I I' Owner's Manual

2-d6CALII\-WIRERIGGINGn."0/',{T)112.EYE l/II. 3/APIH Ir3/,6 Jx 19 SS ::'!J/u. / '"r z - !I .f'7Rf2.rem: G/l2.x 'llL PIN2:.[JALLiE.QrrJIIIillIII[JAC SIRY16nb PIN:§j. /u.11l' ,511Pr# 77/G.O fT) J2e SIVO 5-10-/0::0' \ ' \\\c: ::JI,J.LJ!9CKS TRY :3 R'IDLE.\1Pi 1'f 77/6./ jl!b / i; /9 S5 rr7 2. 5/.n"/ t: /935bilrtPr# 7)IL2Il!:21 F\. .IOf77E2.P. S({;D 5-/0-/0,c·llUpPEe0"\\\\\I\\04J-5IJzI!SruD 1,-/2-/230' 2'/0"5?i-:d 77/ 0'\\1\\\\'1&. 'SA"LD IrJE2.j;fiLL iUfTJI8IIlit"",.IIFoeJ l//6x2'- jt. I77/39I8i3RLL ( ZJT7(1)R2.I .III19 SS5132 / 19 ss "IPr -.-IHd t'flEADSiAY0\ \ \\ \ \ \ \ \'i\j I I/J.\'nne. E.YE. 3/' LtC l/API i[17 2.2. STUD 6-/2-11.,II . I(LRLd-:l5TUr N6UCk:.Le OEseRIP, ION . .JW/R.E xP.;OD't': PIN 5/ZE(' ./ ":. ::2 DESC: /PTIO Nl-Y.5. Z .3 z. /, /9 s'"---I{T) Ei!.2.::Jh,·l1 'so ) ill).J3;h"-- -Ii5 - /D- 0SODFT LOWEICJ \ \ " \ \ \ ·1Prtl 77/l.L.-1II"- -I-IDc5cz.r PT \ 0 NI

IIIIICal 25Running RiggingItemLengthDiameterMaterialMain Sheet45'7/16"Yacht BraidJib Sheet37'6"7/16"Yacht BraidRope39'6"3/8"Yacht Brai.dWire31'5"1/8"7 x 19 SS CableRope39'6"3/8"Yacht BraidWire36'3"1/8"7 x 19 SS CableReef Line20'5/16"Yacht BraidOut haul14'1/4"Yacht BraidEye Splice OneEndMast28'6"1/4"Pre-stretch YachtBraidEye Splice UpperEnd - Bullet Block. on Lower EndBoom8'1/4"Yacht BraidEye Splice OneMain HalyardaHalyard ShackleJib HalyardSnap ShackleIIBoom Topping LiftNOTE:Main and Jib Halyards are wire to rope spliced.Dimensions given are before splicing.Splice length is 1'8"."Ell! I. , t

rBOAT STORAGEWhenever a boat is pulled from the water, for work or storage,care must be taken to provide adequate and proper support ofthe hull.This is especially true of fin-keel sailboats.It is not recommended that the weight of the boat be .restedsolely on the keel.Because of the small area of the keel bot)tom, the localized loads on the hull in the area of the keelwould be severe, and could result in permanent damage to theshape or structure of the boat.If poppets are used for support, they should be located so thatthe pads are under bulkheads, berth fronts or pan stringers, sothat the load is dispersed (See Docking Plan).Failure to prop-erly position the poppets could result in hull depression.Besure to use an adequate number of supports, and locate them toprevent the boat from tipping fore or aft.A storage cradledesigned 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 preventbending of the shaft as the boat changes shape when lifted.Do not careen a fin-keel sailboat.The hull, keel, and ruddershould survive any accidental groundings.However, care must betaken to keep the boat as balanced and upright as possible to·1iprevent excessive loads.WARNING:WHEN HAULING, LAUNCHING, AND SAILING NEAR LOW OVERHEADWIRES, CARE MUST BE TAKEN THAT THE MAST NOT COME IN CONTACT WITHSUCH WIRES.CONTACT COULD CAUSE THE MAST TO CONDUCT ELECTRICITYAND CAUSE INJURY OR DEATH.

ENGINE OPERATING INSTRUCTIONSThe engin e insta lled in your yach t has alrea dybeen run and allsyste ms teste d befo re leavi ng the Cal plan t.We are not going tog tinto a grea t amou nt of deta ii in this area ,for we belie ve the manu al supp lied by the engine manu factu reradeq uatel y cove rs the subj ect.Study your engin e owne r's manu al and get to knowyour engin e.The know ledge could be of grea t assis tanc e toyou. Also , somemanu factu rers have clin ics aimed at the custo mer;cont act themfor deta ils.It is advi sable that you follo w the engin emanu cturer'spro-cedu res and recom mend ation s on run- in and maintenan ce.On yach ts with prop eller shaf ts, plea se use thefollo wing proce dure:Align ment of Engi ne to Shaf tThe engin e must be prop erly and exac tly align edwith the prop ellershaf t. No matt er what mate rial is used to builda boat , it willbe found to be some what flex ible, and when launched, the boat hullwill chang e its shape to a grea ter exte nt thanis usua lly reali zed.It is, there fore , very impo rtant to check theengin e align ment atfrequ ent inter vals and to corr ect any erro rs whenthey appe ar.Mis- align ment betw een the engin e and the prop ellershaf t is thesourc e of troub les whic h are often blam ed on other caus es.It willcrea te exce ssive bear ing wear , rapid shaf t wear, or leaka ge oftrans miss ion oil throu gh the rear seal . A bentprop eller shaf t willhave exac tly the same effe ct, and it is, therefore, nece ssary thatthe prop eller shaf t itse lf be perf ectly strai ght."

.S IIIIIIIIIIIIIlI.ENGINE OPERATING INSTRUCTIONS - Cont inuedThe engin e align ment shou ld be re-ch ecke d afte rthe boat has beenin servi ce for one to three week s and, if nece ssary, the align mentrema de.It will usua lly be found that the engin e js nolong er inalign ment .This is not beca use the work was impr operl y doneatfirst , but beca use the boat has taken some timeto take its finalshap e.It may even be nece ssary to re-al ign at a further perio d.The coup ling shou ld alway s be open ed up and thebolts remo ved,when ever the .boat is haul d out or move d from theland to thewate r and durin g stora geThe flex ibili ty of theboat often puts a verystrai n on the shaf t or the coup lingor both when it is being move d.i radle.seve Durin g the align ment proc edur e, check the set screws which hold theprop eller half coup ling to the shaf t. Thes e mustbe tigh t, incont act with the shaf t, and safe ty wired .Stuf fing BoxThe stuff ing box prov ides a seal for the prop ellershaf t at theinne r end of the shaf t log.It is conn ected to the shaf t logwith heavy wall hose , doub le clam ped at each end.This flex hoseallow s the stuff ing box to main tain ali hment withthe prop shaf t without crea ting exce ssive wearof the pack ing, due to mis- align mentor vibr ation .The pack ing used is wax impr egna ted 3/16" x 3/16" squa reflax.When the shaf t is turni ng, it is norm al to havea sligh t leaka geat the seal , abou t one drop per 30 secon ds. Thisacts as acool ant, as well as a lubr ican t, to prote ct theseal and shaf tsurfa ce.Shou ld exce ssive leaka ge be appa rent, relea se thelocknut and tight en the pack ing nut sligh tly and re-tighte n the lockc.

IENGINE OPERATING INSTRUCTIONS - Cont inuedThe engin e' shou ld be move d aroun d on the bed andsupp orted on thescrew moun ts unti l the two halv es of the coup lingscan be broug httoge ther witho ut using force and so that the flanges meet even lyall aroun d.Neve r attem pt a final align ment with the boaton land.The boatshou ld be in the wate r and have had an oppo rtunity to assum e itsfinal wate r form.It is best to do the align ment with the fuel andwate r tank abou t half full and all the usua l equipment on boardand afte r the main mast has been stepp ed and final riggi ng has beenacco mpli shed .Take plen ty of time in maki ng this align ment ,and do not be satis fied with anyth ing less than perfe ct resu lts.The align ment is corre ct when the shaf t can beslipp ed backw ardand forw ard into the coun terbo re very easi ly andwhen a feele rgaug e indic ates that the flang es come exac tlytoge ther at allpoin ts.The two halve s of the coup ling shou ld be para llelwith in0.003 inch es.In maki ng the fina l check for align meQ t, the engine half coup lingshou ld be held in one posi tion and the align mentwith the prop ellercoup ling check ed in each of four posi tions , rotated 90 0 betw eeneach posi tion. This test will also check whether the prop ellerhalf coup ling is in exac t align ment on its shaft. Then , keep ingthe prop eller coup ling in one posi tion, the alignment shou ld becheck ed, rotat ing the engin e coup ling as desc ribedabov e. I IIII II 11·-11 II

tr IIIIiIfl-I-II I IIIFLOODING OF ENGINE WITH WATERYour Cal Yacht is supplied with a water-lift (wave suppressor)type of muffler that under normal conditions, when the engine isnot running, provides wave suppression and water st?rage to helpkeep water from flooding the engine.NOTE:There is a direct path from the overboard exhaust port viathe water-lift muffler to the engine and from the water pump tothe muffler.Accidental conditions (sea) and operator error(prolonged starting attempts) can thus cause an excessive volume ofwater to fill the muffler and flood the engine.UNDER SUCH ACCIDENTAL SEA AND/OR MISUSE CONDITIONS, ENGINE FLOODINGMAY BE---UNAVOIDABLE.Sea Flooding:Your Cal exhaust system is designed and installed to the higheststandards, and, as stated above, could still flood under certainheavy sea conditions.The only added safety precaution you 'couldadd would be to install a rubber flap to the overboard exhaustport.This would dramatically slow the surge effect of waveshitting the port .Operator Error:This is a nagging source of water-in-the-engine and occurs whenan 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, factorsbeing the amount of each piston's displacement, the water pump'scapacity, and whether the battery is cranking a full R.P.M.

ENGINE OPERATING INSTRUCTIONS - Continuednut.Re-start engine and check again with shaft turning.When it ,becomes necessary to replace the packing (boat should behauled), loosen the lock nut, back off the packing gland nut, andslide it forward on the shaft.Remove all the old packing andreplace it with tpree rings of new packing.Stagger the ends ofeach ring so as not to provide a path for water to leak through.DoB21wind one continuous strip spirally around prop shaft toma;i{e a seal.Slide the packing gland back and tighten enough to create a heavydrag on the shaft.This will seat and form the packing.Back off the packing nut until the shaft feels free and re-setthe lock nut.Re-check for proper leakage when boat is returnedto the water.Be sure the lock is secure, as operating theboat in reverse could cause the packing gland to screw off thestuffing box, allowing water into the boat. Ii II II I"I---- ! m.' @@!"#tMIi&W4i:.,.:.,:aiaQ .t,Mw"tm ··iciii·ii!b "t "eL%?e·IJ

- ,- .-- - - - - - - - - - . . . . .- .- I.r).\,J','"ii)(9). r. 1-. ,./Y" ( . '. . E l'fi 0 ,fPt Th ". id !I@ICD EHGINE DIESEL uN/VE.f.SAL 11CD FUE.L pump OH E.NG/HE.(i) FUELLlHE. FUfL ErvfN LIME. FUfLv)FUE.L VENT(poer RPr t.tX.kP lf CORmIHe.)FIL L PLRrE. (PORr COCIlPlr CORfT)INCt SIDE.)LIN/!,,;LlHE.@ FUE.L TAHIt VENT. - 'V(]) FVE.L LE.Y L SENDE R.@FuE.L FILL(L )r-!H.P.@ FUll SHUT OFF VRLVE. FUEL fAHK /l·5 uRLS\ (8')REVIeELE 5EO : O\t.lNE.fC'S (1)RHUALOE.Sc .eIPfiO N17-3-S0IDArE.fUEL SYSrEfTJ OPT IONA LL RL 2- 25 (UHIVeeML .5"-". 11 H.P)8ANG Oe PUN -rA (T)AR.IHE.De a HO,

- ---Q?HAMILTON DRIVEFUELING PROCEDURE :IIlJI-IWhen prep aring to fuel your boat , the follo wingproc edur esshou ld be follo wed to assu re safe ty:AsProp erly secu re the boat to the dock .B.Turn off the engin e, stov e, heat er, radio , lights, etc .Turn batte ry switc h to OFF.C.D.fUIl!e s.E.tMain tain conti nuou s cont act betw een the nozz leanddeck plate to prev ent a stati c charg e.F.Fill tank to a maxim um 95% of capa city to allowforexpa nsion .G.Clean any spil ls afte r repla cing and tight enin gfuelfill cap.H.,,Clos e all hatch es, port s, etc. , to prev ent entryofBefo re oper ating the engin e or turni ng batte ryswit ch.to ON, open all hatch es and check for fuel leaks. Ongaso line engin e, check for fume s and run the blowerfor 5 minu tes befo re start ing the engin e.Alwa ys be sure the fuel -fill cap is tigh t, to prevent wate r anddirt from getti ng into the fuel tank . Peri odically check thefuel filte r and wate r sepa rator . Thos e shou ldbe drain ed andclean ed, as need ed. The filte r elem ents shou ld·berepla cedannu ally.

ELECTRICALMast er AC and DC Cont rol Pane ls.The mast er elec trica l cont rolpane ls are loca ted on the aft bulk head , behin dthe comp anion waystair s. The AC mast er pane l inclu des circ uitsfor a batte rychar ger, the wate r heat er, and the port and starboard elec trica loutl ets. The DC mast er and acce ssory pane ls handle all othe relec trica l syste ms.IIIIIIIIItCirc uit Brea kers.Acce ssory load s may be selec ted as desir ed byturni ng on the mast er-co ntrol pane l circ uit breakers.The cir-cuit brea kers will auto mati cally open the circ uitby switc hingthem selve s to "OFF " in the even t of an over loadon a part icula rcirc uit. Alwa ys inve stiga te the caus e of the overload and correct any defic ienc ies befo re re-p ositi onin g thecirc uit brea kerto "ON" .ALL-WIRES, CONNECTIONS, AND TERMINALS SHOULD BE" INSPECTED REGU-LARLY FOR LOOSE CONNECTIONS WHICH MAY CAUSE ELECTRICAL SPARKS,HIGH RESISTANCE, OR FIRE S. THIS IS ESPECIALLY IMPORTANT FOR ENGINE ACCESSORY WIRING.-.--Batt ery Sele ctor Switc hBefo re leavi ng your boat , alwa ys turn the master-ba ttery switc hto the "OFF " posi tion to prev ent powe r drain age.DO THIS ONLYAFTER YOU HAVE SHUT DOWN THE ENGINE, for you mayburn out thealter nato r diod es.CAUTION!You may switc h from one batte ry to anot her forcharg ing,but DO NOT pass throu gh the "OFF " posi tion whilethe engin eis runn ing. This may burn out the alter nato r diodes. Keepthe engin e RPM as low as poss ible, when switc hingbatt erie s.I

,.--- - ------ ---- ---- ---- ---- . - . . . . - . ---- .[ .'- .,--- .---- . . --- --- --- --- --- --- -- . . '2l.'I \J'-I'lf/STf SWITCH PI/Hf.lII' . ;a.;:;o T:rE:.---.-- ------T --'--"1-'-------- . - ,rV-- '--- -.---- - ---- .-I, '---- ilIt,U -iY Off-;;;,,;; - ,j!1'if. IrJL 'NC.,: '.-,J;rt:8M Gh!.ID I'II.JG 8LI{IDI'lIrJ{:. R-------J-' .r--O-rd.- - 1I'I'?:'! :Eo?J :"o 60"" LIGHTS Io RIo4CIIOe LIGHTSo §Pi6iOEiL',GiiTS [(NOM1-- -- - - . - - - SflrrurnsrW,TPl tl- I[x.IHL c.rt\t!DI&AmeY \.I,r'HIIII I IUC-11 :I r4 GUD"""'G tiC'11 ' I ltd II-.- -IToI800fI(ON R!. eYITCH f5 WIEHc.IH OPrIO-- ;;--EHGiHE. ST.Q TU. !RfTlPI1f: fE.fI':,!01!5LIGHTS.RUHHIHtI-01.5 101 l- I 0 1Selli. -0. 4.QLI (!t:Io CRItH01Il(t'lDOEL wk,05TO \.IITOH IORgO - -LA!lH lIGH-r) u ,.,p LIGHT !lRTrf:t'I 9rAr fTJErE.1l !l INOleRr Ol! LRMP euNIII FACfOr.V DPflON)0oFILL "-Jtf/l-lCt I tDITlL/GHro StIOrE. FblJU F/C.NOff5: . S E.1IL, L MGIHE.t»ILY)IIIr5YJ')WlSltC.H-rsI.';0Ai:.Ct. TLf:fINLErSOCItE.-rsS"-JlfCH PFH-IeL 11./1. IlIJG I-IGII-IE. MRNC/RL EHG/HE. 1N5T. LWllJI-IG /hL OfJ:JJlr B2f» E.25 OF rllUl'fO f'YPEOttc. I fEtal.:7-7''If): O\.lNEr?'S fT}fll-ltJRi.I!.Ev---- --,DArECLgre /CftLC,qL/3l}I"-IC, 02.IlJ2.lJc,Sc.u m RTlCJ-J.5DeR'oIN: fDCIHaVlDSAlAIJPVN"-I J f77FUlIN E.NO.325

I IIIIIIIIIIIIILIGHTNING GROUNDThe spars and standing rigging on all Cal Yachts are grounded,in compliance with the American Boat and Yacht Council ProjectE-4, to attempt to minimize damage resulting from -lightning andprovide a measure of safety for personnel.Each chainplate, the mast step, and all thru-hulls are attachedby means of a #8 AWG solid copper wire to the engine and/or strut.In the event -lightning strikes the spar, the system is designedto carry the charge by the wire to ground.WARNING:IN AN ELECTRICAL STORM, DO NOT TOUCH THE MAST, BOOM,OR ANY STANDING RIGGING.THESE ARE ALL ELECTRICAL CONDUCTORS,WHICH WILL CARRY HIGH VOLTAGE AND CAUSE SEVERE SHOCK, INJURY,--OR DEATH.--IN THE EVENT OF AN ELECTRICAL STORM, THE FOLLOWINGPRECAUTIONS ARE RECOMMENDED:1.As much as possible, stay below with the hatchesclosed.2.Avoid contact with any items making contact withthe electrical system and with any other metallicparts of the boat.3.Stay out of the water.4.If the boat is struck by lightning, compasses and electrical equipment should be checked to determine that nodamage or change in-cal i bra t ion has occurred.NOTE:WHILE THE GROUNDING SYSTEM SPECIFIED IN THE AMERICANBOAT AND YACHT-COUNCIL PROJECT E-4 IS THE MOS WIDELY USEDLiGHTNING PROTECTION SYSTEM KNOW!rTOUS;-WE URGE YOU TOAYOIDEXPOSING YOURSELF TO LIGHTNING, SINCENO SYS WILL PROVIDECOMPLETE PROTECTIO TO BOAT OR OCCUPANT-S IN ALL CIRCUMSTANCES.

Shore-Power System.The shore-power system accepts 110V ACthrough a three-prong male connection located in the "cockpit.There are two current carrying conductors, positive and negative,as well as a grounded non-current carrying conducto'"r.WARNING:NEVER USE AN ADAPTER THAT ELIMINATES THE GROUNDING CONDUCTOR.SEVERE SHOCK, INJURY, OR DEATH MAY RESULT.A master-circuit breaker is provided for the shore-power system.To activate shore power, throw the circuit-breaker switch afterthe shore-power line is connected to dock power.In addition, there are both audible (buzzer) and visual (yellowlight on panel) reverse polarity indicators.off, attach the power cable to the inlet.cable to the dockside outlet.WARNING:With all switchesNext, attach the powerIF THE POLARITY INDICATORLIGHTS AND/OR SOUNDS, DISCONNECT THE CORD IMMEDIATELY!THIS IN-DICATES A REVERSE POLARITY SITUATION, WHICH IS DANGEROUS.- - - - -SHOCK, INJURY, OR DEATH MAY RESULT.-SEVEREjDIAGNOSE AND CORRECT THEPROBLEM BEFORE PROCEEDING.If the polarity is correct, switch on the breaker for the outletsand/or hot-water tank as desired.Be sure the hot-water tank isfull before turning on the circuit, or you will damage the heatingelement (see plumbing and commissioning sections).It is recommended that all appliances or lights be wired withthree-prong grounded plugs.

::::·;:J;l;,EleaWJ·'ll.· ---.',;;:.·-,.,.,'-.· . -- - ,t IIIIIIIIIIIIII ,'".NAVIGATION LIGHTSNavigation lights must be in accordance with the rules and regulations of the waters in which you intend to cruise.In general, navigation lights are to be used from sunset tosunrise in all weath

Kenyon Mast Collar Installation Instructions(39/35) . Cooking Stoves/Propane Stove Alcohol Stoves Plumbing - Heads Plumbing - Fresh-Water System . Basic Rules for Battery Care and Maintenance Finishes MANUALS 281 ". ' . I J I I I I I I BANGOR PUNTA MARINE . 848 AIRPORT ROAD , F AL