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Edited By: Ed Rant January,1999

1. puey yeys uuojop 304 pesu Gu uo Ord 94 saaw adud eq os 9315 AMD ipa dais Aq obuvy 96 6 93 15 boddns yeys buey jo DE SHOMGA SEEN ary EE 9 ede eu pue inu da ede eu gz adeg ey uo pesn si Bundnoo aig 250 94 SNOLLONYASNI ININNITTV UNV Y3IAVSIAIJO S S Page 59 FIG 7 EE ma 3NION3 FL BN INNOM HOLON TVOIdAL 95 N a 4 N Page 60 5 7 CD 25D BATTERY WIRING DIAGRAM 5 8 BATTERY WIRING DIAGRAM Page 62 ER LAMA NO RE N pur T td e Page 64 CD 28 WIRING SYSTEM CD WIRING SYSTEM 5 11 CD 28 30 ELECTRICAL LAYOUT ied ft nd 5 1 JILVN3HOS TI s 5 13 AC ELECTRICAL SCHEMATIC A C WIRING DIAGRAM Page 68 5 15 SEACOCK DETAILS SEACOCK ASSEN BLY amp INSTALLAT
2. number part name and quantity ses Your order will be prompily M you have any questions Ze don t hesitate tn call the Edson lac tory We will be pleased to assist you steerer parts are under 3 7 3 Fig 960 see price pages N 23 vn T mm sd m 74 gt Miu wer 67065165 27 gt nd el gt K pi wee INTERNATIONAL ENGINE CONTROLS INSTALLATION Great care must be laken to assure and safety of engine controls operation Components must be installed and adjusted so the engine goes into gear smoothly and completely and the throttle operates easily Cables must be in straight or in broad curves Reler to the Engine Connections MuMranons lopnesite For installa tion procedures Don t force Sine controls when operating above idle Force shifting can result in broken cables and loss of boat control Familiarize yoursel with the operation ol the engine controls Caution and train all those on board ENGINE CONNECTIONS NOTE Use the inlormation below as a guideline Most engine and con trol cable manufacturers furnish instructions for installing their products Use their instructions if there Is any variance with the mstruc tions shown below the centering of the cable must be aimag the of the lever 10 al
3. 7 16 50 Forestay W Backstay W Uppers W Lowers W Staysail Stay W Bob Stay W Main Halyard P Jib Halyard P Staysail Halyard P Main Sheet D Jib Sheet D Staysail Sheet D Genoa Sheet D Topping Lift D Club Lift D Clew Reef D Tack Reef D Spinnaker Halyard D Spinnaker Sheet D STANDING AND RUNNING RIGGING CD 27 7 32 x 354 7 32 3776 7 32 x 3471 5 32 1774 3 8 71 3 8 75 7116 75 7 16 60 7 16 35 1 4 46 NA 5 16 x 23 5 16 x 12 7116 75 7 16 60 Note All wire lengths are approximate Key 1 19 Stainless Steel Wire P Prestretched Dacron D Braided Dacron CD 28 1 4 x 37 1 4 x 3978 1 4 x 36 3 16 x 187 NA 1 4 376 7 16 72 7 16 76 7116 75 7 16 357 7 16 357 1 4 51 5 16 35 5 16 26 5 16 x 14 7 16 x 75 7 16 x 60 Page 95 CD 30C 1 4 x 3776 1 4 x 40 1 4 35711 3 16 1871 3 31 1 1 4 x 4 7 16 74 7116 84 7 16 60 7 16 60 7 16 45 7 16 x 75 7 16 x 35 1 4 x 55 5 16 35 5 16 26 5 16 14 7 16 75 7 16 60 See Note in Vendor Addresses Section Ed VENDOR LIST Page 96 In the interest of faster and more efficient service Cape Dory has developed a list of the more important equipment and manufacturers We produced this
4. nterior Wood Surfaces NG AND WARRANTY 4 2 Warranty Notification Procedures CHAPTER 5 0 1 2 LS 14 1 4 18 19 20 21 22 23 24 25 01 UI 1 Q0 AQQHKHDAAND udder D 22D DRAWINGS AN Details teering Assembly 25D 27 30 isc Sav D 27 2 D 22 El 8 ect D 28 Propeller Sha and Alignment In ypical Motor Mo D 25D Battery Wiring 30 Battery Wiring Layout unt rical CD 25D 27 ectrical D PLANS Propeller ft Details Diagram Layout CD 28 DC Elec 30 Electrical era cal AC Elec er cal Ball Va ve 27 28 29 Typical 230 16 Typical 17 CD 22 P Seacock De Se Details tails acock In CD 25D 2 umbing Layo umbing Layout 7 P Layout Schematic Layout stallation ut CD 28 Typical Head Plumbing Head Plumbing Typhoon Spar General Sheetin 26 Typical Pr Sp 9 30 Plumbing Layout Wat r Schem ssur With Optional with Detail ar Detai Reefing Optional 15 15 CD 22 Details Chainpl Typical Chainpl Schaefer Jiffy Hull 5 ate ate Reefing
5. tension on the foot of the sail When the clew has been pulled out and the foot is tight make the line fast around the cleat on the boom There are reef points in the mainsail of Cape Dory Yachts fitted with jiffy reefing Use 18 lengths of 1 4 line and run them through each reef point Lead the line through the reef point under the foot of the sail and tie the reef lines in a reef knot It is the seamanlike procedure to keep the unused sail out of the way and reduce windage To shake out the reef release the lines through the reef points stow them and release the reef line through the reefing cringle that is serving as your clew Then release the reef line on the reefing cringle for the tack and hoist the mainsail so that the luff is tight Return the topping lift to its original position Again make sure the sheet and vang have been eased Generally speaking reefing is desirable when you find yourself heeling more than 20 degrees or wish to slow the boat down to keep it manageable in heavy airs When going off the wind the boat will probably sail as well running under headsails alone since the reefed main will usually blanket the headsail You may wish to leave the mainsail reefed furled and ready to hoist when you change direction to windward The enclosed explanation of quick reefing is from the catalogue of Schaefer Marine Products of New Bedford Massachusetts It is reprinted here with their permission 3 33
6. 53 Owner s packet ship s papers and ignition key given to owner 54 Checklist warranty registration ready for mailing to factory Owner Dealer Date WITHIN SEVEN DAYS OF LAUNCHING RETURN CHECKLIST TO Cape Dory Yachts Inc 160 Middleboro Avenue East Taunton Mass 02718 Page 15 CHAPTER 2 CONSTRUCTION OF YOUR CAPE DORY YACHT CONSTRUCTION 21 MOLDED FIBERGLASS PARTS MAJOR 2 2 HULL The hull is molded in a one piece mold which is turned from side to side as successive layers of fiberglass are applied during the laminating process By placing the mold on its side we can place the fiberglass and work the resin more accurately than would be possible if the mold was always upright The exterior finish of the boat is pigmented gel coat which Is sprayed into the polished mold Next we apply two layers of multidirectional glass strand fiber to minimize roving pattern transfer from successive layers of laminate Finally alternating layers of glass strand fiber and woven roving are applied until the desired thickness has been achieved The thickness of the hull varies depending on the structural requirements a particular area needs with the thickness increasing as you go from the sheer to the keel area 23 DECK AND HEADLINER Like the hull the deck is molded in a one piece mold as a single unit All exterior surfaces including the non skid are pigmented gel coat molded into the deck The deck is laid up wit
7. FU H WWWWW WW WWW CO CO WW CO CO CO H 3 OPERATION AND MAINTENANCE Fiberglass Steering Diesel Auxiliary Engine Electrical System Exhaust System Hand Starting Transmission Cooling Fuel System Shafting Stuffing Box Maintenance Winterization Electrical System D C 12 Volt System A C 110 Volt System Optional Bonding System Lightning Ground Through Hulls and Seacocks Freshwater System Head System 3 22 Scupper Drains 3 23 Bilge Pumps 3 24 Mast Step Reinforcement 3 25 Spars 3 26 Standing Rigging 3 27 Turnbuckles 3 28 Deck Hardware and Chainplates 3 29 Tuning the Standing Rigging 3 30 Running Rigging LO oo 1 OY O1 A OO JO gt WN N p3 pa pa pa pa pA 1 1 OY OY O1 UI Page 3 CHAPTER 4 COMM 4 1 Commissioning WWWWWWW WWW WWW CO CO CO CO CO CO H gt HS HS HS HS HS HS HOU CO PO ES Sails Reefing Optional Sails Bottom Paint Boot Top Paint Exterior Maintenance Cushion Ice Box Curtain Sinks Head General 5 5 Ports and Hatches Winterizing Safety Weather Forecasts Boating Safety Organizations Stoves 55 ON Interior Maintenance
8. HULL TO DECK JOINT When most of the major components of the interior have been installed the hull is made ready to receive the deck Built into the hull is an internal hull flange See the enclosed drawing for details of this assembly This internal flange is made up of the same layers of woven roving that form the topsides of the hull and also the added laminates for champlate reinforcement The deck is raised over the hull and the process of fitting the deck to the hull is begun All bulkheads are carefully scribed and cut until the deck rests on the hull flange The flange is then prepped and coated liberally with a special polyester bonding material and the deck bonded into place The joint is later screwed down in the case of the TY and C 22 and in all others thru bolted on 12 centers We feel our deck to hull joint to be one of the best for several reasons 1 The flange should be internal This gives the largest possible flange area important for flexural strength Also boats with external flanges are subject to damage and leakage when run hard into a dock or other immovable objects Impact in this area starts a crack that water 1s sure to find its way through under normal sailing conditions 2 Weuse a semi rigid bonding compound between the hull and the deck as well as through bolts Due to the abrupt angular discontinuity created at the hull deck intersection large forces can be built up while underway It is best to prevent m
9. Mack Boring Mack Boring Page 97 Seal 124240 91450 Mack Boring Fuel Nozzle 124770 53000 Mack Boring Thermostat 105582 49200 Mack Boring Westerbeke W 13 Westerbeke Zinc 2 11885 Westerbeke Oil Filter Element 30220 Westerbeke Fuel Filter Element 30200 Westerbeke O Ring 30705 Westerbeke O Ring 30201 Westerbeke Alternator Belt 30376 Westerbeke Fuel Filter Element 30548 Westerbeke Electric Fuel Pump Westerbeke Sea Water Pump Cover Gasket 24826 Westerbeke Sea Water Pump Impellor 11764 Westerbeke PORTS amp HATCHES Medium Hatch 139 medium Bomar Inc Small Hatch 139 small Bomar Inc Bronze Oval Ports P 560 Spartan Marine Bronze Round Ports Spartan Marine HEAD CD 25D 27 28 30 HE HTP Gross Mechanical HOT WATER HEATER Raritan Raritan Engineering Spare Parts Heating Element WHIA Raritan Engineering Safety Valve WH3 Raritan Engineering Heat Exchanger HE Raritan Engineering Thermostat WH2 Raritan Engineering PEDESTAL STEERING 5 Pedestal 335 Edson Corporation Chain Assembly 775 Edson Corporation 4 Upright Single Sheave 620 Edson Corporation 4 Swivel Idler 711 Edson Corporation 8 Quadrant CD 30 614 Edson Corporation 8 Offset Quadrant CD 27 28 677 Edson Corporation 1 Wire Take up Eye 618 Edson Corporation 3 16 Wire Rope Clamp 665 Edson Corporation 1 1 8 Self Aligning Bearing 629A Edson Corporation Size 45 Shift and Throttle 816 Edson Corporation Size 456 Brake 6897 Edson Corporation Size 45 Guard 662 Edson Corpo
10. OPTIONAL SAILS The first sail that you will probably want to add to the complement of working sails provided with your Cape Dory is a 150 genoa This sail provides more power and speed in lighter wind conditions and is particularly effective going to windward Cape Dory has genoa and genoa gear packages for all models We also have 150 genoas for the Typhoons CD 22 and C 25D If you choose to add a spinnaker or other sails to your inventory select your equipment carefully Your Cape Dory dealer will assist you in selecting suitable equipment and will make you aware of the optional sails and equipment that Cape Dory has available Due to a very low demand for the spinnaker gear Cape Dory cannot supply this gear other than the gear attached to the mast A popular sail which acts like a spinnaker and a reaching genoa is a flasher This sail is also known as a MPS Multy Purpose Spinnaker It does not require a spinnaker pole and is easier to set and trim than a spinnaker Most Cape Dory brochures show this sail Page 42 3 34 BOTTOM PAINT BOOT TOP PAINT Your Cape Dory was painted with anti fouling paint before it left the factory The area under the cradle poppets and keel supports may require additional painting prior to launching These areas should be well sanded with 120 grit paper and washed with solvent to remove wax prior to painting In certain geographical areas some bottom paints work much better than others If you intend to repaint
11. PORTS AND HATCHES The Spartan ports fitted on your yacht are made of bronze tempered glass and stainless steel A neoprene gasket bedded in a contact adhesive is used to seal the port Note Typhoon ports are non opening Page 44 The hinge pins and port knobs should receive a light periodic oiling to combat any build up of salt spray that may accumulate The glass may be cleaned with any non abrasive household glass cleaner Optional port screens are available which snap into place on the outside of the port Do not use strong solvents on the plastic portions of the screen Hatches made of Lexan material should not be cleaned with any solvent or abrasive cleaner The y y should be rinsed with warm water only and cleaned with an acrylic cleaner Other soaps and detergents will cause the Lexan to film over losing some of its clear qualities 3 40 CURTAINS Generally the curtains supplied have a content of 77 cotton and 23 acetate and therefore should be dry cleaned 3 41 SINKS Stainless steel sinks may be cleaned with any stainless steel cleaner according to the manufacturer s instructions or with a non abrasive cleaner and soft cloth or sponge 3 42 HEAD The plastic seat and vitreous china bowl of your head should be cleaned with non abrasive cleanser and sponge or soft cloth 3 43 INTERIOR WOOD SURFACES Rubbing the wood periodically with a fine bronze wool when oiling will help produce a smooth satin surface
12. a good grease available in your locality Automotive water pump grease or Lubriplate may be used Seacocks should be worked frequently to keep corrosion from forming causing them to jam To Disassemble Your Seacocks there is a locknut on the outer end of the shaft back it off and remove it Next back off the hexagonal end plate removing it completely from the shaft Then from the opposite end pull the shaft out of the housing Do not use a hammer or hard object to force the Page 30 shaft out of the barrel as you may damage the threads After you have cleaned off the old grease inside and out replaced it with new grease reverse the procedure and reassemble Be sure that you tighten the end plate tight enough so that the seacock will not leak but not too tight or the mechanism will not turn A thin layer of lubricant between the end plate and locknut will facilitate tearing down next season For obvious reasons this procedure is to be carried out while the boat is out of the water Your seacocks for the cockpit drain should almost always be left open Their primary function is to be able to shut off a flow of water should the drain hose burst or come disconnected Because these are the least used seacocks on the boat there is a tendency to forget that they are there DON T Work them frequently and service them annually so that they will work should an emergency arise Leave all seacocks open when the boat is stored for the winter so
13. an unchlorinated cleanser If the rusting persists after several cleanings contact your dealer Turnbuckles should be checked that there are sufficient threads exposed and that the cotter pins are in place and taped over The judicious use of a silicone type product on sail genoa and traveler tracks works well to keep these running free in a salt air environment Sheaves should be disassembled occasionally washed and well lubricated with a thin oil Check the spreaders to be certain that they are angled upward with the angle between the upper shroud and the top of the spreader the same as the angle formed by the bottom of the spreader and the shroud The spreader tip should be securely seized to the shroud and it all protected by chafing gear Page 47 Once a month you should go aloft and check all shrouds tangs masthead assembly etc to be certain all bolts are tight and all cotterpins are in place LIFELINES PULPITS AND STANCHIONS Lifelines like standing rigging should receive periodic checks The terminal ends should be engaged properly in the barrels of the tumbuckles and the lock nuts tight As the lines stretch the slack should be taken up Check all swaging for dents or cracks Check pulpits and stanchions for cracks dents and cracks in the weld Check that the bases are tight and properly sealed Periodically some of this stainless hardware shows signs of rusting as mentioned in the standing rigging section If af
14. common AC ground to the engine and is in turn tied into the boat s ground system This ground cable is a safety feature installed to avoid serious electrical shock hazards should a connection to a faulty dockside power source be made Under no circumstances should this cable be disconnected irrespective of claims that a certain amount of electrolysis could be created by the addition of this wire 3 17 BONDING SYSTEM All thru hulls and seacocks below the waterline including the stern tube are connected to one another to the engine block and to the external ground plate with a continuous loop of 18 copper wire This is done to minimize the effects of electrolysis should one fitting become hot for any reason Generally a fiberglass hull is considered to be non conducting and as such the chance of stray electrical currents forming is minimal Bonding system is standard on all diesel equipped Cape Dorys As more and more electrical equipment is added to a boat it becomes increasingly important to BE ALERT TO THE THREAT OF ELECTROLYSIS We recognize that there are various types of instrumentation available to further monitor strong currents and any potential difference between ground and the thru hulls These instruments can all be added to the supplied ground wire system It is highly recommended that a sacrificial zinc be installed on the shaft see shafting section 318 LIGHTNING GROUND SYSTEM Your Cape Dory is equipped with a lig
15. design and rode of good quality appropriate size and length 2 First aid kit 3 Compass Page 48 4 Paddle 5 Flashlight 6 Up to date charts of the waters to be sailed 7 Flares Fire extinguishers are not standard equipment on your Cape Dory they are to be provided by you the owner Fire aboard any boat is a real serious hazard It is important to take adequate precautions against fire and to be well prepared to extinguish one quickly and thoroughly should it occur For this reason U S Coast Guard approved fire extinguishers of the appropriate type and size check U S C G regulations should be installed immediately The permanent location of fire extinguishers where they are easily accessible near areas where fires most likely are to occur engine fuel tanks and galley is important They should not be located where fire may prevent their use At least one extinguisher in a cockpit locker reachable from outside the cabin and one extinguisher installed below is a minimum CHARTS There is no substitute for complete and up to date charts The Coast Guard is constantly making improvements on the aids to navigation which change buoy locations numbers configurations etc These changes are reported in the respective Coast Guard District s Local Notice to Mariners and are on display at all NOAA Chart Distributors Before embarking on any trip outside your home port make certain that you have the latest editions of t
16. for all these engines vary but in general should a starting problem occur first check the overload fuse in the starting circuit The Volvo MD7B has an 1 1 4 square fuse box on the instrument panel which houses a four position fuse The Yanmar is supplied with dual fuses on the engine The Westerbeke has a 20 amp circuit breaker on the engine to supply the protective requirements Other than this another problem that can occur is a faulty ignition switch not making proper contact This and other problems should be corrected by a reputable serviceman or authorized dealer The engine owner s service manual that is supplied with each boat carefully outlines many of the electrical features included in the engine As with all vendor supplied equipment used in the boat a thorough review of the service manual contents of each piece will insure a better knowledge of the correct usage maintenance and repair methods required 3 5 EXHAUST SYSTEM The exhaust gases enter a waterlock muffler on the aft side of the engine Here they are mixed with the cooling water and forced out the transom Little maintenance of this system is required It is recommended that every time the engine is started you look over the transom to see if the cooling water is coming out with the exhaust If it isn t not only will the engine block overheat but the exhaust system will overheat as well The routing of the exhaust hose should not be changed or problems may develop Fo
17. for the degree of protection required in your Page 26 locale If the antifreeze system is used it is mandatory to remove the thermostat to insure that water enters all areas of the block 3 14 ELECTRICAL SYSTEM Some Cape Dory yachts are equipped with a comprehensive electrical system designed to meet your present and future needs The A C alternating current Shore Power and D C Direct Current Ship s Power wiring is plastic coated stranded copper wire with crimped on connectors or soldered joints as required The electrical system is basically maintenance free with only the batteries requiring periodic inspection 3 15 D C 12 VOLT SYSTEM The D C system is powered by 12 volt 75 amp hour batteries located in the cockpit seat lockers They are enclosed in an impact resistant noncorroding plastic case which is firmly attached to the hull All Cape Dory yachts use standard negative ground system which must be considered when purchasing and installing additional equipment The batteries are controlled by means of the BATTERY SELECTOR SWITCH located on the bottom of the D C POWER PANEL which is in the companionway area This switch acts as a master disconnect as well as a selector for battery 1 battery 2 or batteries 1 and 2 together Commonly one battery is reserved for engine starting duty while the second battery supplies all other needs Battery switch is standard on 25D and above CAUTION NEVER TURN THE BATTERY SWI
18. list so that the Cape Dory owner will be able to go directly to the original vendor for replacement parts but we still want you to feel free to call us here at the factory for any additional information ITEM DESCRIPTION BLOCKS Genoa Blocks TY Genoa Blocks CD 22 Genoa Blocks CD 27 28 30 BOTTOM PAINT Antifouling Blue or Brown Boot Top Dado Dark Brown Boot Top Seminole Red ELECTRICAL Battery 12 volts 75 amps Dome Lights bulb 12v15cp Single Swivel bulb GE1142 Double Swivel bulb G51142 8 watt florescent GEFT5 CW Panel Port amp Starboard Lights Stern Light bulb 12v10w Mast Light G5212 amp 12v6w ENGINE CD28 30 Volvo MD7 B Water Pump Impeller Fuel Filter Oil Filter Alternator Alternator Belt Yanmar 1GM Lube Oil Filter Fuel Oil Filter Zinc Belt Impeller Seal MANUFACTURER S PART 02 72 03 72 07 83 Epoxy Cap 246 593 5124M 10 1252 10 2162 10 1872 10 1872 11790 875583 243464 834337 841380 958327 134450 35100 104500 55710 27210 200200 128170 77350 128170 42070 128170 42110 VENDOR Schaefer Marine Schaefer Marine Schaefer Marine Rule Industries Interlux Gloucester Paints Bay State Battery Bass Products Bass Products Bass Products Bass Products Lorco Marine Ahlemann amp Schlatter Gem Spartan Marine Dipetro Kay Dipetro Kay Dipetro Kay Dipetro Kay Dipetro Kay Dipetro Kay Mack Boring Mack Boring Mack Boring Mack Boring Mack Boring
19. lt 4 the compass A Fig 672 Rubber Connector will assist in removing the compass Instruments be removed by the screws in the Edson faceplate Just unplug the instrument and you are set CAUTION When the equipment is im the tropics or in charter service the maintenance schedule must be speeded up Or to put it few words clean it up oil inspect cover The effects of sun saltwater and inexperienced operators be severe LUBRICATION RECORD 225 398 ver Crech and Of ty ole 230 Check pi Tatton Fig 627 grease beige 4 018807 are Bo A ONAL 146 QUCHAINE ALVO NEW BEDFORD 07745 1797 TEL 08 995 87 1 1 FAX 508 5 508 ete gene any zul td Werecomeqnt 930 egi molo LE mow Sos Nave id CAUTION 1 pwenoeo voyages INEM OM ce 047 S Ort sted ween ADEL yos 6 ong were 2 When ine boat min Ire Drake oF aare rt SIOP 10 2940 damage Page 55 EN PEDESTAL STEERING ASSEMBLY As a further service to our customers we have an illus trated parts breakdown
20. of the rig The chainplates were torqued at the factory and when recaulking them you should not exceed the torques listed below 1 2 bolts 200 inch pounds 3 8 bolts 150 inch pounds 5 16 bolts 90 inch pounds 3 29 TUNING THE STANDING RIGGING The purpose of tuning the rig is to adjust the center of effort of the sail plan fore or aft to obtain a slight weather helm in moderate winds and to keep it straight without hooks to port starboard fore or aft Properly tuning the rig is an important process which should be attempted only by qualified personnel consult your Cape Dory dealer The fore and aft alignment of your mast can be checked by comparing it to a vertical structure such as a radio tower chimney etc Before checking the mast alignment in this manner be certain that the boat is resting on her design waterline If the mast is leaning fore or aft ease the turnbuckle toward which the mast is leaning a few turns and take up a corresponding number of turns of the opposite turnbuckle Note when adjusting turnbuckles never use excessive force or the turnbuckle may be contorted Always prevent the upper threaded turnbuckle stud from turning The Cape Dory 30 ketch has a split backstay with two turnbuckles Headstays and backstays should never be taken up so tightly that they will not give an inch or so if you pull on them with moderate force Upper shrouds should also
21. operation Remember alcohol fires can be extinguished with water or Type B fire extinguishers Kerosene fires must be extinguished by smothering or with Type B extinguishers The following precautions refer to all types of stoves Refer to the owner s manual for specific instructions 1 Never leave lighted stove unattended 2 Never leave a stove while it is still hot Remember alcohol can burn with an almost invisible flame 3 Always release pressure in the fuel tank when leaving 4 Close fuel valve if applicable in case of emergency 5 Exercise caution when priming burners Improper priming is one of the most common causes of galley fires Page 51 CHAPTER 4 GENERAL INFORMATION 41 COMMISSIONING Cape Dory dealers are chosen because they are knowledgeable professionals Since you are bearing the launching and commissioning expenses of your new yacht you have the right to expect a thorough and professional job Please note that the checklist provided in this manual is to assist you and your dealer with the first launching of your boat In subsequent years you may wish to review this list in preparing your boat for launching Before your boat is launched we strongly recommend that you read the entire manual In particular read and become familiar with the DEALER S COMMISSIONING CHECKLIST as this is really a step by step set of instructions for launching your yacht WARRANTY 42 WARRANTY NOTIFICATION PROCEDURES Cap
22. please provide the dealer or Cape Dory with your hull number and an accurate description of the part Situations may arise when we will be referring you to local marine stores or marine hardware manufacturers Our intent in these cases is to provide you with the fastest and least expensive service Through our customer service department we strive to maintain our reputation for product quality and excellent service Sincerely Eric J Brehm Karla J Johnson Customer Service Department Page 9 CAPE DORY OWNER S RECORD Complete and save this form for your records and future reference Yacht Name Home Port Hull Identification Number Dealer Name Address Salesman Delivery Date Date Commissioning Checklist Warranty returned to CDY ck ck ch GB Owner s Name Address State Registration Documentation Engine Model and Serial Number Head Model and Serial Number Stove Model Number and Serial Number Spar Number Rigging Kit Number Your Cape Dory is identified by a hull identification number HIN on the starboard corner of the transom This identifies the number of the hull and supplies goverment officials with additional information concerning the builder and the year of manufacture There is also a builder s plate with the hull number In addition there are serial numbers on your boat s engine see the engine manufacturer s owner s
23. sheave assembly into one integrated unit This is fastened in place by the four pedestal bolts The quadrant stop limits the swing of the rudder to about 35 degrees port and starboard This is especially useful when motoring in reverse as the rudder would tend to swing completely to one side with great force resulting in possible damage to either the hull or steering system During installation we have replaced many of the vendor supplied nuts with self locking nuts as we have found they will otherwise loosen during road transit engine vibration and general use It is imperative that the owner take the initiative to inspect the steering system for proper wire tension wire alignment and fastener tension during the sailing season Periodic maintenance is also required on all moving parts In particular the lubrication of the bronze sheaves is critical to the smooth operation of the steering unit The keyway that is cut into the rudder shaft is purposely cut a little long to accept an attachment for a number of automatic pilot systems This saves a very costly alteration from having to be performed in the field were another keyway to be cut and eliminates the need to bolt something to the shaft which would tend to weaken it The head of the rudder shaft above the pillow block bearing has been keyed to accept an emergency tiller Access for this is gained by removing the bronze deck plate in the cockpit sole Should anything ever happen to your
24. should drip water slowly approximately one drop every ten seconds while running to insure that the bearing and packing gland are lubricated by water Check battery switch and electrical system operation Check battery electrolyte and charge level Check head operation Check bilge pump operation ENGINE START UP CHECKLIST CD 22D 25D 27 28 amp 30 only Check engine and transmission oil level and condition Check belt tension on all belt driven components Check that cooling water intake seacock is open Check to see that all clamps on exhaust hose are tight on Yanmar engines make sure that exhaust hose enters waterlock at location marked IN Check engine mount nuts for tightness Check shift and throttle cable connections Check shift and throttle cable operation While coupling is disconnected check prop shaft alignment using feeler gauges 27 28 29 30 31 32 33 34 35 36 37 38 39 40 13 Check prop shaft set screws and see that they are wired in place Start engine according to the manufacturer s recommendations Failure to start may be due to air in the fuel lines Refer to manual for bleeding instructions Immediately after engine starts check to see that water is coming out of the transom exhaust port Check gauges and or warning lights Check entire system for water oil fuel o
25. stem engine controls or pedestal accessories be i hecked regularly tor hghiness and wear Failure to inspect all steering parts engine controls and pedestal accessories may cause of con trol of failure of the engine or steering system boots must houe an estergearv hiller or As equi and board must be famibar wath karma ond operation An emergency drill i just important ertugrd dri and regular ty conducted On a new boat and least once year inspect the system when under strong inad calm day and under power go away trom the boats and wiih the person whe is the maintenance watching put the wheel hard over at lull theettie The maintename man should watch carefully for all parts of the system bending dertig creaking giving any wrd al on of failing placed under heavy load lor period of time for any reason something did tail or weeds adjusting he day is carty and you will have plenty of time When leaving your boat at her mooring or slip make sure that your wheel is property med off DO NOT LEAVE THE STEERING SYSTEM FREE WHEEL Quadrant System Compasses and instruments Most manufacturers of compasses electronic instruments suggest that they all be removed during ne in warm dry area are normally in place by wu or three slotted head screws placed near the top
26. step structure Overtightening the tumbuckles is not necessary and can be dangerous The mast on the Cape Dory 25 Diesel is also stepped on deck however this boat is fitted with a mast compression tube to direct the load to the ballast and safely distribute it through the hull The aluminum compression tube is fitted with a machined aluminum end cap The mast step sits flush on the end cap and is bolted through an aluminum back up plate The bottom end of the tube is set in a putty of polyester and microspheres on the lead keel 3 25 SPARS Masts booms and jib clubs on all Cape Dory yachts are made of high grade extruded aluminum All Spars are anodized but unfortunately anodizing is a semi permanent process but still the best means of protecting aluminum After several years of hard exposure to salt spray and sun the protective virtues may diminish and a protective paint or film may be applied to the mast However anodized spars have been used for many years untreated with no apparent harm As a general rule aluminum masts require minimal care and maintenance When they are removed from the boat for the winter they should be thoroughly washed with plenty of fresh water and a mild detergent After a complete rinsing with fresh water and after all halyards and lifts have been neatly tied off to prevent tangling and fouling a thorough inspection should commence Start at the base of the mast Water will collect here if the drain hole in the m
27. tank having its own shut off valve Only one valve should be open at a time to avoid water from one tank siphoning to the other while sailing If water is left standing in tanks for an extended period of time it may adopt an unappetizing odor and appearance If flushing the tank does not eliminate this problem a mild solution of baking soda may be used After letting the baking soda stand for several hours the tank and water system should be flushed thoroughly before refilling with fresh water Cape Dory water tanks are constructed of polypropylene If too much water pressure is used when filling the tank it may burst or crack To eliminate this possibility the 3 access covers should be opened while filling This also allows you to see when the tanks are full Care must also be taken not to overtighten the access cover Page 31 PUMPS The hand and foot operated fresh water pumps located in the galley and head areas are self priming If a pump fails to operate check first to be certain that there is water in the tank and then to see if the hose is kinked or being constricted by some heavy object If the hose is clear and the pump still fails to operate disassemble the pump and inspect the operation of the internal check valve PRESSURE WATER SYSTEM Your yacht may be equipped with an automatic demand type fresh water system In use it is quite similar to a typical home water system in that no switches need be turned or pedals pushed in or
28. the bottom of your Cape Dory seek the advice of your dealer or knowledgeable local boat owners on what brand of bottom paint works well in your area CAUTION Not all bottom paints are chemically compatible Be sure to tell paint dealer what paint is currently on the bottom of your boat to be certain that you purchase compatible anti fouling paint The boot top paint is INTERLUX DADO BROWN 246 When repainting this area should be well sanded before applying a new coat 3 35 EXTERIOR MAINTENANCE SPAR It goes without saying that removing the spar and storing it inside after the sailing season is over northern climates only is preferable to leaving the spar stepped or outside Regardless of where you sail the spar should be waxed once a season and inspected carefully All moving parts on the spar were treated with a Teflon lubricant when they were installed At least once a season you should do the same Blocks require little maintenance except periodic washing in fresh water and a light oiling or spraying with a silicone lubricant Check all aluminum T tracks for signs of lifting or loose fasteners MAINTAINING TEAK Teak above deck on Cape Dory yachts has been sanded and oiled to a full golden hue before it leaves the assembly area As it gets exposed to sunlight and drying conditions the woods begin to take on a gray appearance that will eventually lead to surface deterioration of the wood Teak which is ignored will eventuall
29. there is no freezing damage The other seacocks should normally be left in the closed position when you leave the boat Be sure that you establish a routine of opening and closing seacocks so that you don t overheat your engine or burst hoses in the head Since the head bowl is near the waterline particular attention should be paid to the seacocks that serve the head They should be shut off anytime you are asleep or off the boat A malfunction in the head or leaving the head intake valve open could cause the boat to flood or sink if undetected Simply closing the seacocks eliminates this hazard Set up a routine to do this all the time 3 20 FRESH WATER SYSTEM FRESH WATER TANKS The CD 22 and CD 27 are equipped with a 24 gallon polypropylene bow tank located under the v berth The water fill for the bow tank is located under the v berth cushions A vent overflow hose is installed and terminated under the deck edge in the fore peak Water is fed from these tanks to manual pump s at the sinks through PVC hose The CD 25D has its tank located under the quarter berth The CD 27 has an additional tank under the port main cabin bunk On the CD 28 and CD 30 there are two 30 gallon water tanks located under the main cabin bunks The deck mounted water fill is tee d to supply both tanks Each tank is vented aft up under the deck edge Water is fed from these tanks to manual pumps at the sinks through PVC hose A manifold joins the two tanks with each
30. 558 Northwest Controls Parr Jabsco Products Now ITT Jabsco Raritan Engineering Co Schaefer Marine Products Spartan Marine Hardware Rule Industries Owned by ITT Jabsco Westerbeke Vernfield Village 1485 Dale Way P O Box 2158 714 545 8251 530 Orange Street 954 525 0378 Industrial Park 158 Duchaine Blvd 508 995 9911 HC 33 Box 1460 1 800 325 3287 Cape Ann Industrial Park 978 281 0440 41 Ledin Drive 508 588 7700 Harleysville PA Costa Mesa CA Millville NJ New Bedford MA Georgetown ME Gloucester MA Avon MA 19438 92628 08332 02745 04548 01930 02322 Page 100
31. 6 31 6 11 0 11 6 13737 3 12 6 1370 3 4 flat 3 4 flat 3 4 flat 1 2 barrel 1 2 barrel 1 2 barrel 4 4 4 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA Page 93 CD 30K 30 2 1 2 22 10 32 2 1 2 9 0 42 10 000 4000 434 33 9 30 0 12 0 11 0 3 4 flat 1 2 barrel 4 T 0 19 0 2 1 2 1 2 barrel 1 2 barrel Forestay W Backstay W Uppers W Lowers W Main Halyard P Jib Halyard P Main Sheet D Jib Sheet D Genoa Sheet D Topping Lift D Spinnaker Halyard D Spinnaker Sheets D STANDING AND RUNNING RIGGING TYD 1 8 2376 1 8 25 1 8 2279 1 8x12 5 16 50 5 16 50 5 16 40 5 16x26 5 16 20 1 4x45 5 16x45 5 16 30 Key 1 19 Stainless Steel Wire P Prestretched Dacron D Braided Dacron Note All wire lengths are approximate TYW 1 8 2078 1 8 27 1 8 2172 1 8x11 5 5 16x56 5 16 48 5 16 40 5 16 32 5 16 20 1 4x45 5 16 40 5 16 30 CD 22 3 16x28 10 3 16 3075 3 16 2871 5 32x15 2 3 8 60 3 8 60 3 8 50 3 8 50 3 8 30 1 4 50 3 8 60 3 8 357 Page 94 C 25D 3 16 3275 3 16 3475 3 16 3177 5 32 17 2 3 8 70 3 8x73 7 16x66 7 16x50 7 16x35 1 4 60 3 8 73
32. AN Page 88 5 35 CD 27 SAIL PLAN Page 89 Page 90 5 37 CD 30C SAIL PLAN m uw mm m Ww QE Qo Un Page 91 5 38 CD 30K SAIL PLAN L O A L W L Beam Draft Displacement Lbs Ballast Lbs Sail Area Sq Ft w 100 foretriangle I J E Main Luff Slug Size Main Foot Slug Size Main Tack Cut Back TECHNICAL INFORMATION TYD TYW CD 22 18 6 18 6 22 4 13 6 13 11 16 3 6 3 1 2 6 3 d 3 0 1900 2000 3200 900 900 1400 157 155 240 22 47 19 1 287 0 20 0 22 0 24 0 70 6 2 970 870 879 9 6 1 2 Barrel 1 2 Barrel 1 2 Barrel 1 2 Barrel 1 2 Barrel 1 2 Barrel 2 1 2 2 1 2 2 1 2 Page 92 CD 25D 25 0 19 0 870 3 6 5120 2050 304 32 0 29 5 107 3 107 3 1 2 Barrel 1 2 Barrel 1 1 2 L O A L W L L O A w Bowsprit Beam Draft Displacement Lbs Ballast Lbs Sail Area Sq Ft w 100 fore triangle I J E Main Luff Slug Size Main Foot Slug Size Main Tack Cut Back E Y P Y Mizzen Tack Cut Back Mizzen Luff Slug Size Mizzen Foot Slug Size TECHNICAL INFORMATION CD 27 CD 28 CD 30C 2T P 28 1 1 4 30 2 1 2 20 0 22 2 1 2 22 10 N A 29 6 3 4 32 2 1 2 8 6 8 10 1 2 9 0 4 0 4 0 42 7500 9000 10 000 3000 3500 4000 354 400 437 34 0 33 3 35 0 29298 31
33. ER PANEL is in the off position when connecting the shore power cord IMMEDIATELY after connecting the shore power cable check the 110 pilot light If it is on and the main breaker off this indicates a live circuit from the shore power receptacle Next check the reverse polarity indicator light If it is on disconnect the shore power cable IMMEDIATELY and determine Page 28 the source of the problem as serious electrical shock hazards may exist to persons on board or along side your yacht even if the main circuit breaker is off The ship s wiring has been thoroughly checked and is of the proper polarity when it leaves the factory If the system has not been altered the reverse polarity condition is in the shore side system and should be brought to the attention of the system operator If the reverse polarity light does not come on the system is safe to operate Turn on the MAIN CIRCUIT BREAKER at the top of the panel and then select whichever branch circuit is needed CAUTION Before turning on the hot water heater insure that the tank is full of water Permanent damage will result from operating the heater with an empty or partially full tank To check that it is full simply open the hot water tap on the pressure water system and watch for continuous water flow On each Cape Dory that has been fitted out with a factory installed 110 volt AC system we have included or added a 8 green coated copper wire as a ground This wire is led from the
34. ION CD 22 27 28 30 7 MIOIVAS TVOIdAL 915 ane H Page 70 2 18 114 TTI LTS Page 71 W31SAS SNISW1d 12 09 1315 45 092 09 5 19 CD 28 30 PLUMBING LAYOUT Page 72 Page 73 1300W v v S3INYA SIATWA 012971209 WALVM dun SS dud gt lt N ERA TY W31SAS 38055384 JLLVW3HOS 38 1553 4 025 Page 74 JOUVHISIO QHVOGH3AO WOM4 W31SAS ONIGTOH 814 TVNOLLAO M ONISIN 1d IT S Page 75 J N EN ER s 202 35 N ANVL 39H VHOSIG AA TVA TVNOLLdO M 4 CCS Page 76 5 23 TYPHOON SPAR DETAILS Page 77 5 24 GENERAL SPAR DETAILS CD 22 260 27 30 Page 78 5 25 SHEET REEFING DETAILS 30 KETCH MAINSHET AND CD 30 amp CUTTER CLUB JIB Page 79 5 26 TYPICAL CHAINPLATE DECK FLANGE SHELF MOLDED INTO HULL RUBSTRAKE V METAL LIGHTNING GROUND WIRE GLASS amp FIBER REINFORCEMENT OVER STEEL Page 80 5 27 TYPICAL CHAINPLATE TURNBUCKLE MANGA
35. KID IMPERFECTIONS Repair of the non skid is similar to that of deep imperfections only that you add trace amounts of non skid grit and dab the gel coat on with the end of a brush with short hand movements GELCOAT BLISTERS Below the water line it is possible for water to get beneath the gelcoat and cause it to blister This occurrence is rare and usually takes the form of small blisters less than 1 4 in diameter While we try to use the latest materials and techniques in combating this phenomenon it is not within our ability to guarantee this never happening due to the very nature of the materials used If you should find yourself with a serious case of the measles contact the factory for the latest recommended repair practices and advice The successful repair is difficult and time consuming and the services of an expert repair facility is advised To minimize the potential of blisters ever forming on your bottom this advice is offered Never sand your bottom gelcoat off Do not use pumice stones or a coarse sandpaper when preparing your bottom for new bottom paint This only deeply scratches the gelcoat surface which increases the chance for water to pass into the laminate Gelcoat is a water proof barrier coating required to protect your boat s laminate not merely a cosmetic coating The continued use of an epoxy based bottom paint is recommended 32 STEERING The rudder post on all tiller steered Cape Dory yachts extends well ab
36. Many excellent teak oils are available as well as other household products such as Liquid Gold Some finishes in a wax base such as the Minwax products Repeated use of this type product builds up a finish that produces a very smooth surface Care should be exercised however when using these products as oiling or varnishing at a later date may not be possible due to the layer of wax that has accumulated Make sure that adequate ventilation is provided when it is called for by a product s manufacturer Page 45 344 GENERAL Dirt hair etc should not be washed Into the bilge during any cleaning process as these may plug the bilge pump strainer and prevent it from functioning when needed Use a dust pan to collect dirt etc when cleaning the cabin sole of your boat Raise covers of lockers when leaving the boat to permit adequate ventilation and prevent mildew should these contain moisture Remove excess moisture which may have collected in lockers with a sponge 3 45 WINTERIZING Winterizing your yacht is a relatively simple procedure We are assuming that the boat will be dry stored in the following instructions If you should decide to wet store your boat be sure to take adequate precautions against water freezing in the engine and plumbing systems on your boat BLOCKING THE HULL A good boat yard is no doubt expert at properly supporting the hull Check to make sure that the weight of the hull is resting on the kee
37. NESE BRONZE CHAINPLATE CASTING M d ANN y m 8 BALSA CORE AN DECK MOLDING DECK FLANGE SHELF MOLDED INTO HULL 4 ALUMINUM REINFORCEMENT TWO BOLTS W LOCKING NUTS LIGHTNING GROUND WIRE UNIDIRECTIONAL FIBERGLASS Page 81 QUICK REEFING As ihe modern offshore racing yacht rapidly becomes sophisticated and offshore racing tisalf becomes more challenging hardware and sail handling systems are tefined and developed to make yachts faster and easier to operate Perhaps the most importanti development in the area of sail handling has been Quick Reefing Time was when the call to reef meant a sacrifice of speed time and lots of crew men on deck Quick Reefing has changed ail this It s very fast requires faw hands and retains proper sail shape Although sophisticated refinements have been developed the basic system is simple and effective Installation con version is easy and the benefits of this fine system ate to racer cruiser alike known as California Reefing Stab Reefing or Jiffy Reefing halyard tidhtanea 2 the reef tack downhad A IE tiga Note Tha hialrikhest hoild uf teat tightened until the reef cingle only if necessary With practic 19 d
38. OWNERS MANUAL Page 2 FOREWORD AND DISCLAIMER This is a modified version of the Cape Dory Owner s Manual included with 1981 vintage Cape Dory sailboats built by Cape Dory Yachts Inc a company that ceased operations in 1991 It is offered here for the use of those seeking a replacement manual for a Cape Dory Typhoon Typhoon Weekender CD 22 CD 25 CD 25D CD 27 CD 28 CD 30 CD 30K or for any sailboat owner who might benefit from the useful information it contains on general sailboat maintenance and repair It is not suggested that it be relied on implicitly but that it act as a supplement to other sources of information currently available References to people companies and products mentioned within the Manual may now be obsolete there is no longer a factory or Cape Dory Service Department to contact for support as the Manual states no Dealers no newsletter etc Also it should be kept in mind that the information in this Manual may be not only dated but may contain inaccuracies or omissions and that neither I nor anyone connected with the original Manual shall be held liable for any losses injuries or damages arising from its use It was written as a guide for the owners of Cape Dorys specifically and its application and suitability for use with other types of boats is not expressed or implied Further it is meant to be distributed freely and not to be used for profit All trademarks logos products and bus
39. TCH TO THE OFF POSITION WHILE THE ENGINE IS RUNNING SERIOUS DAMAGE TO THE ALTERNATOR WILL RESULT The level of charge of the batteries may be checked with a BATTERY CONDITION METER located in the center of the D C POWER PANEL The level of charge of the battery alternator output state of the voltage regulator and power draw to services can all be checked with the use of the DC voltmeter supplied on the 12 volt power panel A voltmeter gauge is located on the engine instrument panel Your voltmeter will indicate differently depending on when the readings are taken Here are a few simple guidelines Fully charged batteries that are in a static state should read between 12 3 12 6 volts on the numerical scale and just barely be touching the high end of the yellow band on the colored dial of a gauge The term static means that the battery hasn t been charged or discharged for at least two hours If the pointer is in the yellow or red low band on a gauge or reads between 11 11 5 volts on a voltmeter then the battery is about half discharged and should be charged to insure its usefulness If the engine is started and the needle does not move up this would indicate that no charge is being delivered to the battery When the battery is being charged the pointer should be between 12 6 13 volts which is approximately the center of the green band on gauge types The pointer may move up to about the 13 7 volt range the high end of the green band
40. ailing upwind in moderate conditions CHECK TO SEE THAT ALL COTTER PINS OR RINGS ARE IN PLACE AND THAT ALL SHARP EDGES ARE TAPED Rigging that has split strands of wire or cracked swage fittings should be discarded and replaced 3 30 RUNNING RIGGING Because of the recent advances made with pre stretched Dacron line and the age old problem of fish hooks forming in stainless halyards after one season of use your boat is equipped with pre stretched halyards They have gone around the world and received acclaim from almost every notable offshore cruising man Periodic inspection of the running rigging will point out any areas excessive chafe Often the offending item causing the chafe can be corrected Otherwise one way to extend the life of the rigging is to either end for end it or move the shackled end of it up a foot or so every year to move the point of wear away from the sheave winch turning block etc Only experience will dictate when they need replacement Drawings are included to illustrate the correct reeving to the mainsheets for all boats and the club jib sheets on the 28 and 30 Swapping sheets end for end will extend the useful life of a sheet that has started to chafe where it passes a sheave or engages a cam cleat 3 31 SAILS Sails should be protected from chafe by padding spreaders and other gear or by installing chafe patches on the sails themselves Spreaders and shrouds can chafe genoas and other overlapping jibs when
41. an t be guaranteed Ed Ahlemann amp Schlatter Browning Marine Bass Products Bay State Battery C E Beckman Bomar Owned by Pompanette Dipetro Kay Corp Edson Corporation Essex Machine Works Gem Products Gloucester Paints Gross Mechanical Lab Imtra Corp International Paint Co Now Interlux Courtaulds Coatings Inc Lewmar Marine Lorco Marine Electric Reported to be defunct Mack Boring amp Parts Co Merriman Holbrook Nicro Fico Marinco P O Box 806 50 Grove Street 978 744 7003 70 Shawmut Road 11 35 Commercial St 508 994 9674 P O Box W 603 826 5791 914 Cromwell Avenue 146 Duchaine Blvd 508 995 9711 50 West Avenue 860 767 8285 140 Industrial Blvd 904 264 0173 P O Box 860 7240 Standard Drive 410 712 4242 30 Samuel Barnet Blvd 508 995 7000 2270 Morris 1 800 INTERLUX New Whitfield Street 1 800 362 7212 715 Perimeter Road 2365 US HWY 22W 908 964 0700 301 River Street 2655 Napa Valley Corp Drive St Charles IL Salem MA Canton MA New Bedford MA Charlestown NH Rocky Hill CT New Bedford MA Essex CT Orange Park FL Gloucester MA Hanover MD New Bedford MA Union NJ Guilford CT Manchester NH Union NJ Grand River OH Napa CA 60174 01917 02021 02740 03603 06067 02745 06426 32073 01930 21076 02155 07083 06437 03032 07063 44045 94
42. ast step has not been kept clear This may hasten the breakdown of the anodizing and start the corrosion process If water has collected and caused corrosion clear the mast step drain hole and refinish the mast base or heel Waxing will help preserve anodizing Proceed up the mast noting any areas that are scratched or abraded If these are small they may be covered with a clear lacquer of a Mast Kote type product to keep corrosion from starting or spreading Sometimes it 15 recommended that you apply to the mast a good hard wax as this helps to protect it further As you proceed up the mast check every cleat and fitting for tightness and for corrosion which may have begun in the screw holes Make certain that no bronze brass or iron fastenings are used on the aluminum as the two metals are incompatible and electrolytical decomposition will start at once Check the tang fittings of the lower shrouds and the base mounts of the spreaders as you proceed up the mast Carefully check all tangs straps and fittings at the masthead Examine the main and jib halyard sheaves for signs of wear or needed maintenance If you see anything that looks at all unusual ask your dealer or local boatyard for assistance Booms and jib clubs should be inspected as carefully with particular attention to gooseneck fittings sheet blocks and bails The combination bow and stern light should also be checked It is good practice to change the bulbs every year as a mid sea
43. be tightened equally and have about an inch of give to them Forward lower shrouds should have one to two inches of give and the aft lowers slightly more UNDER NO CIRCUMSTANCES TAKE UP THE RIGGING TO BAR TIGHT TENSION Both the mast and the boat can be severely damaged by excessive tension Fine tuning of the rig can be completed after the boat has been sailed and may have to be done again after the boat has been out in strong winds When sailing it is important that the mast remain straight and as nearly in column as possible at all times While sailing close hauled sight up the mast track and note any mast curve Does the mast appear to be falling off to leeward at the top or does it hook upwind Repeat this procedure on the opposite tack If the masthead is falling off on both tacks the forward lower shrouds are too tight and the upper shrouds are too loose If the masthead hooks to windward the upper shroud is too tight in relation to the lower on the same side When sailing to windward the forward lower shrouds bear a greater load than the after lower shrouds however the after lower shrouds on the windward side should never be Page 39 loose All shroud tuning should be done from the leeward side If the rig seems to be equally balanced when you begin duplicate every half turn from side to side On Cape Dory boats with bowsprits try to keep the bowsprit straight and not bowed up or down This should be checked while s
44. cated on deck from which your marina can pump out the tank All tanks have a 3 access cover on the top for inspection and clean out The use of deodorizing chemicals as sold for recirculating toilet systems is recommended to control odor The tank and head should be winterized by cleaning and treating them with a Winterguard type antifreeze Winterguard is a non toxic antifreeze which can also be used to winterize your fresh water systems In certain sailing waters where pump out facilities are not available it may be necessary to install onboard holding tank pump out equipment We recommend a 1 1 2 hose tee be placed in the line from the tank to the deck fitting and that a pump be installed from this tee The pump can either be a WHALE GUSHER GP 10 manual diaphragm pump WHALE URCHIN manual diaphragm pump or an electric JABSCO MACERATOR pump model 17260 0003 The discharge from the pump can either be lead to a seacock or a hose for dockside tanks Discharge outside the territorial waters of the United States is permissible as long as this system is valved closed when inside the territorial waters Please refer to the latest regulations for your area to determine which system is best for your boat A vented loop is recommended in all head discharge lines that lead overboard See the drawings for details of head plumbing systems Page 33 3 22 SCUPPER DRAINS The cockpit scupper drains on your Cape Dory use multi ply wire reinforced hose
45. chts is a traditional one which has proven itself over many years of use and thousands of miles of cruising The long keel with attached rudder hull configuration combined with a generous but not bulbous beam provides stiffness and longitudinal stability it also provides protection for the rudder propeller and propeller shaft Our sail plans are not as lofty as those used on more race oriented designs of similar size Instead of high aspect ratio main sails Cape Dory has continued with what it considers to be a more sensible cruising sail plan This means that a smaller head sail is needed that a family or few crew can handle a Cape Dory and that the stresses on the rig and boat are less than those on high aspect ratio rigged boats under identical conditions The interior layouts of Cape Dory yachts are designed to provide comfortable accommodations for a reasonably sized crew on boats of their size This manual consists of three main parts First is a discussion of the construction of your Cape Dory next follows an operation and maintenance section divided up by systems Following this is a general section containing miscellaneous additional data and drawings Page 11 DEALER S COMMISSIONING CHECKLIST Model Hull Number Owner s Name and Address Dealer Date Sold Date Launched Indicates further information and or drawings elsewhere in manual 1 1 Date Initials 1 1 2 Recei
46. cracks sometimes develop after water has entered the body of the fitting by following the lay of the wire causing the wire to corrode and expand Although this problem is more prevalent in the southern latitudes many owners Seal the space between the wire and swages with bees wax Turnbuckle boots are also quite popular but are not recommended by Cape Dory as they cover turnbuckles which should be inspected frequently We DO NOT recommend oiling or greasing the swage fittings as a means of preventing water from running inside them Report to your dealer any fittings that you find to be defective Wire and fittings with any of the following defects require replacement kinked wire wire with broken strands cracked swage fittings bent turnbuckles turnbuckles with stripped threads clevis pins with grooves worn in them and tangs or other fittings with distorted holes The existence of any of the aforementioned conditions should be investigated the reasons for them determined and corrective action taken Page 36 After completing the above inspections the mast may be stepped and the standing rigging secured to the chainplates In all Cape Dory yachts the upper shrouds are attached to the chainplate in a direct line ATHWART to port and starboard of the mast step Lower shrouds are attached fore and aft of the upper The single lower shroud on the Typhoon Weekender is attached aft All running rigging on Cape Dory yachts is Dacron It requires onl
47. der to get water The system is activated by a circuit breaker on the D C Panel Once the system is switched the pump maintains a pre set pressure at all times When you open one of the faucets the slight decrease in pressure which results is sensed by the pressure regulator built into the pump The pump starts and runs until the faucet is shut The pressure then builds back up and the regulator shuts off the pump Several water tanks feed the system and all are connected through the water system manifold The tanks enter from above and each is fitted with a bronze shut off valve Note only one valve at a time should be open to prevent the syphoning of water between the port and starboard tanks in extreme conditions and to prevent air from entering the system from empty tanks Coming off one side of the manifold through a valve is the line leading to the manual backup galley pump This pump is intended for use only when there is a power loss or mechanical difficulty with the electric pump The valve at the manifold should be kept closed when the pressure pump is being used so that the electrical pump won t try to take its suction back through the hand pump and introduce air into the system and or damage the backup pump Coming off the other side of the manifold is the line leading into the PARR 36400 0000 strainer and then the SURE FLOW 220 21334 pump The water leaves the pump at 25 35 PSI and goes to a fitting Here the cold a
48. e Dory Yachts is very proud of its track record of minimum warranty problems After commissioning you as an owner should not expect problems to develop However should you need assistance there is only one very important thing to do CONTACT YOUR CAPE DEALER Your Cape Dory dealer is a knowledgeable professional who is familiar with your boat and capable of answering most of the questions which you may have He will communicate any problems or inquiries which you may have directly to Cape Dory so that we can both work together toward an expeditious and satisfactory solution YOUR DEALER IS NOT HOWEVER AUTHORIZED BY CAPE DORY TO CONSENT TO REPAIRS OR THE REPLACEMENT OF PARTS WITHOUT THE ExPRESS WRITTEN APPROVAL OF CAPE DORY Cape Dory Yachts like most other sailboat manufacturers offers a written limited warranty Federal law requires that a written warranty contain certain information and statements To you as an owner we at Cape Dory Yachts pledge to provide you with a product that is as defect free as possible Our goal will continue to be one of standing behind our products and one of continual improvement Page 52 CHAPTER 5 DRAWINGS AND PLANS 5 1 RUDDER DETAILS Page 53 Page 54 PEDESTAL STEERING MAINTENANCE Tu properly maintain the mowing parts the top of the pedestal it is necessary Lo remove the Compass and its cylinder For proper whet reinstalling Ihe compass we recommend placing
49. ed fiberglass half shells completely filled with a reinforced polyester compound This compound surrounds the pre formed rudder shaft creating a solid rudder of exceptional strength The blade is further reinforced by two layers of glass tape applied to the shell joints On the Typhoon Weekender Typhoon Daysailer and Cape Dory 22 the rudder shaft extends to the bottom of the rudder and into the heel fitting which is attached to the foot of the keel All Cape Dorys from the 25D to the 45 have a bronze gudgeon casting imbedded in the bottom of the rudder to accept the bronze pintle casting and stainless steel pin which is attached to the keel The pintle is set in polysulfide bedding compound and fastened onto the hull with bronze rods passing through the solid heel portion of the keel The entire casting is then faired with polyester putty and glassed into the keel This eliminates the electrolysis problem commonly found when stainless steel weldments are used in seawater 27 DIESEL AUXILIARY One of the more critical installations we perform is the installation of the inboard diesel engine The diesel is installed with fully adjustable flexible mounts attached either to a heavily reinforced fiberglass engine bed or to a rugged metal weldment coated with corrosion resistant paint This system effectively spreads the engine load over a large portion of the hull as well as providing a drip pan to keep oil out of the bilge This area should be pumped out
50. ed in a solution of water and mild detergent The bronze wool will catch any broken wire in the rigging calling attention to potential trouble use bronze wool as unlike steel wool it will not leave particles to rust and soil your sails Follow the bronze wool with a piece of terrycloth sprayed with water dispersing agent such as WD 40 Next see that the spreaders are firmly fastened in place and that the upper shrouds are locked in place on the grooved end of the spreader with a short length of stainless steel wire You should use a spreader boot or some other form of chafing gear to protect your sails from the spreader tip Check the mast tangs clevis pins and cotter pins for the lower shrouds as outlined above for upper shrouds and stays The Cape Dory 30 cutter has additional fittings on the forestay to be checked The tangs for the lower shrouds are designed to allow for some movement so do not overtighten the tang bolt Prior to stepping the mast be sure that halyards are properly reeved Tradition indicates that the main halyard s hauling part is ways secured to the starboard side of the mast and the jib halyard secured on the port side After checking each piece of standing rigging for broken wires rust spots and for secure clevis and cotter pins inspect the swaged terminal fittings at the ends of each shroud and stay These fittings should all be examined using a magnifying glass for any hairline cracks These
51. ery If this should occur ventilate extremely well since poisonous gas will be given off A Red PILOT LIGHT is provided on the panel This light is illuminated whenever the batteries are connected to the system and provides you with an additional reminder that the batteries are on and also provides enough light to read the switch panel labels at night The PILOT LIGHT draws very little current and will not run the batteries down even when left on for long periods of time There are several individual circuits provided on the D C POWER PANEL Each circuit is activated by a toggle switch and protected by a circuit breaker Before adding additional electrical equipment check the required rating of the circuit breaker Also be certain the number and size of the batteries is sufficient for the added loads A tripped circuit breaker is indicated by a raised white button The breaker is reset by first turning the toggle switch off and then depressing the white button Before attempting to reset a tripped breaker an effort should be made to find the cause of the overload the most common being a short circuit in one of the fixtures or wires or trying to operate too many devices on one circuit 3 16 A C 110 VOLT SYSTEM OPTIONAL The A C system operates on 115 volt 60 cycle current Power is supplied from a 30 amp shore service by connecting the shore power cord to the receptacle in the cockpit well Make sure the main circuit breaker on the A C POW
52. h glass strand fiber and woven roving incorporating a balsa core for stiffness and insulation Where hardware and equipment are bolted through wood blocks or solid glass replace the balsa wood In the highly stressed cockpit corners unidirectional roving 15 utilized near the gel coat surface and on the backside of the laminate giving high flexural strengths in these areas This minimizes stress cracking The headliner is a fiberglass part used to provide a cosmetic surface to the inside of the cabin as well as providing attachment points for the major bulkheads It also provides as effective vapor barrier and thermal insulation due to the air gap separating the deck and the headliner Page 16 The headliner is built with glass strand fiber and woven roving After it has been parted key areas are filled solid so that screws may be installed later The headliner is then bonded to the deck accurately with a polyester adhesive compound This is done with the aid of a jig that holds the liner in place while the adhesive cures At this point the deck is parted from the mold and sent to the deck hardware department 2 4 V BERTH GALLEY AND SUB FLOOR ASSEMBLY The v berth area has a molded liner which starts at the main cabin bulk head and runs all the way forward to the anchor rode locker This is built as the other FRP parts are utilizing various cores and laminates as required It is then installed in the hull where it is glassed to the hull wit
53. h two layers of alternating mat and roving In some places the liner is joined further to the hull using a polyester adhesive The galley area also has another separate molded liner very similar to the v berth in concept The molded fiberglass sub floor assembly is designed to fit accurately and lock to the contours of the hull This is bonded in place and a teak and holly sole is screwed down to it This is installed after the v berth and galley units are in place Fiberglass inner liners offer three basic benefits 1 added structural integrity 2 minimizes condensation problems 3 provides an easy to clean surface in storage 2 5 BALLAST The ballast is cast in two sections and mounted inside the keel cavity The cast pieces are first prefit and their location correctly determined The Quality Control Department accurately checks the location of every ballast and records its weight against our specifications Next they are lowered into and encapsulated in a mixture of special low shrink bonding resin and microspheres Besides its shrink characteristics the bonding resin was chosen for having some resiliency should the keel be subjected to some sharp impact loads The ballast is then sealed with several layers of fiberglass securely holding the ballast into the hull This glass is gel coated sealing the ballast from the rest of the boat and giving a smooth clean bilge Page 17 2 6 RUDDER The rudder assembly consists of two pre mold
54. he chart and that they are fully corrected FUELING Appropriate safety precautions are important before during and after fueling Before fueling the first time be familiar with the instructions provided by the engine manufacturer 1 Fuel docks should be approached at REASONABLE speed without wake Observe posted speed limits and instructions Be considerate of others using the docks and watch for a dockmaster or hand who may give you instructions Maintain control of your boat at all times and have your dock lines ready for use before you approach in the event that these are unavailable at the dock 2 Use bow stern and spring lines to properly secure your boat 3 Close and secure all hatches and ports 4 FORBID SMOKING while taking on fuel on or near fuel docks Completely extinguish all smoking materials well in advance of approaching the docks do not recommence until you are well clear of it after fueling and conditions aboard are safe to do so 5 Extinguish any other open flames aboard and see that all equipment e g engine stove cabin heater radios and lights both lanterns and electrical lights etc which may generate heat or sparks of any kind turned OFF Turn off all switches for branch circuits so that there are no Page 49 live electrical circuits MAIN SWITCH should also be turned off AFTER engine is stopped to avoid alternator damage 6 If possible crew members not involved in fueling should leave the boa
55. htning ground system installed in accordance with the American Boating and Yacht Council A B Y C specifications Every shroud and stay is connected to an external ground plate by a 8 A W G stranded copper wire Other equipment requiring bonding include the engine fuel tank mast step and fuel fill cap Within practical working restraints the wires are lead directly to the ground plate Note Typhoon and CD 22 have optional lightning ground systems Page 29 While no one can predict how lightning will react when it hits a spar we know from actual experience that this system offers added protection During a lightning storm refrain from touching any metal objects such as shrouds mast stanchions pulpit etc as these may attract lightning Do not paint the external ground plate with bottom paint as this prevents the plate from grounding out with the seawater Periodically inspect the connections in the bilge to see that they are tight and clean and free from corrosion 3 19 THROUGH HULLS AND SEACOCKS Since some holes below the waterline are necessary ball valves and seacocks are used to open and close those reliably They have been in use for years aboard craft of all types and have proven their value many times over The seacock is essentially a round tapered bronze shaft with a hole running along its diameter It can be rotated from one end in a 90 degree arc within a pipe junction to the open or closed position The seacoc
56. ide stops to prevent the slugs from coming out of the track each time the sail is lowered On larger Cape Dory boats a hinged mast gate is provided After the sail slugs are inserted in the track close the gate and install the cotter pin with ends directed away from the sail so they will not tear it Bend the ends of the pin over and tape them Insert plastic slugs or bolt rope at the foot of the main into the boom sail track Battens are thin wooden or fiberglass stiffeners inserted in the trailing edge of your boomed sails to support the outward curved leach When inserting the batten the thin edge goes into the batten pocket first Battens particularly wooden battens can twist and warp if they are not kept flat Keep this in mind when storing them Battens should always be removed when the mainsail is furled 3 32 REEFING Roller reefing is used on the Typhoon and the CD 22 jiffy reefing is used on the larger boats Remember IF YOU ARE THINKING ABOUT WHETHER OR NOT TO REEF IT S THE TIME TO DO IT Being over canvassed is hard on a crew and boat potentially dangerous and will not make the boat go any faster ROLLER REEFING TYPHOON CAPE DORY 22 Hoist the mainsail to its full height and take up the topping lift until the leach of the sail has no tension on it Then with the crew on the main halyard pull the outboard end of the boom toward the stern of the boat It will move out about an inch Hold the boom out and as the crew slo
57. inesses appearing in the Manual are the sole property of their respective owners and they retain all rights I have no association with and do not represent any of the products businesses or persons named in the Manual A NOTE ON PRINTING THE MANUAL In order for the Manual to print properly with ADOBE ACROBAT READER set paper size to 8 1 2 X 11 and all margins to 1 2 5 If any problems are encountered in printing load the file into a word processor and print it from there The Manual without the illustrations in the Drawings and Plans Chapter 5 which are provided as a separate files is a total of 67 pages Ed Rant January 1999 Cathy Monaghan January 2006 TABLE OF CONTENTS Letter of Welcome Cape Dory Owner s Association Customer Service Cape Dory Owner s Record CHAPTER 1 INTRODUCTION Dealer s Commissioning Checklist 1 1 Shipping Receipt 1 2 Pre launch Checklist 1 3 Post launch Checklist 1 Engine Start up Checklist 1 5 Rigging Checklist 6 Miscellaneous Checklist 1 OY O1 84 00 JJ 2 CONSTRUCTION OF YOUR CAPE DORY YACHT Hull Deck and Headliner V Berth Galley and Subfloor Ballast Rudder Diesel Auxiliary Mechanical Installation Hull to Deck Joint ND PO fa D
58. ing Lift ting 25 Double Berth Se t up Shaft atic Overboard Y Valve 25D 2 Diagram Details structions Discharge Discharge 7 30 HS HS HS HS AHA AHA AHA ABA W XO 4S CO CO C N NR UI oo Page 4 CHAPTER 6 TECHN 6 1 Specifications Specifications VENI 34 UI 33 El C 36 El 38 31 Typhoon D 22 Sail CD 25 Sail an an D 27 Sail 34 CD 25D Sail an D 28 Sail an an D 30C Sail D 30K Sail an an Daysailer Sail 32 Typhoon Weekender Sail 5 5 DOR LI CAL INFORMATI ST VENI DOR AD DRESSES T C D 27 ON 28 tanding and Running Rigging TYD TYW CD 22 25D tanding and Running Rigging CD 27 28 30 30K lan lan YD TYW CD 22 25D 30 30K Page 5 Page 6 LETTER OF WELCOME Dear Skipper Welcome to the Cape Dory fleet You have joined the select group of sailors who recognize the quality construction and traditional workmanship found in every Cape Dory yacht This manual has been prepared to assist you in getting to know you new yacht before setting sail for the first time It als
59. is zinc is used in place of the propeller nuts and can be ordered from Perry s Boat Harbor and Drydock Page 25 Isleton CA 95641 916 777 6461 The nut is 3 4 with 10 threads to the inch and a 1 3 4 hub diameter Alignment is checked by mating the two metal coupling flanges together by hand and measuring the gap between them with a common automotive feeler gauge around the entire periphery There should be no more that 002 gap anywhere Once alignment is arrived at the flex coupling which has been used on the CD 33 and CD 36 and is currently used on the CD 28 should be installed and all bolts tightened Particular attention should be paid to the engine mount nuts and bolts These should be checked on a routine basis 311 STUFFING BOX The propeller shaft and on wheel steering boats the rudder shaft are fitted with stuffing boxes to control the leaking The adjustment of the stuffing box is especially critical on the propeller shaft If it is too tight the packing will overheat and burn and once burned leak uncontrollably If too loose it will leak excessively When new the packing will wear in and may require frequent adjustment The ideal is to have one or two drops of water every ten seconds or so In practice the stuffing box is properly adjusted as long as it is permitted to leak and the leaking is not excessive If you are having trouble keeping the stuffing box from leaking excessively alignment should be rechecked Misa
60. k is least likely to jam open with seaweed or other foreign matter Seacocks are standard on the CD 22 25D 27 28 and 30 The Typhoon and CD 25 have ball valves Before launching and regularly throughout the season you should check to see that all hose clamps are tight and in good condition Seacocks are designed to provide a positive means of stopping a flow of water into the hull should a connection fail or hose rupture These fittings are the single most important safety devices that affect the watertight integrity of your boat Checking them for ease and effectiveness of operation means making certain that the handles move the full arc that they were designed for and that sinks toilets and cockpits drain easily when filled Whenever the boat is left unattended in the water ALL thru hull fittings should be left in the CLOSED position except for those serving the cockpit scuppers Be certain to open the engine cooling seacock BEFORE starting a diesel engine The water pump impeller could be damaged and or the engine and exhaust system damaged by overheating if the engine were to be started with the seacock closed Routine maintenance of seacocks calls for disassembling them when the boat is out of the water applying a waterproof grease to all friction bearing parts and reassembling When disassembling seacocks do so one at a time as the components are individually fitted to each other by their manufacturer Your dealer or marina will suggest
61. l The purpose of cradle bulkhead or poppets is to balance the boat in an upright position not to bear the weight of the boat Before hoisting out show the boat yard the profile of the hull so that they will know how to position crane or straddle the hoist straps The usual locations for the straps of a typical marine lift are just forward of the rudder heel bearing and in the hollow of the fore foot COCKPIT SCUPPERS Flush with fresh water and leave seacocks in the open position so that hoses will not fill with rain water and freeze ICE BOX Clean ice box thoroughly and leave open STOVE Clean stove thoroughly including burners Release pressure in fuel tank and leave tank empty ELECTRICAL SYSTEM Remove batteries from boat and store in a warm dry location off a cement or stone floor They should be completely charged before storing or left on a trickle charge The balance of your electrical system requires little maintenance If you wish each bulb can be removed and the light fixtures given a spray of water dispersant such WD40 or similar products The main switch and fuse panel can also be treated this way to minimize corrosion Page 46 PROPELLER Examine the propeller for any damage or nicks If evidence of either is apparent have the propeller removed and trued HEAD Follow manufacturer s directions closely Remove any water to prevent from freezing The holding tank should be empty when the yacht is
62. laid up for the winter If possible flush the tank with a mixture of non toxic antifreeze and water prior to hauling WATER SYSTEM Pump tanks as dry as possible then add a non toxic water system winterizer that your local marine hardware store will recommend Caution do not use antifreeze or other poisonous substances Pump this solution through the entire fresh water and drain system ENGINE Follow the instructions in the engine owner s manual supplied by the manufacturer and read the section in this manual Disconnect engine cooling water intake to make sure that no water remains in the line Reconnect line and secure hose clamps Remove the drain plug in the muffler and drain FUEL TANKS The best way to store a fuel tank is empty Partially filled tanks invite condensation Completely filled tanks leave you with old fuel in the spring and possible gum deposits Much has been written lately on this subject and new products are being developed to prevent gum deposits Keep informed and consult your dealer or shipyard for recommendations STANDING RIGGING Standing Rigging the fixed rigging supporting your mast should be inspected frequently to ensure trouble free sailing New rigging will often form a thin layer of rust especially at the terminal ends This is caused by impurities surfacing when the wire is cold worked during manufacture The oxidation should eventually stop forming and when it does the stain should be removed with
63. lignment will cause the packing to wear excessively and once corrected should solve the leaking problem All CDY stuffing boxes use 1 4 waxed flax packing Do not use synthetic or Teflon packing 312 MAINTENANCE Owners should refer to the engine manual for recommended maintenance Daily checks should be made on the oil levels and fuel level Particularly important is that the engine mounts and coupling bolts be checked often to see that they remain tight Periodically it is a good idea to go over the entire engine with a set of wrenches tightening all bolts Care must be taken not to overtighten and strip bolts and particular care must be taken on bolts that require certain torques such as head bolts Engine vibration loads may have been experienced during shipment over the roads Beyond the above the engine itself should be kept clean and dry and the fuel fresh water free and dust free The oil and filter should be changed often and the two fuel filters changed at least annually 3 13 WINTERIZATION Winterization is best left up to your storage yard If you do it yourself you should follow the instructions in the engine manufacturer s owner s manual The major problem that can arise during winter layup is the danger of the engine water freezing This can be prevented by either draining the water completely out of the engine and exhaust system or by treating this water with antifreeze Refer to the label for the proper mixing instructions
64. low an equal amount Swivel to each other No mare than 10 total cable bend the engine throttle lever to optionally select he proper travel Holes both 1347 or 2 Inner hole will provide increased throttle travel control hande pressure Transmission lever shitting F forward ete Ew 3 Clamp must be on the same Diane as Ihe Operating lever Another method of reversing wansmission ENGINE CONTROLS MAINTENANCE the control handle shalt bearings with 30 motor od Use a good grade of Teflon spray with an extender nozzle lor the pedestal end of the engine control push pull cables At the engine clean the control cable metal ends and spray with grease This will increase cable and make operation easier Engine cables are subject to high heat from the transmission and salty bilge water both very hard on moving parts If stiff replace 146 DUCHAINE BLVD NEW BEDFORD 02745 1292 TEL 15061 995 9711 FAX 508 295 502 Page 56 LIVHS Of LEO STIVLAG LAVHS HOTTAdOUd OF LT 9 Es Page 57 Ne 4 7 AR 1 ER _ Mei xax ur 901 lt A Sa gt SUVLAG LAVHS 1134034 F s Page 58 235 mp esr ou
65. manual and on some of the accessory equipment which you may elect to have installed We recommend that you record these important numbers carefully and keep copies of them both at home and aboard see Owner s Record form These numbers and an accurate description of your property in the event of theft could be essential to their recovery Marking an inconspicuous place such as the inside of a locker underside of a door or drawer of a door or drawer or the base of the mast with your initials social security number or other unique brand may also aid in the prompt identification of your property should the need to do so ever arise Page 10 OWNER S MANUAL CHAPTER 1 INTRODUCTION The intent of this manual is to help the owner of a Cape Dory to understand and maintain his yacht This manual should be used in conjunction with other publications to fully understand the demands and pleasures of sailing A suggested reading list is provided and monthly periodicals such as Sail Cruising World Motor Boating Sailing Rudder etc are also recommended Obviously personal knowledge and skills are required to handle and maintain any boat successfully Cape Dory yachts are constructed in a recently remodeled building facility located in East Taunton Massachusetts Our boats are assembled using modern methods equipment and materials obtained from the most reputable suppliers The basic hull design of Cape Dory ya
66. nd hot water systems separate On the hot side of the fitting there is a check valve to prevent hot water from backing into the cold water side and a manual shut off valve used to isolate the hot water system for trouble shooting and safety purposes From here the water goes into the hot water tank and back to a under the galley sink One side of the feeds the galley sink and the other the head sink with no fittings in between The cold water leaves the first and passes back to a second under the sink and then on to the two sinks with no intervening fitting between the faucets and Start up varies depending when your boat was shipped from the factory Boats shipped between April 15th and September 15th do not have antifreeze in them while boats shipped September 15th through April 15th do On boats which have antifreeze in them the valve leading into the hot water side of the system was kept closed and only the cold water side of the system was tested here at the factory This water should be flushed out and then the hot water side filled The antifreeze used is safe for potable water systems and made by Sudbury Laboratories here in Massachusetts BE CERTAIN THE HOT WATER TANK IS COMPLETELY FILLED BEFORE TURNING THE 110 VOLT HEATING Page 32 ELEMENT ON OR IT WILL BURN OUT THE ELEMENT Also be careful not to accidently activate the high temperature high pressure relief valve which projects out fr
67. nd into the ocean which is illegal Care must also be taken to see that the fuel fill cap is replaced securely so that no water will leak into the tank Fuel drawn from a cool underhood tank will expand when placed in the warmer ships fuel tank Therefore the tank should only be filled to 95 of capacity to allow for expansion Diesel fuel while less volatile than gasoline is still explosive and extreme care should be taken while fueling or working on the fuel system Never allow a mechanic to use ether as a starting aid Ether can cause over pressurizing of the small cylinder on an auxiliary diesel 3 10 SHAFTING Cape Dorys from the CD 22D to the CD 36 are fitted with 1 diameter bronze Tru Shaft propeller shafts The propellers require a standard tapered SAE bore and are secured with one 3 4 nut a Perry Nut zinc and a 1 8 cotter pin Vibration is minimized through the use of flexible engine mounts Alignment is very critical and should be checked carefully several times the first year and at the beginning of every season Alignment can only be accomplished in the water with the rig tuned All engine mounts are adjustable up and down and athwartships IT IS MANDATORY THAT THE FLEXIBLE COUPLING IF FITTED BE REMOVED WHEN CHECKING ALIGNMENT A common problem is the installation of a zinc between the prop eller and the hull which prevents the alignment from being checked To eliminate this problem a Perry Nut zinc is used Th
68. o is a helpful guide to follow for proper care and maintenance in the future The Cape Dory team of managers supervisors and quality control personnel do their very best through every step of the construction process and strive to build boats of exceptional quality which will provide their owners with many years of sailing pleasure and retain a high resale value Please review the material carefully You will enjoy your new Cape Dory more if you are familiar with the designs and construction of the yacht and with the equipment used on board Any questions you may have can be answered by your authorized dealer as he is a knowledgeable professional and is familiar with your new boat He will continue to be your most important contact for information about your boat and for any problems should they develop We appreciate your confidence in our product and assure you that with proper care you should have many years and miles of enjoyable sailing in your new Cape Dory Again welcome to the fleet May the wind always be fair Sincerely Andrew C Vavolotis President Cape Dory Yachts Inc Page 7 Cape Dory Owner s Association The Cape Dory Owner s Association was formed as the company grew from its original beginnings in 1964 as a sailing dory builder The earliest Cape Dory owners would gather for regattas races and picnics in summer and during the frostbite season in the winter months Later as the Typhoon spread in popularity mo
69. om the side of the tank Once the lever arm has been pulled the valve will not reset and it must be replaced To activate the water system fill up the tanks and open one valve on the manifold We suggest you run the pump and open the cold water side of BOTH faucets until a steady flow of water comes out Close the faucets and repeat on the hot water side You must be sure to eliminate any trapped air from the system or the pump will cycle rapidly or never shut off We hope that we have found any problems here at the plant but always check the clear hose where it qoes into the pump for air bubbles flowing in the line If air appears you must find its source i e a leaking connection leaking strainer faulty manifold or an empty tank Also periodically check for a leak in the pressure side of the system One tip off that something is leaking is the pump coming on at times when no faucet was opened This signifies a loss in pressure which a leak would cause 321 HEAD SYSTEM All Cape Dory 25D 27 28 and 30 s include as standard equipment a marine head with holding tank The CD 28 and 30 have a 24 gallon waste tank installed under the V berth The other models have tanks located in the bilge Refer to the head manufacturer s instructions on use of the marine toilet It is recommended that a minimum amount of flushing water be used on each cycle to maximize the capacity of the holding tank There is a deck pump out fitting conveniently lo
70. ould fail to prime itself after several strokes check to see that the pick up hose is positioned properly then check the pump body for debris The rubber diaphragm may be removed by loosening the screw which holds the stainless steel clamp Inspect the pump body for foreign material and gently lift the intake and outlet flapper valves to determine that they are clear Reassemble the pump and continue pumping Another problem causing the pump to not prime could be a chafed hose This can be checked by holding your hand over the end of the hose to see if suction is felt It is wise to pump the bilge before casting off and again on returning to see if the boat is taking on unusual amounts of water Note If you decide to have an electric bilge pump installed be sure to consult an expert on the wiring and plumbing of that piece of equipment 3 24 MAST STEP REINFORCEMENT Since the masts of the Typhoon 22 25 27 28 and 30 Cape Dory Boats are stepped on deck a reinforcement system is fitted to distribute the load safely to the hull The Typhoon Weekender utilizes a molded in beam to support the mast step Cape Dory 22 s 25 s 27 s 28 s and 30 s use structural metal members located between the deck and the headliner to distribute rigging loads to the forward and aft bulkheads These supports transfer the load to the cabin sole directly beneath the Page 34 bulkhead posts Please refer to section on tuning to avoid overstressing the mast
71. ove the waterline and occasionally when heeling or in a sloppy and confused chop water will enter the cockpit through the fitting at the top of the rudder post This is not cause for concern as the volume is minimal and will drain out the cockpit scuppers Maintenance of the tiller steered Cape Dory system is simple keep the bearing at the top of the rudder post lubricated with a good waterproof grease Tilt the tiller upward and apply the grease to the top of the shaft and bearing Inspect the condition of the key Inspect the gudgeon the heel fitting at the base of the keel where the rudder is connected There should be very little play at that point Page 21 If the tiller cap is removed from the head of the rudder post be certain to re install the tiller cap properly Both the rudder post and the tiller cap have machined keyways in them Be careful that the key is in the keyway and that the tiller cap is installed correctly When the boat is hauled be sure to check the condition of any play in the shaft and gudgeon as described above Refer to the drawing for a better understanding of your steering system PEDESTAL STEERING The optional pedestal steering system on your Cape Dory has been carefully designed installed and aligned here at the factory to give you excellent service with minimal maintenance A metal weldment comprised of the pedestal sheaves wire turning sheaves and quadrant stop is bolted under the deck tying the entire
72. ovement here otherwise things start to work and leaks occur A rigid compound used here might seem the best but they generally don t have enough impact strength and resiliency to prevent leakage over a long period of time 3 Many builders use aluminum toe rail extrusions and thru bolt this structure every 4 This is a very difficult assembly to keep watertight because the fastener heads are exposed while our bolt heads are covered over and the toe rail screws are bunged Page 19 CHAPTER 3 OPERATION AND MAINTENANCE 31 FIBERGLASS Fiberglass is one of the most maintenance free materials utilized today in boat construction If given proper care and treatment the gel coat surface will look new for years If not maintained it will eventually turn to a flat chalky texture We recommend that you wash the exterior fiberglass surfaces of you boat several times each season with a mild soap and plenty of warm fresh water Rinse liberally with fresh water After the boat has dried use a good quality fiberglass cleaner in paste form follow this process with a wax or polish prepared for marine use A fiberglass cleaner with a very gentle abrasive in it may help remove minor scratches and surface wear Be careful as the continued use of cleaners containing abrasives will gradually erode the gel coat surface Marine wax will fill small scratches and provide a gloss finish We suggest you use a wax that does not contain silicone as it gets into
73. primary steering system the key for the deck access plate and the emergency tiller should be readily accessible and not buried in the bottom of a locker Please review carefully the enclosed maintenance hints supplied by the vendor A thorough understanding of how your steering system works is the only way you can be assured of its proper performance year after year Page 22 3 3 DIESEL AUXILIARY The engine fitted in your Cape Dory is a marine diesel Parts are available at any local distributor or directly through our distributor You will find that they stock and ship almost every part you may need to effectively repair or maintain your engine Their name and address is in the vendor list The engine installation is best broken down into several systems and a description of each system follows The systems are electrical exhaust hand starting cooling fuel shafting maintenance and winterization Included in each section is our experience of what has gone wrong with other boats which might help should you encounter a problem 3 4 ENGINE ELECTRICAL SYSTEM Due to the rapid growth and technological developments of marine diesels Cape Dory Yachts has steadily sought to install the best possible engine for the given application in each boat We have used the Volvo MD7B diesel in the CD 28 and CD 30 the Yanmar 5 8 1 GM diesel in the CD 22D CD 25D and CD 27 and we most recently use the Westerbeke 13 in the CD 27 Specifications
74. r exhaust leaks Note sealers and paints may burn off as engine heats up Check throttle and shift operation Recheck stuffing box Report any unusual noises or vibrations to the factory immediately Do not continue to run engine if any are present RIGGING CHECKLIST Check all fasteners on spars for tightness Reeve halyards Attach stays shrouds spreaders and topping lifts Check all clevis pins and cotter pins for security Tape all potential chafe points including spreader bases and ends Check wiring of combination deck and bow light Be sure bulbs work Step Mast and rigging Page 14 4 Check all rigging for length 42 Check all clevis and cotter pins for security Be sure the locking nuts on the turnbuckles are secure Tape all potential chafe points 43 Tune rigging to proper tensions including bobstay on 28 and 30 44 Attach booms sheets blocks oars reefing lines toping lifts etc 45 Wire bow and deck lights MISCELLANEOUS CHECKLIST 46 water tank s and check operation of all pumps and drains 47 Fill alcohol tank 25D 27 28 and 30 Check for leaks and test operation of stove 48 Water test ports and hatches 49 Recheck all through hulls valves seacocks hose clamps hoses and stuffing box 50 Bend on sails 51 Interior appointments complete 52 Optional equipment installed and operational
75. r winterizing the exhaust system a drain plug is fitted to the exhaust muffler allowing it to be drained Page 23 The antisyphon valve should be cleaned periodically This valve can be found by following the small hose on the exhaust elbow back to the engine If it occasionally spurts water most likely a small piece of dirt has lodged itself in the seat and it should be cleaned If it is allowed to drip it will cause the engine to rust If at any time the engine is hard to start and a lot of cranking is required the water injection hose to the exhaust elbow should be removed and allowed to drain into the bilge If this precaution is not followed the muffler could become full of water and back up into the exhaust elbow and then into the cylinder head Obviously once the engine is started this hose must be reconnected immediately or the exhaust system which is normally water cooled will overheat and burn out 3 6 HAND STARTING Hand starting a diesel is so difficult that we do not recommend it Such force is required that injury may result Intelligent use of the two battery system should eliminate the need for hand starting In our opinion it is foolhardy to rely on this feature 37 TRANSMISSION When the engine is not in operation the transmission must be kept in reverse Some transmissions overheat if allowed to free wheel 38 COOLING Some engines are raw water cooled As previously mentioned the cooling water is discharged into the e
76. ration 22 Wheel Various Edson Corporation PUMPS Manual Bilge Pump Pressure Water Pump Galley Foot Pump Head Foot Pump Counter Top Pump Electric Sump Pump Sump Pump Switch or Electric Sump Pump Sump Pump Switch TRACKS 3 4 T Track TY 22 1 T Track CD 25D 28 30 Traveler Bridge CD 28 30 SHIFT amp THROTTLE CABLES 8 Shift Cable CD 27 8 Throttle Cable CD 27 28 6 Shift Cable CD 28 11 Shift and Throttle Whale Gusher 8 36950 GP 0507 GP 4 6A8 37220 0010 Rule 750 Rule 49 36251 0000 44960 0002 1159 6400BC 3300BC 3300BC 3300BC Note Be sure to check actual length on your boat before ordering VENTS 3 Low Vent 3 Vent Deck Plate 3 Vent to Hose Adapter 3 Hi Vent 4 Hi Vent 4 Chrome Deck Plate WINCHES Lewmar 6 7 10 108836 10863DW 10863HA 10923C 10964C 10864DC Page 98 Imtra Parr Jabsco Imtra Imtra Parr Jabsco C E Beckman C E Beckman Parr Jabsco Parr Jabsco Spartan Marine Spartan Marine Nicro Fico Northwest Controls Northwest Controls Northwest Controls Northwest Controls Nicro Fico Nicro Fico Nicro Fico Nicro Fico Nicro Fico Nicro Fico Lewmar VENDOR ADDRESSES Page 99 Note Vendors with indicates no current information could be located via Internetsearch of business addresses and telephone listings All other addresses and telephone numbers are believed to be current as of January 1999 but it c
77. rawn down to 68 qooss Usually when reaching Quick Reel can in neck than olaatad Pro marking between 15 and 10 seconds the halyard provides a good 4011 length when releasing Method B A simplification of the basic Quick realing system has baan developed recently goosa hook replaces the reel lack downhaul and a single ended block and aliding arrangement holds the A production boom and gooseneck featuring this ar rangement is available from Schasfer Tha seal tack cringis be hooked quickly onto the goose neck hook as the halyard is released Page 82 5 30 CD 25D DOUBLE BERTH SET UP SUDER SUPPORT LES PLYWOOD SUDER COMPRESSION TUBE FOLD Down SECTION TO CLEAR COMPRESSION TUBE Page 83 5 31 TYPHOON DAYSAILER SAIL PLAN N M o co mor i N Page 84 5 32 TYPHOON WEEKENDER SAIL PLAN Page 85 5 33 CD 22 SAIL PLAN Ug DM Page 86 CAPE 5348 CD 25 Sail Plan DORY 2 L O A 24 10 L WL 18 0 Beam 4 Displacement 4000 Be hil Sal Area 264 sy i 1 1 27 58 j 9 t 4 I I mm Page 87 5 34 CD 25D SAIL PL
78. rcised 16 Note the diesel fuel is flammable handle it accordingly in a cautious manner 17 Those Cape Dory owners with outboard engines should note that perhaps the safest fueling practice when possible is to remove the tank s from the boat before filling 3 47 WEATHER FORECASTS The U S Coast Guard is in the process of discontinuing the display of weather signals at its stations and other locations along all coasts in favor of the NCAA weather broadcasts which are continuously broadcast on weather channels Wx l and Wx 2 162 40 MHz 162 55 MHz Page 50 Good seamanship requires attention to the weather forecast before leaving port and while you are sailing Tune in to VHF weather and make it a practice to check the broadcast on a regular basis in case there are changes in the forecast 3 48 BOATING SAFETY ORGANIZATIONS Every sailor was once a beginner Very few were born into sailing families and learned at their parents knees Therefore it is to everyone s benefit that there are several fine non profit organizations that are ready to teach interested persons everything from basic seamanship and piloting to celestial navigation Two of these organizations are e United States Power Squadrons U S P S e United States Coast Guard Auxiliary 3 49 STOVES The manufacturer of the stove includes an owner s manual with the appliance Read it carefully and make sure that everyone who uses the stove understands its
79. re and more activities began taking place involving that class With the advent of the Cape Dory 25 other Cape Dory owners readily welcomed the newcomers Today the Cape Dory Owners Association is national in scope and activities are increasing in number rapidly Several Typhoon fleets are actively established and most Cape Dory owners find the Association an excellent means of communication The Association publishes a periodic newsletter which contains interesting as well as helpful information If you are a Cape Dory owner and are not receiving the newsletter please write to us and well enroll you immediately We need to know your name address and the model and hull number of your Cape Dory Addendum Cape Dory Sailboat Owners Association Inc http www capedory org California Cape Dory Owners Association http www toolworks com capedory Lake Michigan Cape Dory Owners Association http www lmcdoa org End of addendum Page 8 CUSTOMER SERVICE The Cape Dory Yachts Customer Service Department has been established to provide technical information and a replacement parts ordering service for Cape Dory Owners Please do not hesitate to contact us with any questions or comments on your boat We appreciate any suggestions that you might have to improve the product We suggest that you place any parts orders through your Cape Dory Dealer but will be happy to accommodate you for special orders Whenever you make an order
80. regularly being careful not to discharge oil overboard The exhaust is a wet system consisting of an engine water injected elbow a waterlock muffler and heavily reinforced rubber hose The main advantage of this type of exhaust system is that it allows the cooling water to cool the exhaust gasses as they leave the engine This system produces a quieter sound and reduces temperatures in the engine room preventing burns and minimizes a fire hazard The fuel system incorporates a custom aluminum fuel tank and a combination of flexible fuel lines and reinforced rubber hose Flexible fuel lines have been chosen as they are very easily repaired in the field should a leak develop Copper fuel lines require special tools to repair which may not be available at sea Every installation includes a fuel filter and another fuel filter water separator for that extra measure of safety 28 MECHANICAL INSTALLATION While the carpenters are completing their joiner work the bulk of the mechanical installations are completed The water tank mounting pans are glassed into place and the tanks installed The plumbing is run to the manifold located under the galley sink and then into the respective compartments where the pumps and water heater are located The heavy wiring from the engine is run up to the electrical panel The bonding system joining all underwater thru hulls is completed Lightning ground and bonding are optional on the Typhoon and CD 22 Page 18 29
81. s and other objects from becoming snagged on them Because of the manufacturing process used in fabricating the wire used on the shrouds and stays you will experience a certain amount of stretch in your rigging after sailing in the first rough weather of the season Repeat the above procedure to be certain that your mast is always well tuned ATTENTION SKIPPER a Please note When rigging and mast are properly assembled and installed avoid taking unnecessary risks that would use rigging assembly for purposes other than what it was designed for Exercise good judgement b Frequent checks for excessive rigging wear and weak areas should be made to ensure maximum safety Especially check for chafing Sails and running rigging can be easily chafed Worn rigging or any pieces that in question should be replaced as soon as possible For further clarification consult your Dealer on any pieces in question d Your sparset also demands attention and periodic checks to ensure that all pieces are secure and free from wear Page 38 3 28 DECK HARDWARE AND CHAINPLATES Most deck hardware is thru bolted and backed up where necessary Periodically these items can leak and should be rebedded with a good brand of caulk such as Life Care must be taken not to overtighten the fasteners as the strength can be reduced severely Particular attention should be paid to the chainplate fasteners as they are very critical to the safety
82. s that do not penetrate the gel coat you may sand them out with 320 wet and dry sandpaper Finish with 400 and 600 grit paper and hand buff with an fine rubbing compound DEEP SCRATCHES AND FLAWS exposed fiberglass Thoroughly clean the damaged area with acetone to remove dirt grease or wax Tape off the area around the flaw with masking tape Thicken a small amount of matching gel coat with talcum powder or cabosil to obtain a putty like Page 20 consistency When ready to apply the putty thoroughly mix a small amount of hardener into the gel putty A tablespoon quantity of gel putty will require ONE DROP of hardener to cure into a hard plastic in mild temperatures Some experimenting will allow you to adjust the amount of hardener to suit your needs Over catalyzing results in a rubber like substance never permitting a complete cure Apply the gel putty with a putty knife filling the flaw slightly above the surrounding surface Allow to harden Sand and buff as previously mentioned for shallow scratches Clean up hands and tools with acetone before putty hardens CAUTION The clear hardener should be handled with great care Flush skin or eyes with large amounts of water if accidentally splashed Be careful of discarding uncured mixed gel coat material Once hardener is added a chemical reaction takes place that generates heat Large quantities can become very hot Submerge material in water until cured for maximum safety NON S
83. safe place for future reference Attach each piece to its respective location on the mast making sure to insert proper clevis pin and locking it with a cotter pin The mast lights should be checked before the mast is installed so that defective bulbs can be replaced easily When all rigging is properly located identification tags and turnbuckles are in place make sure again that each turnbuckle is stationed with a corresponding clevis pin and locked in place with a cotter pin Take note of the maximum dimension your turnbuckle should be opened with turnbuckle barrel equally located between threaded sections Measuring from the center of the clevis pin to the top of the swage the maximum Y dimension should be as follows Cotter Yo al sr GEM 22 m Y Typhoon All 12 1 4 CD 30K Lower Miz Upper amp Lower Y 14 1 2 CD 25D Lowers 12 1 2 Upper Fore Backstay Y 15 5 8 Upper Fore Backstay 14 1 2 CD 30C Lowers Y 14 1 2 CD 27 Lowers Y 12 1 2 Upper Fore Backstay Y 15 5 8 Uper Fore Backstay 15 1 4 Staysail 12 11 CD 28 Lowers Y 14 1 2 Upper Fore Backstay Y 15 5 8 Tighten every shroud and stay so that they have the correct tension and the mast is stayed plumb with no bends or curves in it Insert cotter pins in the threaded studs and spread them to prevent them from falling out Tape the cotter pins with chafe tape to prevent line
84. showing the design and construction of your Edson Pedestal Steerer These parts dtawings will assis you w the proper maintenance of your steering system dsassembly should become necessary the following instructions will provide a ample but precise method ol removing and replacing the steering shalt and its componente DISASSEMBLY 1 With the wheel and brake assembly removed replace the wheel nut with any standard thread 4 or 1 hex 2 Lomen the steering cables and chain by hacking off the take up eyes M the Quadrant or Radial Driver lift the chain off the sprocket and tie to the forward part of the bowl Put cloth just under the sprocket so parts drop down Align the notch in the aft nylon washer with the stamped on the sprocket Caretully drive the pin of the sprocket drive from Ihe rand end toward the grooved endi With a piece of wood against the or 1 hex nut gently tape the wheel shaft from the housing see illustrationk be careful nat to drop the shaft components into the pedesta 2 Remove the sprocket two nylon washers and forward needie bearing amp Remove 2 bearing and washers 9 Wipe out any dirt or old grease before reassembly reassemble reverse the above procedure not grease the bear ings until reassembly is completed NOTE Check your compass for possible readjustment wv When ordering spare parts give m the pedestal serial number part 2
85. son failure is very difficult to correct Record bulb sizes and carry spares aboard your boat The spreaders that support the upper shrouds should be inspected They are designed to angle slightly upward to best support the mast in column The inboard and outboard ends should be covered with chafe tape or spreader boots to prevent tearing sails or halyards If any damage is Page 35 sustained during mast stepping or winter storage replace the spreader DO NOT sail with defective spreaders spar or hardware We do not recommend that a spar be left stepped all winter especially in northern climates where the boat is used for 1 2 year Stress chafe abrasion and generally the shortening of the life of the spar and its components is accelerated when left exposed on the land 3 26 STANDING RIGGING Standing rigging consists of shrouds and stays which support the mast in an upright position Running rigging is used to hoist or trim sails Standing rigging requires attention as failure could result in the loss of a mast Most failures occur from lack of attention poor tuning or improper maintenance rather than a structural failure Before stepping your mast each season inspect all standing rigging thoroughly Starting at the top of the mast systematically check each upper shroud and stay tang and be certain that each clevis pin is secured with a properly placed cotter pin with its ends bent over Wipe down each shroud and stay with bronze wool dipp
86. sure pump and cause the engine not to start until this air is expelled All engines are test run here at the plant and are fully bled however air may be introduced in trucking or launching and must be bled out once the boat is launched The fuel system consists of rubber hoses secured with hose clamps and threaded fittings made tight with pipe dope tape or sealer The complete fuel line from the pick up tube in the tank to the fuel pump in the engine must be tight or air will be introduced All CDY engine installations incorporate two fuel filters which also must be air tight Any time the fuel system is opened up as when changing a fuel filter air will be introduced into the system which must be bled out The only other problems that can occur are caused by dirty or water laden fuel Water is especially harmful in that its presence in the delicate passages of the high pressure pump will cause rust which may ruin the very costly fuel injection system The best way to avoid water in the fuel is to keep the fuel tank nearly full at all times This reduces the air space in the tank which cuts down on condensation A water separator which should be periodically checked and drained when necessary is also provided Diesel fuel stabilizer also works is highly recommended and can be obtained from your local fuel dealer When filling the fuel tank care must be taken not to overfill it This will result in excess fuel being expelled out the vent hose a
87. t 7 An adequate fire extinguisher USCG approved for Class B fires should be readily available in case of emergency 8 Remove fuel fitting Be certain that you are putting fuel in the fuel tank Note the approximate amount required to fill the tank by either looking at the fuel level gauge if one is in the tank 9 Be certain double check that you are taking on the appropriate fuel diesel not gasoline Errors of this type do occur and will result in serious engine damage if not immediately detected and corrected 10 Sometimes If you are in an unfamiliar area you may want to first take a sample of the fuel you plan to pump on board for a visual and smell check to insure that it is diesel and not gasoline 11 Maintain contact between the nozzle of the fuel hose and the fill pipe rim to prevent generation of static electricity sparks 12 Fill slowly to about 95 of capacity do NOT overfill Allowance must be made for thermal expansion of fuel without overflow 13 Replace and secure fill fitting after fueling Carefully clean any spillage Check fuel tank vents at stern for overflow Check below decks and in the bilge for fumes or leakage If fumes or leakage are present adequately ventilate and clean areas completely BEFORE PROCEEDING 14 Open all ports and hatches fully for ventilation 15 Do not fuel during electrical storms avoid fueling at night or in rough water except in emergencies when extreme caution must be exe
88. t ason To check for proper wire tension tock the wheel in usina the pedestal brake or by tying att the wheel Cable tension v best when you cannot Radial Orva CLEANING STAINLESS STEEL Pedestal yuards steering wheels and shafts are al made trom top qual The umplicatuna of as name stainless dues not totally sianless steel will rust 0 certain degree due 1o chemical reaction to air and saltwater Thus 15 manly cosmetic and will require an occasional gelishiag wih an abrasive cleaner or equivalent CLEANING PEDESTAL AND ACCESSORIES Clean them with soap water dant ute chemicals such at or acetone as they break down the super finish on your Fason pedestal move the quadrant or drive wheel by hand with the wheel locked in place Over Lightening will greatly reduce the sensitivity of the system it must be emphasized that all on board must be familiar with the care snd of Ihe Meerng System and engine controls One per son mus Uc asagaed the job of maintenance and must be thoroughly familiar wilh the operation and intent of all ihe equipment If at any Gime your System makes strange noises or reacts differently than it has pret you must lind the causes immediately and correct the Screws nuts bolla as well Cleves and cotter pins that are part of the
89. ter a period of time the rusting continues contact your dealer WINCHES AND BLOCKS The winches installed on your yacht are the finest available Most problems occur when a proper maintenance schedule is not followed It is important that your winches be cleaned and inspected at least twice a season or after a two or three week offshore passage We recommend a high density grease and not an oil for the required lubrication Check to see that all bolts holding the winch down are tight COVERING It is far better to store a boat under cover than to leave it open to the elements The teak trim will fare far better during the winter and the boat will not be subject to the pressure of freezing water a common cause of gel coat stress cracks If your boat cover is durable open a couple of ports to allow air to circulate below decks 3 46 SAFETY Federal regulations REQUIRE certain safety equipment to be onboard your boat personal and throwable floatation devices fire extinguishers horn whistle etc Know what equipment is required and have it aboard and properly stowed before you cast off for the first time In addition to the equipment requirements outlined here the U S Coast Guard can provide additional information and answer your questions It is highly recommended that although not required certain additional items be kept aboard This list is not complete you should have all USCG required gear 1 An anchor of appropriate size and
90. the gel coat and is almost impossible to remove should you want to paint the boat at a later date Stubborn stains may be removed with fiberglass cleaner in some instances More difficult stains may be worked out with judicious use of a very mild abrasive powder such as Bon Ami Stubborn tar and petroleum stains may be removed with careful application of acetone Acetone is a powerful but EXTREMELY flammable solvent which is available in most paint and hardware stores Stress or spider cracks are a common occurrence on the fiberglass boats of even the most careful boatbuilders and boat owners Most of the time these cracks are limited to the gel coat surface and are of cosmetic considerations only not structural If you have any doubt about the seriousness of any crack consult your dealer Cosmetic repair of gel coated surfaces is not a difficult task and a reasonably handy person with a little practice and study can make adequate repairs Structural fiberglass repairs are best left to the experts If for any reason you desire to apply paint to areas of the boat other than to the bottom or boot top seek the advice of qualified personnel at a boat yard in your area for information about the latest development in chemically based paints for fiberglass and the recommended surface preparation procedure Minor repairs of the gel coat surfaces may be done by the owner using one of the following methods SURFACE IMPERFECTIONS On imperfection
91. those sails are sheeted in tightly and can chafe the mainsail when running before the wind Topping lifts frequently chafe the leach of the mainsails Inspect your sails frequently and take care of chafed stitching or small tears before they become a major problem A small ditty bag with some thread and a few sail maker s tools on board can come in handy and save you a few dollars Sails should also be protected from sunlight as much as is practical Ultra violet light can break down the Dacron in the sail cloth and stitching Sails that are left furled on booms jib club booms and forestays without suitable covers are most susceptible to this problem Suitable sail covers are available from Cape Dory through your dealer Page 40 Mildew is no longer the major concern that it was in the days of natural fiber sails Your new sails should be dry before folding if for no other reason than to prevent the unsightly growth of this dark mold In order to retain the shape of your sails they should be folded after each use In the case of the mainsail outhaul tension should be relieved before folding the sail on the boom After the season sails should be inspected and if necessary serviced by a competent sailmaker For appearance s sake stains should be removed and the sails washed gently with a mild soap and thoroughly rinsed The mainsail has plastic slugs which are inserted into the track on the after side of the mast The Typhoon uses sail sl
92. three kur lengths of tape on the pedestal and compass as shown Slit the tape when Erg compass akan the strips of ape when reinstaling the compass lor visual realigument Your compass MUST then be checked vat lor accuracy Latinication of needie bearings should be dome by squeezing Edson Fig 827 Teflon Lubricant into the holes ku ated on top of the Dearing inside the pedestal bowl Spin the wheel whet squeeezing the lubricant in 10 make sore the entire bear mg is versiced Winch grease ur water pump grease be used 43 an allernvive but don t let the bearings run dry Da not over grease as it will tun unto the brake pads Oil the chain with weight motor oil Do NUT grease chain as does not penetrate the kaks condition 4 the were tension of the wire and lightly oil Edson recommends placing about fme layers ul Kleenex on the palm ol your hand squirt os on the tissues and lightly the wire Thi will lubricate the strands but will also a broken or hooked strand by teary 0 small section of 88 you do have wire break replace the ware immechately See Edson Fig 775 Wire and Cham Replacement Kits Caution Wire splinters can couse cuts Replace the wire alter years M stil good keep the wire un board as a spare STEERING WIRE TENSION A top quality roller chain to wire steering can be kept in as mew senulivity by keeping the wire al a correc
93. throughout The hose is 1 inside diameter on the Typhoon and 1 5 8 inside diameter on all other models All connections are sealed with gasket sealer and secured with stainless steel hose clamps Scupper drains and galley sink drains discharge overboard below the waterline Protect these hoses from sharp objects and chafe Inspect hose clamps for security regularly Hose clamps that were tight when the boat was built may loosen in transit or due to the contraction of the rubber hose and should be checked often A failure here could cause your yacht to sink if the seacock was left open 3 23 BILGE PUMPS The Cape Dory 25D 27 28 and 30 are all equipped with a permanently installed diaphragm type bilge pump This type of pump is also available as optional equipment on the Cape Dory 22 The pump itself is located in the cockpit area and is operated by inserting the removable handle into the through deck fitting This arrangement allows the pumping of the bilge with all hatches closed a safety precaution should you have to pump in severe conditions Water is carried from the bilge to the pump by a reinforced plastic hose with a strainer at the bilge end This strainer should be checked FREQUENTLY and cleaned as needed The pump discharges water overboard through a fitting located above the waterline near the transom The pump is designed to pump water containing a variety of debris but can become clogged by excessive solid matter If the pump sh
94. toward the end of the charge cycle at which time the pointer drops back to the 12 6 13 volt range as voltage regulation controls this function If the battery voltage reaches 15 volts which is the high red band on the gauge this indicates that the Page 27 battery is being overcharged and will damage the battery if left unchecked The voltage regulator is most likely at fault When the battery is being discharged having electrical loads placed upon it and no charging current applied it is normal for the pointer to indicate between 11 4 12 6 volts or be in the yellow band A FINAL WORD The above guidelines provided are merely to help you to establish what is normal the usefulness of the meter will depend on your own routine observations which will spot trouble when it occurs The BATTERY TEST SWITCH adjacent to the meter is used to directly connect the meter to the individual batteries The condition may then be read directly from the meter The BATTERY SELECTOR SWITCH must NOT be in the ALL position and the engine should NOT BE RUNNING or false readings will result The batteries should be inspected and serviced at least once a month more frequently when under heavy use The terminals should be free from corrosion and tight on the battery posts and the electrolyte kept at the proper level by topping up with distilled water CAUTION Avoid spilling battery electrolyte into the bilge and avoid getting any salt water in the batt
95. urer s instructions regarding the use of these products To prevent the growth of mildew beneath vinyl cabin cushions elevate them when leaving the boat to allow air to circulate Remove traps on boats so equipped so lockers will be aired 3 38 ICE BOX The ice box on your Cape Dory is designed to drain water from melted ice through scuppers into the bilge Because small food particles juices from meats etc may also drain into the bilge it is wise to use a NAME BRAND bilge cleaner in the bilge as needed or every three to four weeks depending on how frequently you are using the ice box Follow the directions for use which accompany the product which you select Another alternative is to fit a plastic gallon jug on the end of the ice box hose Periodically dump the melted ice out into the sink Food items should not be left for long periods of time in a closed ice box without ice Spoilage odors mold and mildew will result Plan to clean out your ice box both ice and food items at the end of each sail or cruise when you are leaving the boat for an extended period of time Remove the ice box cover to permit thorough drying Clean up any spillage of food in the ice box etc to prevent blocking of the scuppers and drainage of this material into the bilge Clean the fiberglass interior surfaces of your ice box periodically with a sponge dampened with a water and bleach solution this will help prevent mildew and odors in the ice box 3 39
96. ving Record All items on receiving checklist received in good order Dealer should notify factory within ten 10 days of receipt of any shortages or damaged goods PRE LAUNCH CHECKLIST Visually check underwater hull surface for any damage sustained during trucking or handling Through hulls all tight and clear of any foreign objects Seacocks and valves all closed Hose clamps tight Check two propeller retaining nuts for tightness Cotter pin in place and bent over applies to 25D 27 28 and 30 only Newer boats will have Perry nuts installed Record propeller information below Diameter inches Pitch inches Rotation left or right hand of Blades 2 or 3 optional Rudder swings freely side to side on CD 30 s with worm drive steerers wheel must be turned Stuffing box packing adjusted applies to 22D 25D 27 28 and 30 only Bottom under cradle poppets or bulkheads sanded primed and painted 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Page 12 Bilge dry Bilge pump connections okay and handle on board Check hull for any chips in gel coat POST LAUNCH CHECKLIST Immediately after launching check bilge for water If water is present check all through hulls and stuffing box Open seacocks or valves one at a time and check for leaks Check stuffing box It
97. wly eases the halyard turn the boom in a circular motion It makes no difference which way you turn the boom As the leach moves in on the boom pull it aft to make the sail lay as flat and as evenly as possible around the boom When you have reduced the size of the mainsail to the desired level push the boom back in to the gooseneck fitting and have your crew take up on the halyard so that the luff is tight Then ease the topping lift back to its position prior to tucking in the reef JIFFY REEFING C 25D CD 27 CD 28 CD 30 Jiffy Reefing is the more traditional method of shortening sail You do not have to raise the main to its full height on the mast to properly reef but it is somewhat easier if you do as it keeps the sail out of your way Page 41 Reeve the reefing lines through the reefing cringles The grommets on the luff and the leach will then become your new tack and clew Ease off the halyard and pull the tack down to the top of the boom Make the line fast to the cleat on the mast and take up on the halyard until the luff is set with the proper tension Next haul on the clew line pulling the clew down and aft The clew line runs from a padeye up through the grommet down to a cheek block and forward to a cleat It is important that during a jiffy reef the main sheet and the vang should your boat have one be eased to allow proper tensioning along the new foot of the sail The key to this type of reefing is to have sufficient
98. xhaust system The cooling water enters the hull through a screened seacock and is pumped through a Jabsco impeller type pump mounted on the engine If the engine is started with the seacock closed or water obstructed in another way damage to the rubber impeller will result A spare impeller should be carried aboard at all times and is easily changed If really hot water is desired from the hot water heater an add on fresh water cooling kit can be purchased and installed The addition of the kit converts the raw water cooling to a closed fresh water system similar to that used on an automobile except that the auto s radiator is replaced by a heat exchanger on the engine which cools the fresh water loop Sen Dure manufactures this kit and it is available from DiPetro Kay Corp for Volvos Other engines may have fresh water cooling installed at the factory Check your engine owner s manual for further details such as winterizing etc Fresh water cooling is not available for the Yanmar 1 GM 39 FUEL SYSTEM In order to run a diesel s only requirement is clean water free air free fuel and combustion oxygen There are no spark plugs or ignition requirements 95 of all diesel engine problems result from fuel Page 24 problems The engine manual that comes with the engine describes the bleeding procedures and every owner should know how to do this The fuel feed line must be 100 air tight or it will suck in air which eventually will reach the high pres
99. y begin to split and grain will lift Contrary to what you may have heard teak is not a miracle wood that is totally maintenance free It is easy to maintain There are a number of excellent teak cleaning and sealing preparations on the market We suggest that you ask your sailing friends who have teak you admire for their suggestions Many excellent teak cleaning and sealing products are not available nationwide so use the best available in your area The teak may also be varnished put three to six coats on initially plan to apply another coat at midseason and a final coat prior to winter layup Follow manufacturer s directions for the varnish which you purchase use only quality marine varnish Page 43 3 36 INTERIOR MAINTENANCE Periodic cleaning is essential to keep the interior of your boat clean and bright Choose sunny breezy days for your boatkeeping chores as sun and fresh air are a great help in drying and airing interior cushions etc while you continue with chores below they also contribute to your enthusiasm for the task 3 37 CUSHIONS Cloth covered interior cushions are made from several different materials depending on which color or style you selected We therefore recommend that you either have the cushions dry cleaned or clean them with an upholstery shampoo of the spray foam type interior cushions and cockpit cushions should be cleaned with a commercial vinyl upholstery cleaner Follow the manufact
100. y protection from chafe and the ultraviolet rays of the sun Stow in neat seamanlike coils when not in use so that it will run freely without kinks or hockles when it is needed A rinsing in fresh water at the end of the sailing season is recommended 327 TURNBUCKLES Cape Dory boats are equipped with open body integral toggle turnbuckles Prior to every sail all turnbuckles should be checked to see that they are properly adjusted see section on Tuning and above all pinned so that they will not loosen The two cotter pins should be inserted and spread open The threaded sections above and below the barrels may be taped once the turnbuckles are adjusted and locked in place Engine vibration and even wave action at mooring or slip are enough to allow an improperly pinned turnbuckle to work loose Occasionally during the season you should completely disassemble and inspect all turnbuckles DO NOT attempt to do this when sea or wind conditions are placing strain on the mast The shroud turnbuckles upper and lower sidestays may be disconnected and inspected ONE AT A TIME The remaining shrouds will provide adequate mast support Prior to disconnecting headstay and backstay turnbuckles for inspection special measures to support the mast are necessary This can be accomplished by using the halyards as temporary stays Attach the jib halyard to the jib tack shackle haul it in tight and cleat it This will temporarily replace the headstay so that
101. you may disassemble the turnbuckle for inspection Lead the main halyard aft to a stern cleat and follow the above procedure to check the backstay turnbuckle Do not use the coaming mounted genoa sheet cleats for anything other than sheeting the genoa and then only if the sheet is around the winch first These cleats are handily mounted but may pull out of the coaming if the main tension of the sheet is not taken by the winches The barrel section of the turnbuckle should be backed off entirely from the top and bottom sections All threads should be carefully inspected both for broken or worn threads as well as rust corrosion or breakdown of the metal itself The threads in the barrel should be inspected as well as those on the long threaded ends Prior to reassemble lightly lubricate the ends barrel and locking nuts with waterproof grease 1 2 3 4 5 6 7 8 IMPORTANT Read instructions carefully before Page 37 RIGGING INSTRUCTIONS rigging your sailboat SPARTAN MARINE PRODUCTS INC 160 Middleboro Avenue East Taunton Mass 02718 617 623 6776 Hold each coil of wire firmly and carefully unwind with extra precaution avoiding injury from retracting rigging ends that are under tension Take care not to crimp the wire while uncoiling Leave tags on shrouds and stays to avoid confusion till completion A helpful hint is to document wire numbers on your rigging kit list enclosed and retain in a

Edited By: Ed Rant January,1999

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