his typ e of hull damage is considered “i mp rop er storage...

[Page 50] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-26 Securing Boat to T railer Y ou must be ce rtain that your boat is co rrect ly secu red to the trailer before you begin any over-the-road transportation. Use the following ch eck list to secu re your boat...

[Page 51] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-27 When maneuvering on streets or highways, always remember that the boat and trailer have at least doubled the effect ive length and weight of your tow vehicl e. F ollow these guide...

[Page 52] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-28 Backing B acki ng a trailer req uires experience and ski ll. Always operate a towing vehicl e within the limits of your experience . If you do not have this experience , ask someone to instruct you o...

[Page 53] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-29 L ifting and Slinging V erify that the lifting eq uip ment, sp reader b ars, slings, and attaching hardware are p rofessionally certied to a working load o at least ...

[Page 54] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-30 Slings Y ou ca n use a spreader bar and slings to lift your boat. The system must be professionally certied to a working load of at least 1 7 ,5 0 0 pounds ( 7 9 3 8 kg ) with a safety factor of ...

[Page 55] Boston Whaler 37 Justice Series

Boat O p eration Section 2 2-31 F orklift Y ou ca n use a large marine forkl ift to move your boat. The forkl ift must be professionally rated to a worki ng load of at least 1 7 ,5 0 0 pounds ( 7 9 3 8 kg ) wi...

[Page 56] Boston Whaler 37 Justice Series

Section 2 Boat O p eration 2-32 O p erator’ s Notes ...

[Page 57] Boston Whaler 37 Justice Series

3-1 F uel System Section 3 Insp ect the fuel system and fuel tank b efore each mission. Correct the cause of any gasoline or diesel leak immediately. V entilate the area to eliminate vap ors b efore energizing any electrical...

[Page 58] Boston Whaler 37 Justice Series

3-2 Section 3 F uel System WARNING General Descrip tion This boat is eq uipped with both a diesel fuel system for the generator and a gasoline fuel system to power the outboard engines. P lease take time to read and understand ...

[Page 59] Boston Whaler 37 Justice Series

3-3 F uel System Section 3 Gasoline F uel System The Gasoline F uel System Diagram in this sect ion shows locations of the fuel tank, fuel ll, fuel tank vent, fuel level sending unit, fuel withdrawal tubes, fuel shutoff va...

[Page 60] Boston Whaler 37 Justice Series

3-4 Section 3 F uel System Diesel F uel System Diagram F O RWARD ...

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3-5 F uel System Section 3 Gasoline F uel System Diagram F O RWARD ...

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3-6 Section 3 F uel System F uel T ank Bonding System Do not allow any liq uid gasoline to enter the bilge. Liquid gasoline is a re and eplosion haard. asoline vapor is etremely ammable and highly ...

[Page 63] Boston Whaler 37 Justice Series

3-7 F uel System Section 3 DANGER T here is a danger that static electricity can ignite gasoline vap ors that have not b een ventilated outside an enclosed area. Use etreme caution when fueling your b oat with gas or ...

[Page 64] Boston Whaler 37 Justice Series

3-8 Section 3 F uel System Static Electricity A disch arge of static elect rici ty ca n ignite gasoline vapor that has accu mulated during the fueling proce ss. Use extreme ca ution when fueling your boat under unusual ci rcu ms...

[Page 65] Boston Whaler 37 Justice Series

3-9 F uel System Section 3 CAU T IO N General Guidelines Also follow these imp ortant guidelines during fueling op erations: T his fuel system is not designed to sup p ort an automatic “h ands free” fuel nozzle. Never use...

[Page 66] Boston Whaler 37 Justice Series

3-10 Section 3 F uel System H ose Routing The F uel S ystem D iagram in this sect ion shows loca tions of the fuel tank, fuel ll, fuel tank vent, fuel level sending unit, fuel withdrawal tubes and the fuel shutoff valves. F ill ...

[Page 67] Boston Whaler 37 Justice Series

3-11 F uel System Section 3 V ent H ose Rep lacement Removal The fuel tank is vented through the fuel ll tting and fuel ca p. L oosen the two hose cl amps and remove the vent hose from the elbow at the fuel tank. Remove...

[Page 68] Boston Whaler 37 Justice Series

3-12 Section 3 F uel System Contaminated Gasoline Water from co ndensation and sediment from co ntaminated gasoline ca n co llect in the fuel tank. Contaminated gasoline ca n damage boat fuel system components, corrode fuel ...

[Page 69] Boston Whaler 37 Justice Series

3-13 F uel System Section 3 Ethanol- Blended F uels E thanol is an oxygenated hydroca rbon co mpound that has a high oct ane rating and therefore is useful in incr easing the oct ane level of unleaded gasoline. The fuel-system...

[Page 70] Boston Whaler 37 Justice Series

3-14 Section 3 F uel System Automotive gasoline has co ntained various oxygenated hydroca rbon co mpounds as replace ments for lead since . These compounds boost the octane rating of gasoline. Two familiar co mpounds...

[Page 71] Boston Whaler 37 Justice Series

3-15 F uel System Section 3  If E -1 0 gasoline absorbs enough moisture, it ca n suffer phase separation. The ethanol and water mixture will fall out of suspension and co llect in the lowest parts of the fuel system. T...

[Page 72] Boston Whaler 37 Justice Series

3-16 Section 3 F uel System Storage L ong periods of storage and/ or non-use, co mmon to boats, cr eate uniq ue problems. When preparing to store a boat for extended periods— two months or more— it is best to co mpletely re...

[Page 73] Boston Whaler 37 Justice Series

4-1 Boat Systems Section 4 General Descrip tion This sect ion co ntains general theory and funct ional information about the boat systems. This information is intended to give you an idea about how each boat s...

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4-2 Section 4 Boat Systems ...

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4-3 Boat Systems Section 4 ...

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4-4 Section 4 Boat Systems ...

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4-5 Boat Systems Section 4 ...

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4-6 Section 4 Boat Systems ...

[Page 79] Boston Whaler 37 Justice Series

4-7 Boat Systems Section 4 Bow T hruster This boat is eq uipped with a 4 kW bow thruster with a dedica ted battery bank and ch arging system. The elect rica lly driven bow thruster gives the operator more maneu...

[Page 80] Boston Whaler 37 Justice Series

4-8 Section 4 Boat Systems CAU T IO N Navigation L ights Installing after- market accessories such as radar domes, arches, and strob e lights can ob struct the navigation lights and decrease their effectiveness. It is your resp ...

[Page 81] Boston Whaler 37 Justice Series

4-9 Boat Systems Section 4 Magnetic Comp ass All magnetic comp asses are sub ject to magnetic interference, which can p roduce errors called deviation. Comp ass deviation can contrib ute to inaccurate course pl...

[Page 82] Boston Whaler 37 Justice Series

4-10 Section 4 Boat Systems CAU T IO N Signal H orn This boat is eq uipped with a signal horn. The signal horn is mounted on the hard top. The horn button is on the co ntrol co nsole, to the left of the steering wheel on the hel...

[Page 83] Boston Whaler 37 Justice Series

4-11 Boat Systems Section 4 Map L ights There are two dual lamp ( red & white) map lights direct ly above the co nsole. The map lights are powered by the “ M AP L IGH TS ” switch on the helm switch ...

[Page 84] Boston Whaler 37 Justice Series

4-12 Section 4 Boat Systems DANGER Sp reader L ights The aft spreader lights are powered by the “ AF T S P D R L IGH TS ” switch on the helm switch panel. They are protect ed by the “ S P RE AD E R L IGH TS ” breake r on...

[Page 85] Boston Whaler 37 Justice Series

4-13 Boat Systems Section 4 Electric Windshield V ent The windshield vent at the top of the windshield is elect rica lly act uated. A switch labeled “ V E NT” is loca ted on the helm switch panel. B y depre...

[Page 86] Boston Whaler 37 Justice Series

4-14 Section 4 Boat Systems Bilge Pump s This boat is eq uipped with three ( 3 ) automatic bilge pumps: one forward ( 7 5 0 GP H / 2 ,8 3 9 L P H ) , one aft ( 2 0 0 0 GP H / 7 ,5 7 1 L P H ) and one high water emergency ...

[Page 87] Boston Whaler 37 Justice Series

4-15 Boat Systems Section 4 Access to the Pump s The aft pump and high water pump ca n be acce ssed through the eq uipment hatch in the aft cockpit oor. The forward pump can be accessed through a hatch...

[Page 88] Boston Whaler 37 Justice Series

4-16 Section 4 Boat Systems WARNING CAU T IO N F uel & O il Sp illage Regulations prohibit disch arging fuel or oily waste in navigable waters. Discharge is dened as any action which causes a lm, sheen or discolorat...

[Page 89] Boston Whaler 37 Justice Series

4-17 Boat Systems Section 4 The hose should be dedicated to lling use only and should be stored in a clean, dry place. It is a good pract ice to co ver the ends of the hose to ensure the inside stays cl ean. �...

[Page 90] Boston Whaler 37 Justice Series

4-18 Section 4 Boat Systems F resh Water System Maintenance V ery little maintenance is req uired for the fresh water system, other than annual disinfect ing and winterizi ng. P eriodica lly ch eck the entire system to assure that...

[Page 91] Boston Whaler 37 Justice Series

4-19 Boat Systems Section 4 Deck Showers This boat is eq uipped with two deck showers: one is loca ted on the starboard side, aft of the transom door and the other is loca ted forward of the dive door on the po...

[Page 92] Boston Whaler 37 Justice Series

4-20 Section 4 Boat Systems CAU T IO N Water H eater Make sure the fresh water tank is full b efore op erating the water heater. O p erating the water heater emp ty will cause damage to the system. 1 . M ake sure the “ F RE S H ...

[Page 93] Boston Whaler 37 Justice Series

4-21 Boat Systems Section 4 The water heater is eq uipped with a temperature and pressure relief valve that co mplies with the standard for Relief V alves & Automatic Gas S hut off D evice s for H ot Water ...

[Page 94] Boston Whaler 37 Justice Series

4-22 Section 4 Boat Systems CAU T IO N Turn off the water heater, wait for the water to co ol then make ce rtain that the system is co mpletely drained before laying up for the winter season. rain and ush the reshwater ...

[Page 95] Boston Whaler 37 Justice Series

4-23 Boat Systems Section 4 V anity The vanity in the ca bin features a large sink and fresh water fauce t. Additional amenities incl ude a toothbrush holder and storage shelf. On the forward side of the ca bine...

[Page 96] Boston Whaler 37 Justice Series

4-24 Section 4 Boat Systems Sky L ights The ca bin on this boat has a set of sky lights in the aft ce iling. The sky lights have retract able shades which allow for the adjustment of sun light into the ca bin. H anging L ocker &a...

[Page 97] Boston Whaler 37 Justice Series

4-25 Boat Systems Section 4 Maintenance M aintenance of the raw water system req uires periodic inspection of the raw water intake strainer and all ttings and hoses for system integrity to prevent leaks. Clea...

[Page 98] Boston Whaler 37 Justice Series

4-26 Section 4 Boat Systems The waste system incl udes a V acu -F lush® toilet, a 1 0 gallon ( 3 7 .8 L ) holding tank with vacu um pump and a thru-hull vent. Waste from the head is direct ed into the 1 0 gal. ( 3 7 .8 L ) ...

[Page 99] Boston Whaler 37 Justice Series

4-27 Boat Systems Section 4 V acu- F lush® H ead The foot pedal at the base of the toilet opens a mech anica l seal which allows a vacu um to force waste through the opening in the bowl to the vacu um generator,...

[Page 100] Boston Whaler 37 Justice Series

4-28 Section 4 Boat Systems Macerator & Dockside Discharge The system ca n be emptied by two methods:  The preferred method is via docksi de pumpout through the “ Waste” deck plate on the port transom.  Alternative...