Cal Boats CAL 27 Mk III, Owner'S Manual

Page 1: ...Owner s Manual ...

Page 2: ...NG RIGGING 12 Wire Rigging 13 BOAT STORAGE 14 ENGINE OPERATING INSTRUCTIONS 15 Alignment of Engine to Shaft 15 Stuffing Box 16 FLOODING OF ENGINE WITH WATER 16 Operator Error 17 FUELING PROCEDURE 19 ELECTRICAL 20 Master AC and DC Control Panels 20 Circuit Breakers 20 Battery Selector Switch 20 CAUTION 20 SHORE POWER SYSTEM 21 LIGHTNING GROUND 23 NAVIGATION LIGHTS 24 We recommend 24 WATER SYSTEM 25...

Page 3: ...UMBING 30 THRU HULL FITTINGS 31 PERIODIC MAINTENANCE 32 Maintenance Key 33 BASIC RULES FOR BATTERY CARE AND MAINTENANCE 34 FINISHES 36 Gelcoat 36 Teak 36 Laminated Surfaces 37 Hull Liner and Cushion Covers 37 Lexan and Plexiglas 37 Spars and Hardware 37 ...

Page 4: ... Lbs 907 Kilograms RIG DIMENSIONS I 33 0 10 06 Meters J 11 0 3 35 Meters P 28 0 8 53 Meters E 11 0 3 35 Meters 100 Foretriangle 181 5 Sq Ft 16 86 Sq M Mainsail Area 154 0 Sq Ft 14 31 Sq M Total 335 5 Sq Ft 31 17 Sq M Mast Height Above Water 36 4 11 1Meters MISCELLANEOUS Berths 5 5 Fresh Water Capacity 22 Gallons 80 Liters Ice Box Capacity 5 4 Cubic Ft 153 Liters Fuel Capacity 12 5 Gallons 47 5 Lit...

Page 5: ...CAL 27 Mk III BOAT DIMENSIONS 5 27 9 5 6 3 3 3 3 1 11 SLING 1 5 1 5 7 27 9 11 0 5 0 10 3 5 0 SLING LIFT LIFT BANGOR PUNTA MARINE CAL 27 III DOCKING PLAN 1 12 1983 JPF ...

Page 6: ...6 CAL 27 Mk III BOAT DIMENSIONS ...

Page 7: ...CAL 27 Mk III BOAT DIMENSIONS 7 BANGOR PUNTA MARINE CAL 27 III ARRANGEMENT 10 28 1982 JPF ...

Page 8: ...n this section to aid you and your dealer PRE LAUNCH CHECK LIST 1 All seacocks operational closed and tightened 2 Accessory thru hulls installed and tightened 3 Diesel Propeller in place 2 nuts and cotter pin installed 4 Zinc anodes installed on shaft 5 Batteries secure filled and charged 6 Rigging installed on spar cotter pins spread and taped 7 Masthead sheaves free to rotate lubricated 8 Mast l...

Page 9: ... installed Collar on Cal 35 and Cal 39 only 9 Mast bolted to mast collar ears 10 Turnbuckles attached cotter pins spread and taped 11 Boom and running rigging installed 12 Water tank filled See Note 2 Water Heater 13 Faucets work and lines checked for leaks 14 Stove fuel tank filled system checked for leaks Refer to Propane Stove Instructions if applica ble 15 Electrical equipment operational See ...

Page 10: ... INDICATORS LIGHT AND OR SOUND DISCONNECT THE CORD IMMEDIATELY THIS INDICATES A REVERSE POLARITY SITUATION WHICH IS DANGEROUS SEVERE INJURY OR DEATH MAY RESULT DIAGNOSE AND CORRECT THE PROBLEM BEFORE PROCEEDING Note No 2 If your Cal Yacht is equipped with a water heater it will be installed to operate off both the engine cooling system and the 110V AC electric system Before switching the 110V syst...

Page 11: ... the lower shrouds slack Adjust the headstay and backstay to achieve a straight spar when sighting up the trailing edge Next with the boat level athwartship tighten the upper shrouds to get the mast straight Finally tighten the lowers no more than hand tight Final tuning must be accomplished while sailing In a light breeze 6 8 knots adjust the shrouds to achieve a straight spar on either tack In h...

Page 12: ...e and are properly aligned All standing rigging should be inspected for cracks in the swages proper installation of cotter pins and wear on clevis pins Replace any damaged or suspect rigging As you may have noticed on some sailboats the swaged ends of the shrouds will ooze rust and in severe cases the swage will split One way to prevent this problem is to heat up the swaged section and place a bar...

Page 13: ...Wire Rigging 13 WIRE RIGGING ...

Page 14: ...ure to properly position the poppets could result in hull depression Be sure to use an adequate number of supports and locate them to prevent the boat from tipping fore or aft A storage cradle designed for this boat is available through your Cal dealer When hauling any boat with a propeller shaft be sure to disconnect the coupling before lifting the boat This will prevent bending of the shaft as t...

Page 15: ...y all around Never attempt a final alignment with the boat on land The boat should be in the water and have had an opportunity to assume its final water form It is best to do the alignment with the fuel and water tank about half full and all the usual equip ment on board and after the main mast has been stepped and final rigging has been accom plished Take plenty of time in making this alignment a...

Page 16: ...ll the old packing and replace it with three rings of new packing Stagger the ends of each ring so as not to provide a path for water to leak through D o not wind one continuous strip spirally around prop shaft to make a seal Slide the packing gland back and tighten enough to create a heavy drag on the shaft This will seat and form the packing Back off the packing nut until the shaft feels free an...

Page 17: ...to the overboard exhaust port This would dramatically slow the surge effect of waves hitting the port Operator Error This is a nagging source of water in the engine and occurs when an operator repeatedly attempts to start an engine i e he grinds the starter not 2 or 3 times but continually The amount of cranking time varies from engine to engine factors being the amount of each piston s displaceme...

Page 18: ...tion Key 22 Engine diesel universal 23 Fuel pump on engine 24 Fuel line 25 Fuel return line 26 Fuel shut off valve 27 Fuel tank 12 5 gals 28 Fuel level sender 29 Fuel fill line 30 Fuel fill plate port cockpit coming side 31 Fuel tank vent line 32 Fuel Vent port aft cockpit coaming 33 Filter 1 2 3 4 5 6 8 7 9 11 10 12 ...

Page 19: ...act between the nozzle and deck plate to prevent a static charge G Fill tank to a maximum 95 of capacity to allow for expansion H Clean any spills after replacing and tightening fuel fill cap Before operating the engine or turning battery switch to ON open all hatches and check for fuel leaks Always be sure the fuel fill cap is tight to prevent water and dirt from getting into the fuel tank Period...

Page 20: ...ar circuit ALWAYS INVESTIGATE THE CAUSE OF THE OVERLOAD AND CORRECT ANY DEFICIENCIES BEFORE RE POSITIONING THE CIRCUIT BREAKER TO ON ALL WIRES CONNECTIONS AND TERMINALS SHOULD BE INSPECTED REGULARLY FOR LOOSE CONNECTIONS WHICH MAY CAUSE ELECTRICAL SPARKS HIGH RESISTANCE OR FIRES THIS IS ESPECIALLY IMPORTANT FOR ENGINE ACCESSORY WIRING Battery Selector Switch Before leaving your boat always turn th...

Page 21: ...e both audible buzzer and visual yellow light on panel reverse polarity indicators With all switches off attach the power cable to the inlet Next attach the power cable to the dockside outlet WARNING IF THE POLARITY INDICATOR LIGHTS AND OR SOUNDS DISCONNECT THE CORD IMMEDIATELY THIS INDICATES A REVERSE POLARITY SITUATION WHICH IS DANGEROUS SEVERE SHOCK INJURY OR DEATH MAY RESULT DIAGNOSE AND CORRE...

Page 22: ...y Charger 70 Refrigerator 80 Outlets 1 Cabin Lights 3 31 Running Lights 32 Masthead Light 33 Anchor Light 13 Water Pump 11 Bilge Pump Voltmeter Test Switch Light Ground DC Negative DC Positive DC Battery 1 Battery 2 Ground AC Function Typical DC Function Typical Ground Black Hot Neutral Hot 1 82 1 11 3 3 32 31 13 1 1 1 81 Battery 1 Battery 2 DC Panel ...

Page 23: ...CONDUCTORS WHICH WILL CARRY HIGH VOLTAGE AND CAUSE SEVERE SHOCK INJURY OR DEATH IN THE EVENT OF AN ELECTRICAL STORM THE FOLLOWING PRECAUTIONS ARE RECOMMENDED 2 As much as possible stay below with the hatches closed 3 Avoid contact with any items making contact with the electrical system and w i t h any other metallic parts of the boat 4 Stay out of the water If the boat is struck by lightning comp...

Page 24: ...ollowing navigation lights B Red green 10 point side lights mounted near the bow C White 12 point stern light D White 20 point bow light mounted on the mast E White 32 point masthead light mounted on top of the spar A B are wired to the RUNNING LIGHTS switch on the DC panel C is wired to the BOW LIGHT switch D is wired to the MASTHEAD LIGHT switch We recommend 1 Underway by sail the running lights...

Page 25: ...her move the valve handle NOTE DO NOT FILL WATER TANKS TO MORE THAN 90 OF CAPACITY TO ALLOW FOR EXPANSION The optional pressure water system pump is located under the companionway step next to the tank selector valve This is a self priming pump With the pressure system a hand held shower is included in the head When not in use be sure to leave the shower connected to the sink to prevent possible s...

Page 26: ...26 WATER SYSTEM BANGOR PUNTA MARINE CAL 27 III STANDARD WATER SYSTEM 10 6 1982 JPF ...

Page 27: ...WATER SYSTEM 27 BANGOR PUNTA MARINE CAL 27 III PRESSURE WATER OPTION 10 6 1982 JPF ...

Page 28: ... OFF position there is no pressure anywhere inside the boat Please refer to Marinetics Corp Document 609 5 Turn on the burner valve you desire and light If the system is new or the tanks have just been replaced there could be a quantity of air in the supply line WARNING YOU MAY GO THROUGH MORE THAN ONE MATCH BUT DO NOT LEAVE BURNER VALVE ON WHILE GETTING ANOTHER MATCH LIT THE GAS COULD BE COMING O...

Page 29: ...COOKING STOVES PROPANE STOVES 29 BANGOR PUNTA MARINE CAL 27 III THRU HULL LOCATIONS 10 6 1982 JPF ...

Page 30: ...arge side of the holding tank For dockside discharge open the dockside line and deck fitting and insert the dockside pump FOR OVERBOARD DISCHARGE CLOSE THE DOCKSIDE LINE AND OPEN THE OVERBOARD LINE AND THRU HULL SEACOCK IN THE DISCHARGE LINE IS A DIAPHRAGM PUMP THIS WILL DISCHARGE THE HOLDING TANK THROUGH THE THRU HULL FEDERAL AND STATE LAWS AND USCG REGULATIONS SHOULD BE CONSULTED REGARDING THE D...

Page 31: ...event of a hose f a i lure These shut off valves will also prevent flooding of the head i f a head valve fails ALL THRU HULL SHUT OFF VALVES SHOULD BE SHUT OFF WHEN THE THRU HULLS ARE NOT IN USE This will prevent any problem in case of accident Be sure to re open the shut off valve on the engine before starting the engine Following this procedure will result in a secure boat ...

Page 32: ...NES HEADS ETC Item End of First Week Monthly Winterizing Remarks Deck Fittings 5 1 4 5 Rudder Blade 1 1 Rudder Post 6 1 6 1 4 5 6 Propeller Shaft 1 1 1 4 Stuffing Box 1 2 5 1 2 1 4 Zinc Anode 1 1 Replace at least once a year Propeller 1 1 4 5 Bilges 4 7 Cockpit Drain Hoses 2 2 5 2 4 5 7 8 7 8 Some cockpit hoses have low points that hold water Sea Cocks 1 2 3 2 1 4 6 Pumps 1 1 2 5 1 4 5 7 8 Water T...

Page 33: ... Cocks 1 2 3 2 1 4 6 Pumps 1 1 2 5 1 4 5 7 8 Water Tanks 2 2 1 4 7 Piping Fresh 2 2 1 4 7 Water Lighting 1 3 4 3 WD 40 or CRC Battery 1 1 4 1 4 8 4 Clean with baking soda water solution Water Filter 1 2 4 1 4 7 Fuel Filter 1 5 1 5 1 4 5 4 Outside Only Air Filter 1 1 5 1 5 Exhaust System 1 2 5 1 2 5 1 4 5 7 Engine Mounts 1 5 1 5 1 3 5 Maintenance Key 1 Check condition 2 Check water tightness 3 Lubr...

Page 34: ...e bubbling stops Wash with water dry and apply silicone grease available from battery dealers 4 Examine battery for broken or cracked covers case and cracks in sealing compound If any of the above defects are present remove battery at once and have repaired Acid loss from any of the above defects will shorten battery life Acid escaping through cracked covers or sealing compound will cause corrosio...

Page 35: ...r which was put in the previous week has been used it is reason able to expect that too much charging current has passed through the battery hence the volt age regulator should be checked All cells in the battery should take the same amount of water If one cell should take more than the others and does this each week it would be expected that the container is leaking Whether the leakage is through...

Page 36: ... holes you should rely on your dealer or local gelcoat repairman to provide a good cosmetic repair Gel coated surfaces can be painted However to assure a good finish which will last care ful preparation and application is necessary This should be done by professionals Teak The interior and exterior woodwork on your Yacht is primarily teak This unique wood will not rot and requires minimum maintena...

Page 37: ...e of Lexan or Plexiglas Clean these with window cleaner or a mild detergent Do not use chemical cleaners or abrasive cleaners as these will damage the finish Spars and Hardware The spars on your Yacht are painted with tough and durable urethane paints that withstand the harsh effects of the elements They should be washed with fresh water whenever possible and thoroughly rinsed before being stored ...

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